JP6645730B2 - 接続体及び接続体の製造方法 - Google Patents
接続体及び接続体の製造方法 Download PDFInfo
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- JP6645730B2 JP6645730B2 JP2014219705A JP2014219705A JP6645730B2 JP 6645730 B2 JP6645730 B2 JP 6645730B2 JP 2014219705 A JP2014219705 A JP 2014219705A JP 2014219705 A JP2014219705 A JP 2014219705A JP 6645730 B2 JP6645730 B2 JP 6645730B2
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Description
また、本発明に係る接続体は、回路基板上に異方性導電接着剤を介して電子部品が接続された接続体において、上記異方性導電接着剤は、バインダー樹脂に導電性粒子が配列され、上記電子部品に形成された接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって密、上記配列方向と直交する方向に亘って疎に配列されているものである。
また、本発明に係る接続体は、回路基板上に異方性導電接着剤を介して電子部品が接続された接続体において、上記異方性導電接着剤は、バインダー樹脂に導電性粒子が配列され、上記電子部品に形成された接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子の上記基板電極の長手方向の外接線が、該長手方向に隣接して捕捉された導電性粒子を貫くものである。
また、本発明に係る接続体の製造方法は、回路基板上に、導電性粒子を含有した接着剤を介して電子部品を搭載し、上記電子部品を上記回路基板に対して押圧するとともに、上記接着剤を硬化させることにより、上記電子部品を上記回路基板上に接続する接続体の製造方法において、上記接着剤は、バインダー樹脂に導電性粒子が配列され、上記接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記電子部品に形成された接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって密、上記配列方向と直交する方向に亘って疎に配列されるものである。
また、本発明に係る接続体の製造方法は、回路基板上に、導電性粒子を含有した接着剤を介して電子部品を搭載し、上記電子部品を上記回路基板に対して押圧するとともに、上記接着剤を硬化させることにより、上記電子部品を上記回路基板上に接続する接続体の製造方法において、上記接着剤は、バインダー樹脂に導電性粒子が配列され、上記接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記電子部品に形成された接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子の上記基板電極の長手方向の外接線が、該長手方向に隣接して捕捉された導電性粒子を貫くものである。
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。
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5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。導電性粒子4の大きさは1〜10μmが好ましいが、本発明はこれに限定されるものではない。
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6に示すように、格子状かつ均等に配列されるものがある。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、透明基板12の透明電極17の配線ピッチや液晶駆動用IC18の電極端子19のファインピッチ化が進んでいることから、透明基板12上に液晶駆動用IC18をCOG接続する場合、ファインピッチ化された電極端子19及び端子部17aとの間においても確実に導電性粒子が挟持され導通を確保するために、異方性導電フィルム1は、導電性粒子4が高密度で配列されている。
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。
ここで、本発明においては、隣接する電極端子19間の端子間スペース23における導電性粒子4同士の粒子間距離は、電極端子19と端子部17aとの間に捕捉された導電性粒子4同士の粒子間距離よりも長い。したがって、液晶表示パネル10は、ファインピッチ化された電極端子19の端子間スペース23において導電性粒子4が連なることによる端子間ショートを防止することができる。
また、図8(A)に示すように、異方性導電フィルム1は、端子部17a及び電極端子19の配列方向を長手方向とするフィルム状に形成され、導電性粒子4が、長手方向にわたって疎、幅方向に亘って密に配列されていてもよい。
また、図9〜図11に示すように、異方性導電フィルム1は、フィルムの長手方向Lfと直交する幅方向Ltに対して、導電性粒子4を傾斜させて配列し、フィルムの長手方向Lfを端子部17aの配列方向と平行、且つフィルムの幅方向Ltを端子部17aの長手方向と平行に配置させることにより、異方導電性フィルム1の長手方向Lfに直交する方向の、導電性粒子Pの外接線(二点鎖線)が、その導電性粒子Pに隣接する導電性粒子Pc、Peを貫いてもよい。
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。
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。
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、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たITOパターングラスを用いた。
実施例1では、導電性粒子がバインダー樹脂層に規則配列された異方性導電フィルムを用いた。実施例1で用いた異方性導電フィルムは、延伸可能なシート上に粘着剤を塗布し、その上に導電性粒子を格子状かつ均等に単層配列した後、当該シートを所望の延伸倍率で延伸させた状態で、バインダー樹脂層をラミネートすることにより製造した。使用した導電性粒子(商品名:AUL704、積水化学工業社製)は粒子径4μmで、接続前における粒子間距離は0.5μm、粒子個数密度は28000個/mm2である。
実施例2では、接続前における粒子間距離が1μm、粒子個数密度が16000個/mm2の異方性導電フィルムを用いた他は、実施例1と同じ条件とした。
実施例3では、接続前における粒子間距離が1.5μm、粒子個数密度が10500個/mm2の異方性導電フィルムを用いた他は、実施例1と同じ条件とした。
実施例4では、接続前における粒子間距離が3μm、粒子個数密度が5200個/mm2の異方性導電フィルムを用いた他は、実施例1と同じ条件とした。
実施例5では、接続前における粒子間距離が0.5μm、粒子個数密度が50000個/mm2の異方性導電フィルムを用いた他は、実施例1と同じ条件とした。
比較例1では、バインダー樹脂組成物に導電性粒子を加えて調整し、剥離フィルム上に塗布、焼成することにより、バインダー樹脂層に導電性粒子がランダムに分散されている異方性導電フィルムを用いた。使用した導電性粒子(商品名:AUL704、積水化学工業社製)は粒子径4μmで、粒子個数密度は100000個/mm2である。
比較例2では、粒子個数密度は16000個/mm2である他は、比較例1と同じ条件とした。
Claims (10)
- 回路基板上に異方性導電接着剤を介して電子部品が接続された接続体において、
上記異方性導電接着剤は、バインダー樹脂に導電性粒子が配列され、
上記電子部品に形成された接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、
上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって疎、上記配列方向と直交する方向に亘って密に配列されている接続体。 - 回路基板上に異方性導電接着剤を介して電子部品が接続された接続体において、
上記異方性導電接着剤は、バインダー樹脂に導電性粒子が配列され、
上記電子部品に形成された接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、
上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって密、上記配列方向と直交する方向に亘って疎に配列されている接続体。 - 上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子の上記基板電極の長手方向の外接線が、該長手方向に隣接して捕捉された導電性粒子を貫く請求項1又は2に記載の接続体。
- 上記異方性導電接着剤は、上記導電性粒子密度が5000個/mm2以上である請求項1〜3のいずれか1項に記載の接続体。
- 上記異方性導電接着剤は、上記導電性粒子が規則配列された異方性導電フィルムであり、
上記導電性粒子は、フィルム幅方向への配列方向が該フィルム幅方向に対して傾斜するとともに、フィルム長手方向への配列方向が該フィルム長手方向に対して傾斜している請求項1〜4のいずれか1項に記載の接続体。 - 回路基板上に、導電性粒子を含有した接着剤を介して電子部品を搭載し、
上記電子部品を上記回路基板に対して押圧するとともに、上記接着剤を硬化させることにより、上記電子部品を上記回路基板上に接続する接続体の製造方法において、
上記接着剤は、バインダー樹脂に導電性粒子が配列され、
上記接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記電子部品に形成された接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、
上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって疎、上記配列方向と直交する方向に亘って密に配列される接続体の製造方法。 - 回路基板上に、導電性粒子を含有した接着剤を介して電子部品を搭載し、
上記電子部品を上記回路基板に対して押圧するとともに、上記接着剤を硬化させることにより、上記電子部品を上記回路基板上に接続する接続体の製造方法において、
上記接着剤は、バインダー樹脂に導電性粒子が配列され、
上記接続電極間のスペースにおける導電性粒子同士の粒子間距離は、上記回路基板に形成された基板電極と上記電子部品に形成された接続電極との間に捕捉された上記導電性粒子同士の粒子間距離よりも長く、
上記基板電極及び上記接続電極の配列方向において、上記導電性粒子が、上記配列方向にわたって密、上記配列方向と直交する方向に亘って疎に配列される接続体の製造方法。 - 上記回路基板に形成された基板電極と上記接続電極との間に捕捉された上記導電性粒子の上記基板電極の長手方向の外接線が、該長手方向に隣接して捕捉された導電性粒子を貫く請求項6又は7に記載の接続体の製造方法。
- 上記異方性導電接着剤は、上記導電性粒子密度が5000個/mm2以上である請求項6〜8のいずれか1項に記載の接続体の製造方法。
- 上記接着剤は、上記導電性粒子が規則配列された異方性導電フィルムであり、
上記導電性粒子は、フィルム幅方向への配列方向が該フィルム幅方向に対して傾斜するとともに、フィルム長手方向への配列方向が該フィルム長手方向に対して傾斜している請求項6〜9のいずれか1項に記載の接続体の製造方法。
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JP2014219705A JP6645730B2 (ja) | 2014-01-28 | 2014-10-28 | 接続体及び接続体の製造方法 |
PCT/JP2015/050620 WO2015115161A1 (ja) | 2014-01-28 | 2015-01-13 | 接続体及び接続体の製造方法 |
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US15/112,872 US10299382B2 (en) | 2014-01-28 | 2015-01-13 | Connection body and connection body manufacturing method |
CN201580006279.7A CN106415937B (zh) | 2014-01-28 | 2015-01-13 | 连接体及连接体的制造方法 |
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KR102621211B1 (ko) * | 2016-05-05 | 2024-01-04 | 데쿠세리아루즈 가부시키가이샤 | 이방성 도전 필름 |
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JP7301468B2 (ja) | 2019-04-17 | 2023-07-03 | 株式会社ディスコ | 被加工物の加工方法、熱圧着方法 |
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KR102639862B1 (ko) | 2024-02-22 |
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US10299382B2 (en) | 2019-05-21 |
CN106415937B (zh) | 2020-05-19 |
WO2015115161A1 (ja) | 2015-08-06 |
KR102368746B1 (ko) | 2022-02-28 |
JP2015164169A (ja) | 2015-09-10 |
KR20220029770A (ko) | 2022-03-08 |
KR20160114054A (ko) | 2016-10-04 |
CN106415937A (zh) | 2017-02-15 |
TW201540146A (zh) | 2015-10-16 |
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