JP5152499B2 - 電気装置及びその接続方法 - Google Patents

電気装置及びその接続方法 Download PDF

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Publication number
JP5152499B2
JP5152499B2 JP2008136369A JP2008136369A JP5152499B2 JP 5152499 B2 JP5152499 B2 JP 5152499B2 JP 2008136369 A JP2008136369 A JP 2008136369A JP 2008136369 A JP2008136369 A JP 2008136369A JP 5152499 B2 JP5152499 B2 JP 5152499B2
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Prior art keywords
connection
anisotropic conductive
connection terminal
adhesive
wiring board
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Expired - Fee Related
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JP2008136369A
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JP2009004768A (ja
Inventor
美佐夫 小西
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Dexerials Corp
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Dexerials Corp
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    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/30Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/321Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by conductive adhesives
    • H05K3/323Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by conductive adhesives by applying an anisotropic conductive adhesive layer over an array of pads
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    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/02Non-macromolecular additives
    • C09J11/04Non-macromolecular additives inorganic
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    • C09J7/00Adhesives in the form of films or foils
    • C09J7/30Adhesives in the form of films or foils characterised by the adhesive composition
    • C09J7/38Pressure-sensitive adhesives [PSA]
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    • C09J9/00Adhesives characterised by their physical nature or the effects produced, e.g. glue sticks
    • C09J9/02Electrically-conducting adhesives
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    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
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    • H01R4/04Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation using electrically conductive adhesives
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    • C09J2203/326Applications of adhesives in processes or use of adhesives in the form of films or foils for bonding electronic components such as wafers, chips or semiconductors
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Description

本発明は電気部品と半導体素子の接続方法に関する。
従来より、半導体素子のような電気部品を配線基板に接続するのには、バインダー樹脂に導電性粒子が分散された異方導電性接着剤が用いられている。
電気部品と配線基板を接続する工程の一例について説明すると、配線基板と電気部品とで異方導電性接着剤を挟み込み、押圧する。これにより、電気部品の接続端子の先端部分と、配線基板のランド部分とで導電性粒子が挟み込まれると共にバインダー樹脂(接着剤)が押しのけられ、電気部品が配線基板に電気的に接続される。
接着剤が熱硬化性を有する場合には、上述の押圧時に加熱押圧し、接着剤を熱硬化させて電気部品を配線基板に固定する。このように、異方導電性接着剤を用いれば、電気部品を配線基板に電気的にも機械的にも接続することができる。
近年、半導体素子のコストダウンや、ファインピッチ化、電気部品本体の狭額縁化等に伴い、半導体素子の細長化が進んでいるが、接続端子の先端部分の面積が狭い場合には、その先端部分とランド部分とで導電性粒子が挟み込まれる確率が低くなり、接続端子とランド部分に導通不良が起こり易くなる。
これに対し、異方導電性接着剤に含有される導電性粒子の含有率を高くすれば、接続端子とランド部分とで導電性粒子が挟み込まれる確率が高くなるが、異方導電性接着剤の製造コストが高くなる。
このように、従来技術では導通信頼性の高い電気装置を、製造コストを抑えて製造することが困難であった。
本発明は上記従来技術の不都合を解決するために創作されたものであり、その目的は、導通信頼性の高い接続を備えた電気装置を低コストで提供すること、またそのための接続方法及びその接続方法に使用する接着フィルムを提供することである。
上記課題を解決するため、本発明は、配線基板上に配置されたランド部分と、電気部品の接続端子とが互いに対向し、異方導電接着剤の導電性粒子によって電気的に接続されている接続部分を有する電気装置であって、
接続部分として、第一の接続部分と、第一の接続部分よりも導電性粒子の含有率が少ない第二の接続部分を有する電気装置を提供する。
また、本発明は、上述の電気装置の製造に使用する接着フィルムとして、導電性粒子を含有する第一の異方導電性接着剤層と、第一の異方導電性接着剤層よりも導電性粒子の含有率が低い第二の異方導性電接着剤層とが、帯状の剥離フィルム上の異なる位置に設けられた接着フィルムを提供する。
さらに、本発明は、上述の電気装置の製造に使用する接続方法として、配線基板上に配置されたランド部分と、電気部品の接続端子とを、異方導電性接着剤層を介して対向配置し、配線基板と電気部品のいずれか一方又は両方を押圧し、配線基板のランド部分と、電気部品の接続端子とを電気的に接続する接続方法であって、
第一の接続端子と該第一の接続端子と対向配置したランド部分との間の異方導電性接着剤層の導電性粒子の含有率を、第二の接続端子と該第二の接続端子と対向配置したランド部分との間の異方導電性接着剤層の導電性粒子の含有率よりも高くする接続方法を提供する。
本発明の電気装置では、導電性粒子の含有率が互いに異なる第一、第二の接続部分によって、電気部品が配線基板に接続されている。このため電機部品の接続端子の接続面積に広狭がある場合に、接続面積の狭い第一の接続端子を、導電性粒子の含有率の高い第一の接続部分で対応するランド部分に接続することが可能となるので、導通信頼性を高めることができる。また、接続面積の狭い第二の接続端子を、導電性粒子の含有率の低い第二の接続部分で対応するランドに接続することが可能となるので、導電性粒子の使用量を低減し、接続に要するコストを抑えることができる。
また、本発明の接続方法によれば、本発明の電気装置の製造が可能となり、本発明の接着フィルムによれば、本発明の接続方法が容易となる。
以下、図面に基づいて本発明を具体的に説明する。なお、各図中、同一符号は同一又は同等の構成要素を表している。
図1(a)は本発明の接着フィルム50の一例の平面図を示しており、同図(b)はそのB−B切断線断面図を示している。
この接着フィルム50は帯状の剥離フィルム51と、剥離フィルム51上に配置され、導電性粒子59が分散された異方導電性接着剤層52とを有している。
異方導電性接着剤層52としては、同じ種類のバインダー樹脂56を主成分とし、導電性粒子59の含有率(重量%)が異なる2種類の異方導電性接着剤層、即ち、導電性粒子59の含有率が高い第一の接着部55と、第一の接着部55よりも導電性粒子59の含有率が低い第二の接着部58とが異なる位置に設けられている。
ここでバインダー樹脂56としては、エポキシ樹脂、メラミン樹脂、フェノール樹脂、尿素樹脂など種々の熱硬化性樹脂を用いることができ、これらの樹脂を単独、又は2種類以上を混合してもよい。
また、バインダー樹脂56に用いる樹脂は熱硬化性樹脂を主成分とするものに限定されず、熱硬化性樹脂に熱可塑性樹脂等他の樹脂を添加したものでもよく、また、紫外線や可視光などの光照射によって硬化する光硬化性樹脂を主成分とするものを用いることもできる。
一方、導電性粒子59としては、金属粒子や、樹脂粒子の表面に金属被膜層が形成されたもの等を単独又は2種類以上で含有させることができる。第一、第二の接着部55、58に含有させる導電性粒子の種類は互いに同じでも異なっていてもよいが、第一、第二の接着部55、58に含有させる導電性粒子59の含有率は、導電性粒子59の粒子径、この接着フィルム50を用いて接続しようとする電気部品の配線端子あるいは配線基板のランドの面積やピッチ等に応じて互いに異なるようにする。
また、剥離フィルム51上に形成する第一、第二の接着部55、58の膜厚はそれぞれ特に限定されるものではないが、接着フィルム50で配線基板に接続しようとする電気部品を確実に配線基板に固定するためには、10μm以上40μm以下であることが好ましい。
第一、第二の接着部55、58はそれぞれ剥離フィルム51の幅よりも狭い幅で帯状に形成されている。そして、第一の接着部55は、剥離フィルム51の一方の側縁部に沿って配置され、第二の接着部58は剥離フィルム51の他方の側縁に沿って配置されている。
一方、図3(a)は接着フィルム50で接続する配線基板60の一例を示している。この配線基板60は基板本体61と、基板本体61の一面の別々の領域に配置された第一、第二のランド部分63、64とを有している。第一のランド部分63の表面面積は、第二のランド部分64の表面面積よりも大きくされている。
また、第一、第二のランド部分63、64はそれぞれ直線状に配列しているが、第一のランド部分63の配列ピッチは第二のランド部分64の配列ピッチよりも狭くなっている。
図2は、配線基板60に接続する電気部品65の一例を示している。この電気部品65は細長い部品本体66と、部品本体66の一面に配置された第一、第二の接続端子67、68とを有している。
なお、本発明において、電気部品は半導体素子に限定されず、種々のものを用いることができる。また、一つの電気部品に、複数の接続端子が配設された接続領域の数は1個でも複数個でもよく、したがって、一つの電気装置における、電気部品と配線基板との接続領域の個数についても、1個でも複数個でもよい。
第一、第二の接続端子67、68は、それぞれ上述の電気部品65の第一、第二のランド部分63、64に対応し、第一の接続端子67の先端部分53の面積は、第二の接続端子68の先端部分54の面積よりも狭くなっている(図6(b))。
この電機部品65を上述の配線基板60に接続する方法としては、まず、配線基板60の第一、第二のランド部分63、64の配列方向と、接着フィルム50の走行方向とが平行になるように、配線基板60を圧着台(図示せず)に配置する。
次に、接着フィルム50を配線基板60上に走行させ、接着フィルム50の第一、第二の接着部55、58を、配線基板60の第一、第二のランド部分63、64上に位置させる。そして、押圧ローラ等を用いて接着フィルム50を配線基板60に押し当てる。これにより、接着フィルム50の第一の接着部55が配線基板60の第一のランド部分63上に接着し、接着フィルム50の第二の接着部58が配線基板60の第二のランド部分64上に接着する。
次に、切断手段を用いて、接着フィルム50の配線基板60に接着した領域を他の領域から分離する。接着フィルム50の第一、第二の接着部55、58と配線基板60との間の接着力は、この第一、第二の接着部55、58と剥離フィルム51との間の接着力よりも強くされているので、接着フィルム50の配線基板60への押圧を解除すると、配線基板60に接着していた接着フィルム50の領域が剥離フィルム51が剥離し、第一、第二の接着部55、58が配線基板60に転着される(図6(b))。
そこで、前述の電気部品65の第一、第二の接続端子67、68が配置された面を配線基板60側に向け、第一、第二の接続端子67、68が配線基板60の第一、第二のランド部分63、64に対向するように、電気部品65を配線基板60上に配置する。
これにより、電気部品65の第一の接続端子67の先端部分53が接着フィルム50の第一の接着部55に密着し、電気部品65の第二の接続端子68の先端部分54が接着フィルム50の第二の接着部58に密着する。
次に、この状態で、電気部品65を加熱押圧する。加熱によって異方導電接着剤層52が昇温し、バインダー樹脂56が軟化する。
バインダー樹脂56が軟化すると、第一、第二の接着部55、58が流動性を呈するので、押圧によって第一、第二の接続端子67、68の先端部分53、54が第一、第二の接着部55、58を押しのけ、その先端部分53、54が第一、第二の接着部55、58中の導電性粒子59に接触する。
ここで、導電性粒子59の含有率が均一な場合には、第一の接続端子67の先端部分53に導電性粒子59が接触する確率は、第二の接続端子68の先端部分54の面積に比して第一の接続端子67の先端部分53の面積が狭い分低くなってしまうが、第一の接着部55における導電性粒子59の含有率は、第二の接着部58における導電性粒子59の含有率よりも高くされているので、第二の接続端子68だけではなく、第一の接続端子67の先端部分53にも導電性粒子59が確実に接触する。
更に、加熱押圧を続けると、第一、第二の接続端子67、68が第一、第二のランド部分63、64に押し付けられて、各先端部分53、54に接触した導電性粒子59が第一、第二の接続端子67、68と第一、第二のランド部分63、64とで挟み込まれた状態になる。
この状態でバインダー樹脂56の重合反応が進行し、第一、第二の接着部55、58が第一、第二の接続端子67、68と第一、第二のランド部分63、64の周囲を取り囲んだ状態で硬化する。
これにより、図4及びそのC−C切断面である図3(c)に示すように、第一、第二の接着部55、58が硬化した電気装置40が得られる。こうして得られる電気装置40は、導通信頼性の高いものとなる。
また、異方導電性接着剤層52全体の導電性粒子59の含有率を高くするとコストが高くなるが、第二の接着部58の導電性粒子59の含有率が低くされている分、異方導電性接着剤層52全体では導電性粒子59の含有率が低くされているので、製造コストが安価になる。
なお、図4の符号43は、第一の接続端子67と第一のランド部分63が接続された第一の接続部分41が位置する第一の接続領域を示しており、同図の符号44は第二の接続端子68と第二のランド部分64が接続された第二の接続部分42が位置する第二の接続領域を示している。
この電気装置40では、例えば、配線基板60の電気信号は、接続面積が広い第二の接続部分42から電気部品25に入力され、その電気信号は電気部品25で処理された後、接続面積が狭い第一の接続部分41から配線基板60に出力される。
本発明の接着フィルム50において、導電性粒子59の含有率が互いに異なる第一、第二の接着部55、58の配置は、上述の例に限られず、例えば、図5に示す接着フィルム70のように配置してもよい。
図5(a)は接着フィルム70の平面図を示しており、図5(b)は図5(a)のD−D切断線断面図を示している。この接着フィルム70は帯状の剥離フィルム71と、剥離フィルム71表面に延設された異方導電性接着剤層72とを有している。図5において、異方導電性着剤層72は、それぞれ、図1の第一、第二の接着部55、58と同様に導電性粒子の含有率が異なる第一、第二の接着部75、78からなり、第一の接着部75は第二の接着部78よりも導電性粒子の含有率が高くなっている。また、第一の接着部75と第二の接着部78は、帯状の接着フィルム70の長手方向に、交互に繰り返されている。
図5(a)の破線はこの接着フィルム70を用いて好適に接合することのできる電気部品65の接続面の大きさを示している。この電気部品65は、図2に示したように、先端部分の面積が狭い第一の接続端子67と先端部分の面積が広い第二の接続端子68がそれぞれ直線状に配列したものである。図5(a)に示すように、接着フィルム70の幅は、電気部品65の接続面の長辺の長さよりもやや長く、第一、第二の接着部75、78の繰り返しピッチは、電気部品65の接続面の短辺の長さよりもやや長く、第一、第二の接着部75、78で接続単位79を構成している。
したがって、接着フィルム70を接続単位79ごとに用い、電気部品65と配線基板を前述と同様に対向配置して接続すると、電気部品65の接続端子のうち先端部分の面積が狭い第一の接続端子67は導電性粒子の含有率の高い第一の接着部75で確実に接続することができ、先端部分の面積が広い第二の接続端子68は、導電性粒子の含有率の低い第二の接着部78で、製造コストを抑えつつ確実に接続することができる。
本発明の接着フィルムにおいて、第一、第二の接着部55、58の配置は特に限定されるものではなく、例えば、図6に示した電気装置80のように、四角形の電気部品65bの対角線で2分される領域に、接着フィルムの異方導電性接着剤層82bとして、導電性粒子含有率の高い第一の接着部85と、導電性粒子の含有率の低い第二の接着部88をそれぞれ別々に配置し、先端面積の狭い接続端子とランド部分とが接続されている第一の接続領域43bと、先端面積の広い接続端子とランド部分とが接続されている第二の接続領域44bを形成することにより、電気部品65bを配線基板60bに接続してもよい。
本発明においては、導電性粒子の含有率が異なる3つ以上の接着部分で未硬化接着剤層を構成してもよく、また、接続端子が半田バンプである場合のように、加熱押圧により接続端子とランド部分とが金属結合することを期待できる場合には、未硬化接着剤層の一部又は全部を導電性粒子の含有率がゼロの接着部分で構成してもよい。
さらに、本発明の接続方法では、第一、第二の接着部55、58を別々の剥離フィルム51上に配置し、第一、第二の接着部55、58が形成された剥離フィルム51をそれぞれ配線基板60上に走行させ、第一、第二の接着部55、58を別々の剥離フィルム51上から同じ配線基板60に転着させることもできる。
また、配線基板60上の第一、第二のランド部分63、64と電機部品65の第一、第二の接続端子67、68の間に異方導電性接着剤層52を配置して接続するにあたり、異方導電性接着剤層52を配線基板60に転着させてから、異方導電接着剤層52と電機部品65とを密着させて接続してもよく、電気部品65に異方導電性接着剤52を転着させてから、配線基板60と異方導電接着剤層52とを密着させて接続してもよい。
また、第一、第二の接着部55、58の配線基板60への配置方法としては、例えば、導電性粒子の含有率が互いに異なるペースト状の第一、第二の異方導電性接着剤を用意し、配線基板60と電気部品65のいずれか一方に、導電性粒子の含有量の異なる第一、第二の異方導電性接着剤を塗布して第一、第二の接着部55、58を形成し、異方導電性接着剤層52とすることもできる。
本発明の接続フィルム、接続方法及び電気装置は、電気的接続と機械的接続を同時に行うことが必要とされる種々の電気装置で有用である。
(a)本発明に用いる接着フィルムを説明する平面図、(b)その断面図 本発明に用いる電気部品を説明する平面図 (a)〜(c)本発明により配線基板と電気装置を接続する工程を説明する断面図 第二の発明の電気装置の一例を説明する平面図 (a)本発明の接着フィルムを説明する平面図、(b)その断面図 本発明の電気装置を説明する平面図
符号の説明
40 電気装置
41 第一の接続部分
42 第二の接続部分
50 接着フィルム
51 剥離フィルム
52 異方導電接着剤層
55 第一の接着部(異方導電接着剤層)
56 バインダー樹脂
58 第二の接着部(異方導電接着剤層)
59 導電性粒子
60 配線基板
63 第一のランド部分
64 第二のランド部分
65 電気部品
67 第一の接続端子
68 第二の接続端子
70 接着フィルム
71 剥離フィルム
72 異方導電性接着剤層
75 第一の接着部
78 第二の接着部
80 電気装置
82b 異方導電接着剤層
85 第一の接着部
88 第二の接着部

Claims (5)

  1. 配線基板上に配置されたランド部分と、電気部品の接続端子とが互いに対向し、異方導電接着剤の導電性粒子によって電気的に接続されている接続部分を有する電気装置であって、
    接続部分として、第一の接続部分と、第一の接続部分よりも導電性粒子の含有率が少ない第二の接続部分を有し、
    第一の接続部分の接続端子の先端部分の面積が、第二の接続部分の接続端子の先端部分の面積よりも狭い電気装置。
  2. 第一の接続部分の導電性粒子と第二の接続部分の導電性粒子とが同じである請求項1記載の電気装置。
  3. 配線基板上に配置されたランド部分と、電気部品の接続端子とを、異方導電性接着剤層を介して対向配置し、配線基板と電気部品のいずれか一方又は両方を押圧し、配線基板のランド部分と、電気部品の接続端子とを電気的に接続する接続方法であって、
    電気部品の接続端子は、第一の接続端子と第二の接続端子とを有し、第一の接続端子の先端部分の面積を、第二の接続端子の先端部分の面積よりも小さくし、
    第一の接続端子と該第一の接続端子と対向配置したランド部分との間の異方導電性接着剤層の導電性粒子の含有率を、第二の接続端子と該第二の接続端子と対向配置したランド部分との間の異方導電性接着剤層の導電性粒子の含有率よりも高くする接続方法。
  4. 導電性粒子を含有する第一の異方導電性接着剤層と、第一の異方導電性接着剤層よりも導電性粒子の含有率が低い第二の異方導電性接着剤層とが、帯状の剥離フィルム上の異なる位置に設けられており、第一、第二の異方導電性接着剤層が、接着フィルムで接続する電気部品の大きさに応じた長さの接続単位を構成し、該接続単位が剥離フィルムの長手方向に配列している接着フィルムを配線基板上に走行させ、接着フィルムの第一、第二の異方導電性接着剤層を配線基板に転着させることにより、第一、第二の異方導電性接着剤層を配線基板上に配置する請求項3記載の接続方法。
  5. 導電性粒子を含有する第一の異方導電性接着剤層と、第一の異方導電性接着剤層よりも導電性粒子の含有率が低い第二の異方導電性接着剤層とが、帯状の剥離フィルム上の異なる位置に設けられており、第一、第二の異方導電性接着剤層が、接着フィルムで接続する電気部品の大きさに応じた長さの接続単位を構成し、該接続単位が剥離フィルムの長手方向に配列している接着フィルムを使用し、接続単位ごとに第一、第二の異方導電性接着剤層を配線基板上に転着させる請求項3又は4記載の接続方法。
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