JP5760401B2 - Metal foil die cutting method - Google Patents

Description

The present invention relates to a die-cutting process of the metal foil to manufacture a patterned metal foil patterns in an arbitrary shape by being cut by the blade portion of the mold.

  Conventionally, corrosion processing by etching has been used as a technique for forming a metal foil pattern by patterning a metal foil of a large area into an arbitrary shape. In this method, a resist material having etching resistance is patterned on the metal foil, and then immersed in an etching solution or the like, whereby the metal foil in a portion without the resist material can be removed. On the other hand, in this method, it is necessary to pattern the resist material, and there is a problem that it becomes difficult to pattern the resist material as the metal foil has a large area. In addition, since a large amount of an etching solution that corrodes the metal foil is used, a great amount of cost is required for installation of corresponding equipment and environmental measures.

  As another metal foil patterning method for solving this problem, for example, a punching method using a die blade as described in Patent Document 1 has been developed. Durability, shape accuracy, and processing area differ depending on the type of mold, but fine pattern processing of about several hundred μm has become possible in recent years due to high precision and large area of the mold.

  When the metal foil is punched by the above-described mold, the durability of the mold becomes a problem. In particular, when the metal foil is punched with a blade portion having a sharp tip, the blade portion is likely to deteriorate. Therefore, in order to improve the durability of the mold, a half-cut method is generally performed. This is a method in which the metal foil and the buffer material are simultaneously punched, the tip of the blade is pressed from the metal foil side, and is stopped at an intermediate portion in the thickness direction of the buffer material. Thereby, it becomes possible to prevent that the front-end | tip of a blade part is crushed. Furthermore, by using an adhesive film as the cushioning material, it is possible to prevent misalignment of the metal foil and form a highly accurate pattern.

Japanese Patent No. 3116209

By the way, when metal foil is die-cut on the above-mentioned pressure-sensitive adhesive film, it is necessary to remove a metal foil unnecessary area, which is an unnecessary portion in the metal foil, from the pressure-sensitive adhesive film after die cutting. When the metal foil unnecessary region is integrally formed on the adhesive film, the unnecessary portion can be continuously peeled off by winding.
However, when the metal foil unnecessary areas exist discontinuously, that is, when a plurality of metal foil unnecessary areas exist apart from each other, each metal foil unnecessary area cannot be easily removed from the adhesive film. There is. In particular, when the metal foil unnecessary region exists as a floating pattern at a location separated from the edge of the metal foil, it is difficult to remove the metal foil unnecessary region when the metal foil pattern is mass-produced.

This invention is made | formed in view of such a subject, Comprising: It aims at providing the die cutting method of the metal foil which enabled the metal foil unnecessary area | region to be easily removed from an adhesive film.

In order to solve the above problems, the present invention proposes the following means.
The metal foil die-cutting method of the present invention is a metal foil die-cutting method in which the metal foil laminated on the pressure-sensitive adhesive film is pressed against the tip of a blade portion to cut the metal foil. The step of laminating the metal foil, and when the tip of the blade is pressed against the metal foil and viewed parallel to the thickness direction of the metal foil, is defined by the tip of the pressed blade. The metal foil is cut by a separating line, and the metal foil is separated from the adhesive film in a predetermined range with the separating line as a center to separate the metal foil required area and the metal foil unnecessary area of the metal foil. When the tip of the blade portion is pressed against the metal foil unnecessary region and viewed in parallel with the thickness direction, one or more severing lines defined by the tip of the pressed blade portion When cutting the metal foil unnecessary area Said metal wherein a shredding step of the metal foil unnecessary area is peeled off from the adhesive film in a predetermined range about said fine wire breakage, prior to the separation step and the shredding process, which is laminated on the adhesive film in When the tip of the blade portion is pressed against the foil and viewed in parallel with the thickness direction of the metal foil, the metal foil adheres to the reference line defined by the tip of the pressed blade portion. A preliminary step for obtaining a peel length to be peeled off from the film, and after the laminating step and the shredding step, when viewed in parallel to the thickness direction, the thin lines adjacent to each shred line are provided. The distance to the disconnection line or the separation line is set to be equal to or less than a value obtained by doubling the peeling length in any part of the fine cut line.

In the metal foil die-cutting method, it is more preferable that at least a part of the metal foil required region is set such that the minimum value of the distance from the adjacent separation line is larger than the peeling length.

In the metal foil die cutting method described above, it is more preferable that the tip of the blade portion is formed at an acute angle.
Moreover, in the metal foil die cutting method described above, it is more preferable to perform the separation step and the shredding step simultaneously.

According to die-cutting method of the present onset bright metal foil, it is possible to easily remove the metal foil unnecessary area from the adhesive film.

It is a top view of the metal foil pattern of 1st Embodiment of this invention. It is sectional drawing of the cutting line AA in FIG. It is a flowchart which shows the die cutting method of the metal foil of this embodiment. It is front sectional drawing explaining the preliminary | backup process in the die cutting method of the metal foil. It is a top view explaining the preliminary process. It is front sectional drawing explaining the lamination process in the die cutting method of the metal foil. It is front sectional drawing explaining the isolation | separation process and shredding process in the die cutting method of the metal foil. It is a top view explaining the isolation | separation process and a shredding process. It is front sectional drawing which shows the state which removed the metal mold | die from metal foil in the die-cutting method of the metal foil. It is front sectional drawing which shows the state which removed the metal foil unnecessary area | region from the adhesive film in the die cutting method of the metal foil.

Hereinafter, an embodiment of a metal foil pattern and a metal foil stamping method according to the present invention will be described with reference to FIGS. 1 to 10. This metal foil pattern is obtained by punching a metal foil into a predetermined pattern, and can be used as, for example, a wiring pattern of a substrate.
As shown in FIG. 1 and FIG. 2, the metal foil pattern 1 of the present embodiment is configured by a metal foil required region 3 in which a ring-shaped through hole 2 is formed while being formed in a sheet shape with metal. In addition, the metal foil pattern 1 is formed by removing the metal foil unnecessary area | region 4 corresponding to the shape of the through-hole 2 from metal foil so that it may mention later.

Next, a metal foil die-cutting method according to this embodiment for manufacturing the metal foil pattern 1 configured as described above will be described.
As shown in FIG. 3, the metal foil die-cutting method includes a preliminary step S <b> 1 for obtaining the peeling length of the metal foil, a laminating step S <b> 2 for laminating the metal foil, a metal foil required region of the metal foil, and no metal foil required A separation step S3 for separating the region and a shredding step S4 for shredding and removing the separated metal foil unnecessary region are provided.
In the present embodiment, the separation step S3 and the shredding step S4 are performed simultaneously.

  First, in the preliminary step S1, as shown in FIGS. 4 and 5, the tip 22a of the blade portion 22 of the mold 21 is placed on the metal foil 12 laminated on the adhesive film 11 from the metal foil 12 side. The metal foil 12 is cut by performing a half-cut method of pressing and stopping until reaching the middle part in the thickness direction Z. In FIG. 5, the mold 21 is not shown for convenience of explanation.

For example, the adhesive film 11 can have a structure in which an adhesive material is applied on a film substrate. As described above, in order to cut the metal foil 12 by the half-cut method, it is desirable that the film substrate has a film thickness of 50 μm or more. If the film substrate is thinner than 50 μm, it is difficult to stop the tip 22a of the blade portion 22 at an intermediate portion in the thickness direction Z of the film substrate.
Since the adhesive film 11 and the metal foil 12 need to be peeled after the metal foil pattern 1 is formed, the adhesive film 11 needs to set an adhesive force in consideration of not only the stickiness but also the peelability.

The metal foil 12 may be copper, aluminum, nickel, brass, gold, silver, lead, or an alloy thereof, but is not limited thereto. By surface-treating the metal foil 12, the adhesion between the adhesive film 11 and the metal foil 12 can be changed.
In consideration of the die-cutting property by the mold 21, the film thickness of the metal foil 12 is desirably 5 μm or more and 1 mm or less. If it is less than 5 μm, handling of the metal foil 12 is difficult, and if it exceeds 1 mm, it is difficult to perform die cutting itself. Further, considering the durability of the mold 21, the film thickness of the metal foil 12 is desirably 200 μm or less. For the lamination of the metal foil 12, for example, a roll-to-roll laminating process can be used.

The mold 21 can be a corrosion mold, a cutting mold or the like, but is not limited thereto. Pre-hardened steel, quenched and tempered steel, precipitation hardened steel, alloys of tungsten carbide and cobalt, other superhard alloys, etc. can be used as the material for forming the mold 21. There is no limit. When the metal foil 12 is punched with high accuracy, it is desirable to form the angle α of the tip 22a of the blade portion 22 at an acute angle. As the angle α is reduced, the burrs 12a and the like formed on the metal foil 12 at the time of cutting are reduced, but the durability of the mold 21 is reduced. In general, the angle α is preferably about 40 ° to 60 °.
In the present embodiment, the blade portion 22 extends in parallel to the bottom surface 23a of the base plate 23 of the mold 21 and has a triangular cross section that is symmetric with respect to the plane T1 orthogonal to the bottom surface 23a. It is formed into a shape.

In the half-cut method, when the tip 22a of the blade portion 22 reaches the middle portion in the thickness direction Z of the adhesive film 11, it is defined by the tip 22a of the pressed blade portion 22 when viewed in parallel with the thickness direction Z. The metal foil 12 is peeled from the adhesive film 11 within a predetermined range R1 with the reference line C1 as a center. By bringing the bottom surface 23 a of the mold 21 into contact with the metal foil 12, the accuracy of the cutting depth by the blade portion 22 in the thickness direction Z of the adhesive film 11 can be increased.
The range R1 from which the metal foil 12 peels is the specifications such as the material (hardness) of the film base and the adhesive strength of the adhesive film 11, the specifications such as the material and thickness of the metal foil 12, and the material of the blade 22 When the specifications such as the shape and the depth and the depth reached by the tip 22a of the blade portion 22 in the thickness direction Z are determined, they are uniquely determined. For this reason, in the preliminary process S1, a test for cutting the metal foil 12 with the same specifications as those performed later in the separation process S3 and the shredding process S4 is performed, and the reference line C1 when viewed in parallel with the thickness direction Z is obtained. By obtaining the peeling length L of the metal foil 12 as the center, the peeling length L of the metal foil 12 in the separation step S3 and the shredding step S4 can be estimated.

For example, when the adhesive force of the adhesive film 11 is increased, the metal foil 12 is difficult to peel off, so that the peeling length L is reduced. When the pressure-sensitive adhesive film 11 becomes hard, the burr 12a becomes smaller, so the peeling length L becomes smaller. When the metal foil 12 is thick, the burr 12a becomes large and the peeling length L becomes large. When the surface roughness of the metal foil 12 is increased, the adhesive strength between the adhesive film 11 and the metal foil 12 is increased, so that the peeling length L is decreased. And if the angle (alpha) of the blade part 22 becomes small, since the deformation | transformation of the metal foil 12 at the time of a cutting | disconnection will become small, the peeling length L will become small.
When there are several types of specifications of the adhesive film 11, the metal foil 12, and the blade portion 22, the test with different specifications is repeated in the preliminary step S <b> 1 and the peeling length L for various specifications is obtained in advance. It is preferable.

  Next, in the lamination step S2, as shown in FIG. 6, the metal foil 12 is laminated on the adhesive film 11.

Subsequently, in the separation step S3 and the shredding step S4, as shown in FIG. 7, the blade portions 24, 25, and 26 are pressed against the metal foil 12, and the metal foil 12 is cut by a half-cut method. At this time, the tip 24a of the blade portion 24 and the tip 25a of the blade portion 25 are pressed against the metal foil 12 to separate the metal foil required region 3 and the metal foil unnecessary region 4 of the metal foil 12, and the metal foil unnecessary region 4 The tip 26a of the blade portion 26 is pressed against the metal foil, and the metal foil unnecessary region 4 is finely cut.
The blade portion 24, the blade portion 25, and the blade portion 26 are formed in an annular shape and are coaxially attached to the bottom surface 27 a of the base plate 27. The cross sections of the blade portion 24, the blade portion 25, and the blade portion 26 by the plane perpendicular to the annular axis are formed in the same cross-sectional shape as the blade portion 22 used in the preliminary step S1. Then, by bringing the bottom surface 27a of the base plate 27 into contact with the metal foil 12, the cutting depth of the adhesive film 11 in the thickness direction Z by the blade portions 24, 25, 26 is the blade portion used in the preliminary step S1. 22 is adjusted to the same cutting depth.
When viewed in parallel with the thickness direction Z, the blade portions 24, 25, and 26 have a distance from the tip 26a of the blade portion 26 to the tip 24a of the blade portion 24 and the tip 25a of the blade portion 25, whichever of the tips 26a. Also in this part, the distance L1 is set to be a value equal to or less than twice the peeling length L.

Furthermore, as shown in FIG. 8, when viewed parallel to the thickness direction Z, the metal foil required region 3 is set such that the minimum value of the distance from the adjacent separation line C3 is set larger than the peeling length L. Even in step S3, it has a non-peeling region 3a that does not peel from the adhesive film 11. In FIG. 8, for convenience of explanation, the base plate 27 and the blade portions 24, 25, and 26 are not shown.
Similarly, the metal foil required area 3 has a non-peeling area 3b in which the minimum value of the distance from the adjacent separation line C2 is set larger than the peeling length L.

As shown in FIGS. 7 and 8, the blade portion 24 cuts the metal foil 12 along a separation line C <b> 2 defined by the tip 24 a of the pressed blade portion 24 when viewed in parallel with the thickness direction Z. At the same time, the metal foil 12 is peeled from the adhesive film 11 around the separation line C2. Similarly, the blade portion 25 cuts the metal foil 12 along the separation line C3 defined by the tip 25a and peels the metal foil 12 from the adhesive film 11 around the separation line C3.
Further, when the blade portion 26 is viewed in parallel with the thickness direction Z, the metal foil unnecessary region 4 is cut along the cutting line C4 defined by the tip 26a of the pressed blade portion 26 and the metal foil unnecessary region 4 is cut. Is peeled from the adhesive film 11 around the chopping line C4.
As a result, when viewed in parallel with the thickness direction Z, the metal foil 12 is peeled in the range of the peeling length L around the separation lines C2, C3 and the chopping line C4.

Since the blade portions 24, 25, and 26 are formed as described above, when the metal foil 12 is cut by the blade portions 24, 25, and 26, when viewed parallel to the thickness direction Z, the cutting line C4 is cut. To the adjacent separation lines C2 and C3 is the distance L1 in any part of the chopping line C4.
For this reason, the part peeled by each blade part 24,25,26 connects, and the metal foil unnecessary area | region 4 whole will be in the state peeled from the adhesive film 11. FIG.
For example, when the peel length L is 250 μm, the distance from the chopping line C4 to the adjacent separation lines C2 and C3, in other words, the width of each of the metal foil unnecessary regions 4 to be chopped is 500 μm or less, The entire metal foil unnecessary region 4 is peeled off from the adhesive film 11.
Thereafter, the metal foil unnecessary region 4 is removed from the adhesive film 11 as shown in FIG. 10 by removing the mold from the metal foil 12 as shown in FIG. 9 and inverting the adhesive film 11.

  Next, the metal foil pattern 1 comprised by the metal foil required area | region 3 shown in FIG. 1 and FIG. 2 is manufactured by removing the adhesion film 11 from the metal foil required area | region 3 by a well-known method.

As described above, according to the metal foil pattern 1 and the metal foil 12 die cutting method of the present embodiment, the preliminary length S1 is performed to determine the peeling length L of the metal foil 12, and in the shredding step S4, When viewed in parallel with the thickness direction Z, the metal foil unnecessary region 4 is such that the distance from the chopping line C4 to the adjacent separation lines C2 and C3 is equal to or less than the distance L1 that is twice the peel length L. Disconnect. For this reason, the part peeled off by each blade part 24, 25, and 26 will be connected, and the metal foil unnecessary area | region 4 will be in the state peeled from the adhesive film 11, and the metal foil unnecessary area | region 4 is easily removed from the adhesive film 11 can do.
Therefore, the yield for producing the metal foil pattern 1 is improved, and the production cost of the metal foil pattern 1 can be reduced.

When the metal foil required area 3 and the metal foil unnecessary area 4 are separated in the separation step S3, the non-peeled areas 3a and 3b of the metal foil required area 3 are not peeled from the adhesive film 11. For this reason, it can prevent that the metal foil required area | region 3 is removed with the metal foil unnecessary area | region 4. FIG.
The tips of the blade portions 24, 25, 26 are formed at acute angles. For this reason, it is possible to reduce the deformation of the metal foil 12 when the metal foil 12 is cut, and to reduce the peeling length L.
Moreover, since separation process S3 and shredding process S4 are performed simultaneously, the time required to manufacture the metal foil pattern 1 can be reduced.

When the blade portion of the mold is pressed against the metal foil 12, the metal foil 12 is cut. At this time, the metal foil 12 is not cut perpendicular to the surface of the metal foil 12, and the metal foil 12 is gradually deformed by the blade portion and cut in a ruptured form. Although the shape changes depending on the shape of the tip of the blade portion and the angle between the blade portion and the metal foil 12, a burr 12a of about several μm to several tens of μm is formed on the adhesive film 11 side with respect to the metal foil 12. In general, a metal foil pattern in which such burrs are formed is treated as defective, and therefore, die cutting conditions in which no burrs are formed have been developed.
On the other hand, the defect which the metal foil 12 peels from the adhesive film 11 by the burr | flash 12a of the part which cut | disconnected the metal foil 12 is also confirmed. Even if the formation of the burr 12a is minimized, if the adhesive force of the adhesive film 11 is weak, the metal foil 12 peels from the adhesive film 11 by about several hundreds of micrometers in the vicinity of the portion where the metal foil 12 is cut. In this invention, the metal foil unnecessary area | region 4 whole can be peeled from the adhesive film 11 by utilizing the peeling | exfoliation of such metal foil 12 and the adhesion film 11, and finely cutting the metal foil unnecessary area | region 4 with a metal mold | die. .

As mentioned above, although embodiment of this invention was explained in full detail with reference to drawings, the concrete structure is not restricted to this embodiment, The change of the structure of the range which does not deviate from the summary of this invention, etc. are included.
For example, in the die cutting method of the metal foil 12, the burrs 12a of the metal foil 12 can be removed by adding a post-process such as etching. Thereby, the metal foil pattern 1 can be formed in a smooth shape with few irregularities.
When the width of the metal foil unnecessary region 4 (interval between the separation line C2 and the separation line C3) is wide, two or more blade parts may be disposed between the blade part 24 and the blade part 25.
The manufactured metal foil pattern 1 can be retransferred onto a substrate (not shown). In order to perform retransfer, a method of applying an adhesive on a substrate and performing adhesive transfer can be employed, but the method is not limited thereto. Furthermore, the resin-embedded metal wiring can be formed by embedding and transferring the metal foil pattern 1 inside the insulating resin.
In general, the price of the mold varies depending on the shape and length of the blade portion. Therefore, when the metal foil unnecessary region is cut finely, it is desirable to design the blade portion to be as short as possible.

Moreover, in the said embodiment, although the distance of the non-peeling area | region 3a of the metal foil required area | region 3 and the separation line C3 was made larger than the peeling length L, this distance shall be made into the value which doubled the peeling length L. Thus, it is possible to more reliably prevent the metal foil required region 3 from being removed together with the metal foil unnecessary region 4.
In the said embodiment, separation process S3 and shredding process S4 were performed simultaneously. However, the order of these steps is not limited, and the shredding step S4 may be performed after the separation step S3, or the separation step S3 may be performed after the shredding step S4. Furthermore, in the shredding step S4, the metal foil unnecessary region may be cut into a plurality of times.

DESCRIPTION OF SYMBOLS 1 Metal foil pattern 3 Metal foil required area | region 4 Metal foil unnecessary area | region 11 Adhesive film 12 Metal foil 22, 24, 25, 26 Blade part 22a, 24a, 25a, 26a Tip C1 Reference line C2, C3 Separation line C4 Cut line L Peeling Length Z Thickness direction

Claims (4)

A metal foil die-cutting method for cutting the metal foil by pressing the tip of the blade portion against the metal foil laminated on the adhesive film,
A laminating step of laminating the metal foil on the adhesive film;
When the tip of the blade is pressed against the metal foil and viewed parallel to the thickness direction of the metal foil, the metal foil is cut by a separation line defined by the tip of the pressed blade And separating the metal foil from the adhesive film in a predetermined range around the separation line, and separating the metal foil required region and the metal foil unnecessary region of the metal foil,
When the tip of the blade portion is pressed against the metal foil unnecessary region and viewed in parallel with the thickness direction, the metal foil is cut by one or more severing lines defined by the tip of the pressed blade portion. A shredding step of cutting the unnecessary region and peeling the metal foil unnecessary region from the adhesive film in a predetermined range around the shredded line,
Before the separation step and the shredding step,
When the tip of the blade is pressed against the metal foil laminated on the adhesive film and viewed parallel to the thickness direction of the metal foil, the reference defined by the tip of the pressed blade A preliminary step for obtaining a peeling length at which the metal foil peels from the adhesive film around a line;
With
After the laminating step and the shredding step, when viewed in parallel to the thickness direction, the distance from each shred line to the adjacent shred line or the separation line is any of the shred lines. The metal foil die-cutting method is characterized in that it is set so as to be equal to or less than a value obtained by doubling the peeling length in the portion.   The metal foil die-cutting method according to claim 1, wherein at least a part of the metal foil required region is set such that a minimum distance from the adjacent separation line is larger than the peeling length.   The metal foil die-cutting method according to claim 1 or 2, wherein a tip of the blade portion is formed at an acute angle.   The metal foil die-cutting method according to any one of claims 1 to 3, wherein the separation step and the shredding step are performed simultaneously.

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