JP7086532B2 - Manufacturing method of electronic device and breathable sheet used for it - Google Patents

Description

The present invention uses a breathable sheet that is used as an interposition between the suction stage and the base material when printing is applied to the surface of the base material that is suction-fixed to the suction stage of the vacuum suction device by printed electronics. Regarding the manufacturing technology of electronic devices.

With the miniaturization of electrical equipment, the development of small, lightweight, or thin electronic components such as integrated circuits, wiring materials, and electronic boards (hereinafter collectively referred to as electronic components) has been promoted. ing. In recent years, printed electronics have been attracting attention as a technology to meet such demands. Printed electronics is a film (hereinafter, non-breathable base material) made of various inks containing conductive components or insulating materials (hereinafter, various inks used in printed electronics may be simply referred to as inks). It is a technical field of printing on the surface of a base material such as (referred to as) and making various electronic components on this base material. By using printed electronics, for example, electronic components are made on the surface of light and thin base materials such as films and fabrics (nonwoven fabrics, knits, woven fabrics) and flexible base materials, making them smaller and lighter. Flexible electrical equipment can be provided.

In this printed electronics, a film is often used for the substrate in order to give flexibility after mounting the electronic component. Since the mounted electronic component generates heat during operation, an opening is provided in the area where the component is mounted to promote heat dissipation of the electronic component or to exhibit flexibility. Further, there is known a technique of providing a wiring called a flying lead in an opening in order to perform alignment when mounting a copper wiring and an electronic component. In the present specification, an opening opened in a material such as a film as a base material is referred to as an opening, and is referred to as a non-breathable base material regardless of the presence or absence of such an opening.

A non-breathable substrate provided with such an opening is known as a TAB (Tape Automated Bonding) technique in which electronic components are continuously mounted on a single tape. In this TAB technique, before mounting an electronic component, a connection wiring with an electronic component to be mounted in a post-process is pre-printed on a non-breathable base material, which is also generally called a carrier tape. Printed electronics technology is used to form this wiring, and conductive ink is printed on a non-breathable substrate in a predetermined pattern. The wiring pattern is variously designed in relation to the arrangement with the electronic components mounted in the opening, and is not limited to the case where it is provided only on one surface of the non-breathable base material, but the electrons provided on the other non-breathable base material. In order to realize multi-layer wiring for electrical connection with parts, a wiring pattern that extends from the surface of the base material to the wall surface that defines the opening, and a structure that can be connected on the other side of the base material, etc. Complex mounting techniques are also known.

Japanese Unexamined Patent Publication No. 2000-244112 (hereinafter, Patent Document 1) discloses a technique for manufacturing a printed flexible wiring board using a non-breathable base material provided with an opening. In this literature technology, a flexible wiring board (non-breathable base material) having through holes (openings) formed is sandwiched between a porous adsorption paper and a porous material of a predetermined thickness on the lower surface thereof, and the entire lower surface thereof is covered. Place it on a printing table with a space. Next, the non-breathable base material is fixed by sucking downward from the suction holes uniformly provided in the entire area of the table and reducing the pressure on the lower surface side of the porous material. In this state, a step of filling the through hole with the conductive paste from the upper surface of the flexible wiring board by printing is disclosed. In this printing technique, the wiring provided on the front and back of the flexible wiring board is connected to each other by substantially backfilling the inside of the through hole formed in advance with the conductive paste. At this time, since the flexible wiring board is adsorbed and fixed, an attractive force acts also inside the through hole, and the conductive paste is excessively attracted to the porous material side. Therefore, in the technique of Patent Document 1, it is proposed that the above-mentioned adsorption paper is interposed between the flexible wiring board and the porous material constituting the table surface, and the conductive paste prevents contamination of the suction port on the table side. ing. As a prior art disclosed in Patent Document 1, a spacer having a "relief hole" is arranged at a position corresponding to the lower part of the through hole, and a suction force from the suction port acts on the "relief hole". Illustrates a configuration that does not. In comparison with this conventional technique, the technique of Patent Document 1 is expected to eliminate the complexity of positioning the "relief hole" and the "through hole" (see [0004] and [FIG. 4] of Patent Document 1). ..

The above-mentioned literature technique exemplifies a printing technique in which a relatively small opening extending over the front and back of a non-breathable base material is provided for conduction, and improves the alignment accuracy of the area to be printed when suctioning and fixing the base material. It has been proposed as a less necessary technique. On the other hand, in Japanese Patent Application Laid-Open No. 7-45668 (Patent Document 2), a rectangular device hole having a relatively large opening area and a plurality of trapezoidal outer lead holes having a relatively small opening area are provided around the device hole. A suitable printing technique has been proposed by applying it to the provided non-breathable substrate. In this publication technique, a TAB tape having a lead (wiring) provided in a predetermined opening such as a device hole is supported on a stage, and when a squeegee pressure is applied to the TAB tape from a screen mask and resist is applied, the TAB tape is applied. Convex on a printing stage (corresponding to the table in Patent Document 1; hereinafter collectively referred to as a suction stage) corresponding to the opening position, protruding into a device hole and supporting a lead formed so as to cross the outer lead hole. A portion is provided so that the lead on the opening does not deform even when squeegee pressure is applied.

On the other hand, as a technique related to this printed electronics, the applicants have published International Publication No. WO2016 / 021239A1 (International Publication No. WO2016 / 021239A1) in order to improve the sharpness of an image formed on a non-breathable substrate having no opening. Hereinafter, Patent Document 3) is proposed. The breathable sheet proposed in this publication is configured to include at least one non-woven fabric layer and at least one support layer, and may be laminated to further include other breathable members. Here, since the support layer in contact with the plurality of suction ports provided in the suction stage is directly subjected to the suction action, a mesh-like material having little morphological change such as a woven fabric or a knitted fabric is used, preferably made of SUS. Use a plain weave mesh. In addition, when the sintered metal or porous ceramics previously used in printed electronics are directly placed on the adsorption stage, the unevenness of the surface of the conventional material affects the smoothness of the printed surface of the non-breathable substrate. It was difficult to form a clear image. Therefore, in the technique of Patent Document 3, in order to make the image formed on the surface of the non-breathable base material clear, a non-woven fabric layer on which the non-breathable base material is placed is laminated and arranged on the support layer, and the non-woven fabric is suction-fixed. The structure keeps the surface of the breathable base material smooth. With this proposed technique, it is possible to clarify a fine ink pattern on a non-breathable substrate having no opening.

Japanese Unexamined Patent Publication No. 2000-244112 ([Claims], [0004], [0008], [0019] to [0033], [FIG. 1] to [FIG. 3], etc.) JP-A-7-45668 ([Claims], [0013], [0016], [Fig. 1] to [Fig. 3]) WO2016 / 0121239A1 ([Claims] [0003], [0019] to [0025], [Fig. 1], etc.

As disclosed in each literature technique referred to in the background art, for example, in Patent Document 2, an electronic device is mounted on a non-breathable substrate provided with a plurality of types of openings from a surface different from the surface on which leads are formed. We are dealing with the TAB method to be implemented. Further, the technique of Patent Document 3 is a COF (Chip On Film; chip) in which a fine wiring pattern is printed on the surface of a non-breathable base material having no holes and an electronic device is placed and connected to the surface. It can be expected to be used for on-film technology. In this way, among the manufacturing technologies for a wide variety of electronic devices in which the workpiece is adsorbed and fixed to the adsorption stage, printed electronics are becoming finer day by day and are non-breathable in order to maintain ink pattern accuracy. Strictness is also required for the adsorption and fixation state of the base material. Therefore, it is difficult to completely prevent "contamination" on the adsorption stage side by a printing material such as conductive ink through the opening with an adsorption paper such as Patent Document 1. In the present specification, the shape of the ink transferred to the electronic device via the printing pattern is referred to as an ink pattern. It is said that it is extremely difficult to clearly form a fine ink pattern as proposed in Patent Document 3 because the suction force is dissipated by the provided opening and the non-breathable base material is displaced at the squeegee pressing portion by printing. Problems also arise. Further, the technique proposed in Patent Document 2 that utilizes the "convex portion" according to the shape of the opening is a non-ventilated material to be printed because the convex portion is directly provided on an expensive suction stage that requires high-precision metal processing. It is necessary to prepare for each opening form of the sex substrate, and there is also a problem that the manufacturing cost of the electronic device is increased and the yield is decreased, including the desorption step of the adsorption stage.

The present invention has been made in view of the above-mentioned conventional problems, and simplifies the process for mounting an electronic device on a non-breathable substrate having an opening, and "contamination" of the adsorption stage in the process. The purpose is to provide a technique that can improve the yield at low cost by solving the problem and clearly forming a fine ink pattern.

In order to achieve this object, according to the method for manufacturing an electronic device according to the present invention,
A support layer made of a mesh-like material in contact with the adsorption stage and a breathable sheet on which a non-woven fabric layer was laminated were placed on a flat adsorption stage, and a non-breathable substrate was adsorbed and fixed on the surface of the non-woven fabric layer. A method for manufacturing an electronic device that prints on this non-woven fabric in a state.
An opening is formed in the non-breathable substrate, and the surface of the predetermined region of the non-woven fabric layer corresponds to the above-mentioned opening and is embedded in the non-woven fabric layer so as not to protrude from the surface of the breathable sheet. It is characterized in that the formed non-breathable sealing portion is provided, and the above-mentioned non-breathable base material is suction-fixed and printed at the same position between the sealing portion and the above-mentioned opening.

Further, according to the configuration of the breathable sheet of the present invention suitable for the manufacturing technique of the present invention described above, the non-woven fabric layer for contacting the non-breathable substrate and the mesh-like material for contacting the adsorption stage are used. It is a breathable sheet in which a support layer is laminated.
A non-breathable sealing portion formed by embedding in the non-woven fabric layer so as not to protrude from the surface of the breathable sheet in the predetermined region of the above-mentioned nonwoven fabric layer according to the shape of the opening provided in the non-breathable substrate. It is characterized by the provision of.

By applying the technique according to the present invention, it is possible to homogenize the suction fixing over the entire surface of the adsorption stage (or the non-breathable base material), eliminate the contamination of the adsorption stage by the printing ink, and make the ink clear. Patterns can be obtained and efficient manufacturing of electronic devices can be realized.

An explanatory view schematically showing a plane and a cross section thereof in order to explain a suitable form of the breathable sheet according to the present invention. In order to explain a suitable embodiment of the manufacturing method according to the present invention, an explanatory view schematically showing a plane and a cross section in which each component is suction-fixed on an adsorption stage as in FIG. In order to explain the effect of the embodiment of the present invention, a drawing substitute photograph obtained by observing and taking an ink pattern printed on a non-breathable substrate with an optical microscope. A drawing substitute photograph showing the results of printing according to a comparative example in the same manner as in FIG.

Hereinafter, preferred embodiments of the technique of the present invention will be described with reference to the drawings. In the following description, in order to facilitate understanding of the present invention, specific shapes, numerical conditions, and arrangement relationships will be illustrated and described, but the technique according to the present invention is limited to these specific conditions. However, any suitable design change or modification can be made within the scope of the object of the present invention. Further, in the drawings referred to below, components having the same function are designated by the same reference numerals and hatching, and the reference numerals and hatching of some constituent components are omitted.

First, the configuration of a breathable sheet suitable for use in the production method of the present invention will be described with reference to FIG. FIG. 1 is a schematic view of a rectangular breathable sheet, which is a preferred embodiment of the present invention, in which the surface for adsorbing and fixing the non-breathable substrate is shown at the upper part, and the cross section at the position indicated by the alternate long and short dash line I-I is shown at the lower part. It is an explanatory diagram. First, the breathable sheet 11 has a non-woven fabric layer 13 for contacting and fixing with a non-breathable base material (not shown) and a support layer 15 made of a mesh-like material for contacting with a suction stage (not shown). It is laminated. The schematic configuration of this breathable sheet is preferably a configuration according to the above-mentioned Patent Document 3. Specifically, as described in the same document, a plain woven mesh made of stainless steel (SUS) of 70 mesh or more and 400 mesh or less is used for the support layer 15, and various fibers such as polyolefin resin and acrylic resin are used. The non-woven fabric layer 13 is prepared by forming the formable synthetic resin into fine fibers by a melt spinning method, a dry spinning method, a wet spinning method, a direct spinning method (melt blow method, spunbond method, electrostatic spinning method, etc.) or the like. It is preferable that these two interlayer bonds are laminated and integrated with a commercially available spray-like adhesive containing styrene-butadiene rubber, polyvinyl alcohol, nylon hot melt or the like as a main component so as not to impair the air permeability.

Next, in the predetermined area of the nonwoven fabric layer 13 of the breathable sheet described above, for example, a hot melt film made of nylon or another thermoplastic resin, a sealing treatment with a binder made of a resin such as acrylic, and the nonwoven fabric layer being made of a thermoplastic resin. If it is configured, it is non-breathable by means such as sealing by heat fusion, or forming a well-known resist or the like into a non-woven fabric layer in a predetermined shape by a well-known method such as spraying, coating, transfer, or printing. A sealing portion 17 is provided. The predetermined region and the predetermined shape represent the shape and the arrangement condition according to the shape of the opening provided in the non-breathable base material. In forming the sealing portion, the non-breathable base material having an opening is laminated on the breathable sheet in advance, fixed on the suction stage, and the above-mentioned resin is printed on the non-breathable base material only in a predetermined area. It is best to provide a breathable seal. Further, if necessary, the sealing portion can be formed by a well-known means through an additional sealing treatment such as fixing the printed material resin to the constituent fibers of the nonwoven fabric layer by heating. FIG. 1 exemplifies a case where rectangular sealing portions 17 are formed at four locations, but the shape and arrangement relation correspond to openings provided in a non-breathable base material which is a printed matter. Is. The height at which the sealing portion 17 protrudes from the main surface of the nonwoven fabric layer 13 is preferably equal to or less than the thickness of the non-breathable substrate. Further, in the lower sectional view of FIG. 1, the interface between the nonwoven fabric layer 13 and the sealing portion 17 is shown by a dotted line, but the sealing portion 17 is prevented from easily falling off due to handling in the manufacturing process of the electronic device. It is better to make it a non-breathable area where the materials are firmly integrated with each other.

Next, a preferred example of the production method of the present invention will be described with reference to FIG. In FIG. 2, in the same manner as in FIG. 1, the above-mentioned breathable sheet 11 is placed on the suction stage 21 in which the suction port 19 is provided, and the sealing portion 17 and the opening provided in the sheet 11 are formed. It is explanatory drawing which shows typically the state in which the base material 23 is sucked and fixed at the position where the non-breathable base material 23 is substantially fitted. Since the opening and the sealing portion 17 are present at the same position, the reference numeral of the opening is omitted. Further, the vacuum suction device for supplying the suction force to the suction stage 21 is not shown. As can be understood from this figure, since the sealing portion 17 is fitted in the opening provided in the non-breathable base material 23, the entire surface of the base material 23 is substantially kept non-breathable. Moreover, smooth suction fixing can be realized on all printed surfaces. Therefore, even when a printing means (ink material, screen, squeegee) (not shown) is applied to the entire surface of the non-breathable base material in this state, the ink material may be contaminated on the suction port 19. It is possible to print a clear pattern without any problems.

Although the embodiments of the present invention have been described above with specific configurations, the technique of the present invention is not limited to these specific conditions. For example, the shape of a substantially square is exemplified as the sealing portion 17, but it may be a rectangle such as a rectangle, a circle, an ellipse, a triangle, or another polygon depending on the shape of the opening provided in the non-breathable substrate. You can also do it. Further, the size of the sealing portion 17 is designed to be smaller than that of the opening, so that the alignment can be facilitated. At this time, the gap between the opening and the sealing portion is made equal to the diameter of the suction port, so that the gap does not substantially affect the ink pattern. Further, although not shown, a binder, a hot melt film, or the like can be embedded in the non-woven fabric layer so that the sealing portion does not protrude from the surface of the breathable sheet. In this case, it is possible to allow a margin for alignment with the non-breathable base material. In addition, in order to cope with a non-breathable substrate having a sprocket hole as disclosed in Patent Document 2 described above, a protrusion is provided on the edge of the breathable sheet of the present invention by a well-known technique for alignment. You may try to simplify it.

Hereinafter, preferred examples and comparative examples of the present invention will be illustrated, and the evaluation results of actual printing will be described. First, a configuration example of the breathable sheet according to the embodiment will be described. The basic configuration of the example was produced according to the above-mentioned Patent Document 3. That is, a 100-mesh (wire diameter 0.1 mm, opening interval 0.15 mm) support 15 made of commercially available SUS plain weave, a non-woven fabric having a mesh size of 17 g / m ² made of polyacrylonitrile fiber having a fiber diameter of 400 nm, and an acrylic binder. The non-woven fabric layer 13 (25 g / m ² with a total mesh size) coated with the above was laminated and pressure-bonded to prepare a 170 mm square breathable sheet. After that, the printing paste "LS-460H-1-Ultra-Fine-Ag-" containing silver is formed so that 20 mm square squares are formed in four places according to the shape of the non-breathable base material 23 shown in FIG. "Paste" (manufactured by Asahi Chemical Laboratory Co., Ltd., trade name) was printed and formed to form a sealing portion 17. Further, in the comparative example, those having the same configuration were prepared except that the sealing portion was not provided.

Next, the conditions of the printing test will be described. In this embodiment, a commercially available printing machine "WHT Lab" (manufactured by Mino Group Co., Ltd., trade name) having a function of an adsorption stage and a printing machine is used, and a commercially available polyethylene terephthalate film (commercially available as a non-breathable base material 23) is used. A thickness of 12 μm) was used. Each of the above-mentioned breathable sheets was fixed to the suction stage with tape, and subsequently, for the breathable sheet of the example, the sealing portion 17 and the opening of the film were aligned and fixed by suction. At this time, as the printing pattern used for printing, a plurality of 0.3 mm × 1 mm rectangles were formed at intervals of 0.2 mm, and printing was performed using the above-mentioned print paste. As for the print evaluation result, the portion adjacent to the opening shown by the two-dot chain line in FIG. 2 described above was observed with an optical microscope. The results are shown in FIG. 3 for Examples and FIG. 4 for Comparative Examples.

First, as can be understood from FIG. 3, in the breathable sheet according to the embodiment, the lines constituting the rectangular pattern could be clearly printed up to the edge corresponding to the opening of the non-breathable base material. On the other hand, in the result of the breathable sheet of the comparative example shown in FIG. 4, clear streaks could not be formed and the line width became non-uniform. The reason for this is that since the adsorption force is uniform in the examples, the printed pattern and the non-breathable substrate are in close contact with each other at the portion pressed by the squeegee, and then the close contact state is immediately eliminated when the squeegee no longer presses the printed pattern. Will be done. On the other hand, in the comparative example, in order to weaken the adhesion of the non-breathable base material to the adsorption stage (and the breathable sheet) by the dissipation of the suction force, the non-breathable base material becomes the printed pattern after the pressing by the squeegee is released. The state of close contact and lifting continues for a while. Subsequent peeling with a delay causes the non-breathable substrate to be dragged by the printed pattern, causing the ink pattern to shift. At the same time, it is probable that after the pressing by the squeegee was released, the peeling from the print pattern was delayed, and the ink was transferred to the non-breathable substrate with a thickness larger than necessary, which made it unclear. From the above, it was confirmed that a good ink pattern can be formed by the configuration of the present invention including the sealing portion corresponding to the opening formed in the non-breathable base material.

11: Breathable sheet, 13: Non-woven fabric layer, 15: Support layer, 17: Sealing part,
19: Suction port, 21: Suction stage, 23: Non-breathable substrate, A: Shooting position of evaluation result.

Claims (2)

A support layer made of a mesh-like material in contact with the adsorption stage and a breathable sheet on which a non-woven fabric layer was laminated were placed on a flat adsorption stage, and a non-breathable substrate was adsorbed and fixed on the surface of the nonwoven fabric layer. A method for manufacturing an electronic device that prints on the non-woven fabric in a state.
An opening is formed in the non-breathable base material, and the non-woven fabric layer is embedded in the non-woven fabric layer so as to correspond to the opening on the surface of a predetermined region and not to protrude from the surface of the breathable sheet. A method for manufacturing an electronic device, characterized in that a non-breathable sealing portion is provided, and the non-breathable base material is suction-fixed and printed at the same position between the sealing portion and the opening. A breathable sheet in which a non-woven fabric layer for contacting a non-breathable substrate and a support layer made of a mesh-like material for contacting an adsorption stage are laminated.
A non-breathable sealing portion formed by embedding in the non-woven fabric layer so as not to protrude from the surface of the breathable sheet is provided in a predetermined area of the nonwoven fabric layer according to the shape of the opening provided in the non-breathable substrate. A breathable sheet characterized by being provided.

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