JP6324746B2 - 接続体、接続体の製造方法、電子機器 - Google Patents
接続体、接続体の製造方法、電子機器 Download PDFInfo
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- JP6324746B2 JP6324746B2 JP2014018532A JP2014018532A JP6324746B2 JP 6324746 B2 JP6324746 B2 JP 6324746B2 JP 2014018532 A JP2014018532 A JP 2014018532A JP 2014018532 A JP2014018532 A JP 2014018532A JP 6324746 B2 JP6324746 B2 JP 6324746B2
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Description
a+b+c≦0.8D ・・・(1)
[a:接続電極の段部高さ、b:基板電極の段部高さ、c:段部間ギャップ、D:導電性
粒子の径]
また、本発明に係る接続体の製造方法は、回路基板上に異方性導電接着剤を介して電子部品を接続する工程を有し、上記回路基板に形成された基板電極及び上記電子部品に形成された電極端子には、各側縁部に段部が形成され、上記基板電極及び上記電極端子は、各主面部間に、上記異方性導電接着剤に含有された導電性粒子が挟持され、上記導電性粒子と上記基板電極及び上記電極端子の各上記段部とが、以下の式(1)を満たすものである。
a+b+c≦0.8D ・・・(1)
[a:接続電極の段部高さ、b:基板電極の段部高さ、c:段部間ギャップ、D:導電性粒子の径]
また、本発明に係る電子機器は、接続体を備えた電子機器において、上記接続体は、上記記載のものである。
以下では、本発明が適用された接続体として、ガラス基板に、電子部品として液晶駆動用のICチップが実装された液晶表示パネルを例に説明する。この液晶表示パネル10は、図1に示すように、ガラス基板等からなる二枚の透明基板11,12が対向配置され、これら透明基板11,12が枠状のシール13によって互いに貼り合わされている。そして、液晶表示パネル10は、透明基板11,12によって囲繞された空間内に液晶14が封入されることによりパネル表示部15が形成されている。
また、図2に示すように、透明基板12は、物理的な損傷や短絡等を防止するために、基板表面に窒化膜や酸化シリコン膜などの無機膜や有機膜などからなる絶縁性の保護膜23が形成されている。保護膜23は、公知の成膜手法により、端子部17aや基板側アライメントマーク21を除く領域に形成されている。これにより、保護膜23と隣接する端子部17aの側縁部には保護膜23による段部28が形成される。したがって、端子部17aは、断面視において、両側縁部において段部28が隆起し、主面部が平坦化されている。
液晶駆動用IC18は、例えば、図3に示すように、実装面18aの一方の側縁に沿って電極端子19(入力バンプ)が一列で配列され、一方の側縁と対向する他方の側縁に沿って電極端子19(出力バンプ)が複数列で千鳥状に配列されている。電極端子19と、透明基板12のCOG実装部20に設けられている端子部17aとは、それぞれ同数かつ同ピッチで形成され、透明基板12と液晶駆動用IC18とが位置合わせされて接続されることにより、接続される。
次いで、異方性導電フィルム1について説明する。異方性導電フィルム(ACF:Anisotropic Conductive Film)1は、図4に示すように、通常、基材となる剥離フィルム2上に導電性粒子4を含有するバインダー樹脂層(接着剤層)3が形成されたものである。異方性導電フィルム1は、熱硬化型あるいは紫外線等の光硬化型の接着剤であり、液晶表示パネル10の透明基板12に形成された透明電極17上に貼着されるとともに液晶駆動用IC18が搭載され、熱圧着ヘッド33により熱加圧されることにより流動化して導電性粒子4が相対向する透明電極17の端子部17aと液晶駆動用IC18の電極端子19との間で押し潰され、加熱あるいは紫外線照射により、導電性粒子が押し潰された状態で硬化する。これにより、異方性導電フィルム1は、透明基板12と液晶駆動用IC18とを接続し、導通させることができる。
導電性粒子4としては、異方性導電フィルム1において使用されている公知の何れの導電性粒子を挙げることができる。導電性粒子4としては、例えば、ニッケル、鉄、銅、アルミニウム、錫、鉛、クロム、コバルト、銀、金等の各種金属や金属合金の粒子、金属酸化物、カーボン、グラファイト、ガラス、セラミック、プラスチック等の粒子の表面に金属をコートしたもの、或いは、これらの粒子の表面に更に絶縁薄膜をコートしたもの等が挙げられる。樹脂粒子の表面に金属をコートしたものである場合、樹脂粒子としては、例えば、エポキシ樹脂、フェノール樹脂、アクリル樹脂、アクリロニトリル・スチレン(AS)樹脂、ベンゾグアナミン樹脂、ジビニルベンゼン系樹脂、スチレン系樹脂等の粒子を挙げることができる。
異方性導電フィルム1は、導電性粒子4が平面視において所定の配列パターンで規則的に配列され、例えば図5に示すように、格子状かつ均等に配列されることが好ましい。平面視において規則的に配列されることにより、異方性導電フィルム1は、導電性粒子4がランダムに分散されている場合に比して、液晶駆動用IC18の隣接する電極端子19間がファインピッチ化し端子間面積が狭小化するとともに、導電性粒子4が高密度に充填されていても、液晶駆動用IC18の接続工程において、導電性粒子4の凝集体による電極端子19間のショートを防止することができる。
ここで、導電性粒子4を規則配列した異方性導電フィルム1を用いた場合、図6に示すように、電極端子19及び端子部17aの両段部27,28間に導電性粒子4が咬みこまれる場合がある。このとき、導電性粒子4と、導電性粒子4を挟持する電極端子19及び端子部17aの各段部27,28とは、以下の式(1)を満たす。
a+b+c≦0.8D ・・・(1)
[a:電極端子19の段部高さ、b:端子部17aの段部高さ、c:段部間ギャップ、D:導電性粒子4の径]
c≦1μm ・・・(2)
次いで、透明基板12に液晶駆動用IC18を接続する接続工程について説明する。先ず、透明基板12の端子部17aが形成されたCOG実装部20上に異方性導電フィルム1を仮貼りする。次いで、この透明基板12を接続装置のステージ上に載置し、透明基板12の実装部上に異方性導電フィルム1を介して液晶駆動用IC18を配置する。
a+b+c≦0.8D ・・・(1)
[a:電極端子19の段部高さ、b:端子部17aの段部高さ、c:段部間ギャップ、D:導電性粒子4の径]
評価用ICの接続に用いる異方性導電フィルムのバインダー樹脂層は、フェノキシ樹脂(商品名:YP50、新日鐵化学社製)60質量部、エポキシ樹脂(商品名:jER828、三菱化学社製)40質量部、カチオン系硬化剤(商品名:SI‐60L、三新化学工業社製)2質量部を溶剤に加えたバインダー樹脂組成物を調整し、このバインダー樹脂組成物を剥離フィルム上に塗布、焼成することにより形成した。
導通抵抗を測定するための評価素子として、外形;1.8mm×20mm、厚み0.5mm、バンプ(Au‐plated);幅30μ×長さ85μm、高さ15μm、バンプ間スペース幅;50μmの評価用ICを用いた。
導通抵抗を測定するための評価用ICが接続される評価用ガラス基板として、外形;30mm×50mm、厚み0.5mm、導通抵抗を測定するための評価用ICのバンプと同サイズ同ピッチの櫛歯状の電極パターンが形成されるとともに、電極パターンを除く領域に保護膜が形成されたITOパターングラスを用いた。
隣接するICバンプ間のショート発生率を測定するための評価素子として、外形;1.5mm×13mm、厚み0.5mm、バンプ(Au‐plated);幅25μ×長さ140μm、高さ15μm、バンプ間スペース幅;7.5μmの評価用ICを用いた。
隣接するICバンプ間のショート発生率を測定するための評価用ICが接続される評価用ガラス基板として、外形;30mm×50mm、厚み0.5mm、隣接するICバンプ間のショート発生率を測定するための評価用ICのバンプと同サイズ同ピッチの櫛歯状の電極パターンが形成されるとともに、電極パターンを除く領域に保護膜が形成されたITOパターングラスを用いた。
実施例1では、異方性導電フィルムとして、粒子径4μmの導電性粒子を使用した。接続前における粒子個数密度は28000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは0.8μmである。
実施例2では、粒子径3.5μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。ICバンプ及び基板電極の各段部の高さa、bは実施例1と同じ条件とした。
実施例3では、粒子径3.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。ICバンプ及び基板電極の各段部の高さa、bは実施例1と同じ条件とした。
実施例4では、粒子径3.5μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは1.2μmである。
実施例5では、粒子径3.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。ICバンプ及び基板電極の各段部の高さa、bは実施例1と同じ条件とした。
実施例6では、粒子径3.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。ICバンプ及び基板電極の各段部の高さa、bは実施例1と同じ条件とした。
実施例7では、粒子径4.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは1.4μmである。
比較例1では、粒子径3.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは1.4μmである。
比較例2では、粒子径4.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は28000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは0.8μmである。
比較例3では、粒子径4.0μmの導電性粒子を使用した異方性導電フィルムを用いた。接続前における粒子個数密度は40000個/mm2である。また、ICバンプの側縁部に形成された段部の高さaは0.8μm、ガラス基板に形成された基板電極の側縁部に形成された段部の高さbは1.4μmである。
Claims (7)
- 回路基板と、
上記回路基板上に異方性導電接着剤を介して接続されている電子部品とを備え、
上記回路基板に形成された基板電極及び上記電子部品に形成された電極端子には、各側縁部に段部が形成され、
上記基板電極及び上記電極端子は、各主面部間に、上記異方性導電接着剤に含有された導電性粒子が挟持され、
上記導電性粒子と上記基板電極及び上記電極端子の各上記段部とが、以下の式(1)を満たす接続体。
a+b+c≦0.8D ・・・(1)
[a:接続電極の段部高さ、b:基板電極の段部高さ、c:段部間ギャップ、D:導電性粒子の径] - 上記各側縁部に形成された段部間に、上記導電性粒子が挟持されている上記基板電極及び上記電極端子を含む請求項1記載の接続体。
- さらに、上記導電性粒子と上記基板電極及び上記電極端子の各上記段部とが、以下の式(2)を満たす請求項1又は2に記載の接続体。
c≦1μm ・・・(2) - 上記異方性導電接着剤は、フィルム状に形成され、
上記導電性粒子は、規則的に配列されている又は個々に離間している請求項1〜3のいずれか1項に記載の接続体。 - 回路基板上に異方性導電接着剤を介して電子部品を接続する工程を有し、
上記回路基板に形成された基板電極及び上記電子部品に形成された電極端子には、各側縁部に段部が形成され、
上記基板電極及び上記電極端子は、各主面部間に、上記異方性導電接着剤に含有された導電性粒子が挟持され、
上記導電性粒子と上記基板電極及び上記電極端子の各上記段部とが、以下の式(1)を満たす接続体の製造方法。
a+b+c≦0.8D ・・・(1)
[a:接続電極の段部高さ、b:基板電極の段部高さ、c:段部間ギャップ、D:導電性粒子の径] - 接続体を備えた電子機器において、
上記接続体は、上記請求項1〜4のいずれか1項に記載の接続体である電子機器。 - 上記電子機器は、表示装置である請求項6に記載の電子機器。
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CN202011369788.5A CN112614818A (zh) | 2014-02-03 | 2015-02-03 | 连接体 |
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