TW201038703A - Film adhesive and anisotropic conductive adhesive - Google Patents

Film adhesive and anisotropic conductive adhesive Download PDF

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Publication number
TW201038703A
TW201038703A TW098144435A TW98144435A TW201038703A TW 201038703 A TW201038703 A TW 201038703A TW 098144435 A TW098144435 A TW 098144435A TW 98144435 A TW98144435 A TW 98144435A TW 201038703 A TW201038703 A TW 201038703A
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TW
Taiwan
Prior art keywords
film
adhesive
epoxy resin
resin
conductive particles
Prior art date
Application number
TW098144435A
Other languages
English (en)
Inventor
Hideaki Toshioka
Yasuhiro Okuda
Original Assignee
Sumitomo Electric Industries
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Filing date
Publication date
Application filed by Sumitomo Electric Industries filed Critical Sumitomo Electric Industries
Publication of TW201038703A publication Critical patent/TW201038703A/zh

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J171/00—Adhesives based on polyethers obtained by reactions forming an ether link in the main chain; Adhesives based on derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/02—Non-macromolecular additives
    • C09J11/04—Non-macromolecular additives inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
    • C09J133/04—Homopolymers or copolymers of esters
    • C09J133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C09J133/062—Copolymers with monomers not covered by C09J133/06
    • C09J133/068—Copolymers with monomers not covered by C09J133/06 containing glycidyl groups
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J9/00—Adhesives characterised by their physical nature or the effects produced, e.g. glue sticks
    • C09J9/02—Electrically-conducting adhesives
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20—Conductive material dispersed in non-conductive organic material
    • H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/321—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by conductive adhesives
    • H05K3/323—Assembling 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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    • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
    • C08G2650/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group
    • C08G2650/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
    • C08G2650/56—Polyhydroxyethers, e.g. phenoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L2205/05—Polymer mixtures characterised by other features containing polymer components which can react with one another
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
    • C08L2666/14—Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
    • C08L33/062—Copolymers with monomers not covered by C08L33/06
    • C08L33/068—Copolymers with monomers not covered by C08L33/06 containing glycidyl groups
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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Description

201038703 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種用以接著且電性連接已設置電極、 電路等之基板或電子零件等之膜狀接著劑及異向導電性接 著劑。 【先前技術】 於近年之電子機器的小型化、高機能化之趨勢中，正 〇 朝向構造零件中之連接端子的狹小化。因此，於電子構裝 Ο 領域中，可容易地進行如此之端子間連接的各種膜狀接著 劑正被使用。例如，已被使用於1C晶片與可撓性印刷配線 板（FPC ) 、1C晶片與ITO (銦錫氧化物）電極電路所形 成的玻璃基板等之接合》 膜狀接著劑係具有於樹脂組成物中含有導電性粒子之 異向導電性接著劑（ACF: Anisotoropic Conductive Film) 與不含有導電性粒子之非導電性膜（NCF: Non Conductive 〇 Film )。任一種皆被夾住於連接對象之間，予以加熱、加 壓而接著連接對象。異向導電性接著劑之情形，藉由加熱、 加壓而使接著劑中之樹脂流動，密封各個的連接對象上之 所相對峙的電極間之間隙，同時導電性粒子之一部分也被 咬合於所對峙的電極間而達成電性連接。非導電性膜之情 形係藉由加熱、加壓而使樹脂成分流動，使連接對象之電 極彼此直接接觸而達成電性連接。此等膜狀接著劑之情 形，將降低厚度方向所相對峙的電極間之電阻（連接電阻） -4- 201038703 的導通性能、與提高面方向所相鄰的電極間之電阻（絕緣 電阻）的絕緣性能被認爲必要。 另外，爲了使用於液晶顯示裝置（LCD)等之精密機 器周邊的連接，膜狀接著劑被要求具有高的連接信賴性。 因此’除了導通/絕緣性能之外，也要求具有耐環境性，例 如藉由高溫高濕試驗或熱循環試驗等而評估其性能。 構成膜狀接著劑之絕緣性的樹脂組成物，主要使用環
^ 氧系之熱硬化性樹脂組成物。例如，組合環氧樹脂、苯氧 I I 樹脂等之熱硬化性樹脂與硬化劑的樹脂組成物已被泛用。 環氧樹脂係具優越之耐熱性、耐濕性，但是此硬化物 非常的脆弱而缺乏韌性（可撓性）。因此，將有因裂痕之 發生而發生剝離之情形，接著力將變低。另外，環氧樹脂 係藉由因連接時之熱導致硬化收縮而發現接著力，因此硬 化收縮而於接著界面或接著劑內部發生應力。硬化收縮時 之應力係與接著劑之貯藏彈性率成比例而增大，由於環氧 Q 樹脂係硬化後之貯藏彈性率爲高的，硬化收縮時之應力變 高，若殘留應力殘留於接著界面或接著劑內部而其後於高 溫高濕狀態被解放時，便發生界面剝離。 爲了彌補上述環氧樹脂之缺點，倂用丙烯酸橡膠、NBR 等之橡膠系材料或丙烯酸樹脂等之熱可塑性樹脂與環氧樹 脂，將可撓性賦予膜狀接著劑。例如，於專利文獻1中揭 示：賦予可撓性之成分係使用環氧化聚丁二烯，與萘系環 氧樹脂、苯氧樹脂倂用的異向導電性之電路連接用構件。 201038703 【發明內容】 發明所欲解決之技術問題 爲了賦予可撓性之上述材料係與環氧樹脂之相溶性爲 非常得低，於使用如此材料的膜狀接著劑之情形，環氧樹 脂與橡膠材料等並非完全溶解的狀態，環氧樹脂分散於橡 膠材料等之中，形成所謂的海島構造之狀態。爲了製作如 此之分散狀態，具有充分混合構成膜狀接著劑之成分的必 要，或是使用特殊之攪拌裝置而混合，具有嚴格管理製造 條件的必要。 於專利文獻1中，雖然於賦予可撓性之成分中使用賦 予官能基（環氧基）之環氧化聚丁二烯而提高與環氧樹脂 之相溶性，與其分子量作一比較，由於官能基之比例爲低 的，其效果爲低的。 本發明係爲了解決上述之問題，課題在於提供一種膜 狀接著劑，其可撓性爲高的，能夠提高接著力，同時其構 造成分之混合爲容易。 解決問題之技術手段 本發明係一種膜狀接著劑，其係以分子量爲3 0,000以 上之雙酚A型苯氧樹脂、分子量爲5 00以下之環氧樹脂、 甲基丙烯酸環氧丙酯共聚物、橡膠改性環氧樹脂、及潛在 性硬化劑作爲必要成分（本發明申請案第1項發明）。 甲基丙烯酸環氧丙酯共聚物係一種使甲基丙烯酸環氧 丙酯與其他之共聚合單體予以共聚合之聚合物，相對於聚 201038703 合物主鏈而言，具有分枝狀環氧基。因此，因爲與環氧樹 脂之相溶性將變高’變得難以引起相分離，與環氧樹脂之 混合爲容易。另外，由於爲柔軟之成分，能夠將可撓性賦 予膜狀接著劑，故能夠提高接著力。 ' 甲基丙烯酸環氧丙酯共聚物之環氧當量較佳爲1000 以下（本發明申請案第2項發明）。若環氧當量爲大的， 亦即分子鏈中之環氧基數目爲少的時，與環氧樹脂之相溶 性將變低。另外，分子鏈中之環氧基能夠於硬化時與環氧 C) ^ 樹脂進行反應而作成網狀構造，其結果，能夠抑制高溫高 濕條件下之熱膨賬，具優越之長期連接信賴性。若環氧當 量較1 000爲大時，由於與環氧樹脂之反應點爲少的，變得 無法作成有效的網狀構造，耐熱、耐濕性將變差。 甲基丙烯酸環氧丙酯共聚物之玻璃轉移溫度（Tg)較 佳爲較該雙酚A型苯氧樹脂之玻璃轉移溫度爲低（本發明 申請案第3項發明）。一般而言，爲了耐熱性及耐濕性之 Q 提高，提高於膜狀接著劑中所含之樹脂成分硬化後的玻璃 轉移溫度爲必要。若玻璃轉移溫度爲高的時，在高溫區域 之熱膨脹係數將減低，因而高溫/高濕環境下之特性變化將 變少'。 膜狀接著劑中較佳更含有導電性粒子（本發明申請案 第4項發明）。含有導電性粒子之膜狀接著劑係可使用於 作爲異向導電性接著劑。 若上述之縱橫比爲5以上之導電性粒子配向於膜之厚 201038703 度方向時’因爲異向導電性將進一步提高而較佳（本發明 申請案第5項發明）。還有，所謂配向於厚度方向，導電 性粒子之長邊方向係相對於膜面而成爲排列於垂直方向之 狀態。 發明之效果 依照本發明，可以得到一種膜狀接著劑，其可撓性爲 高的而能夠提高接著力，同時其構造成分之混合爲容易。 〇 【實施方式】 以下，說明本發明之實施形態。還有，實施例並非限 定本發明之範圍。於圖式之說明中，將同一符號賦予同一 構造成分，省略所重複的說明。另外，圖示之尺寸比率未 必一致於說明之物。 本發明係一種以分子量爲3 0,000以上之雙酚A型苯氧 樹脂、分子量爲5 00以下之環氧樹脂、甲基丙烯酸環氧丙 酯共聚物、橡膠改性環氧樹脂及潛在性硬化劑作爲必要成 Q 分的膜狀接著劑。 甲基丙烯酸環氧丙酯共聚物係使甲基丙烯酸環氧丙酯 與其他之共聚合單體予以共聚合的聚合物’相對於聚合物 主鏈而言，具有分枝狀環氧基。因此，因爲與環氧樹脂之 相溶性將變高，變得難以引起相分離’所以與環氧樹脂之 混合爲容易。另外，由於爲柔軟之成分，能夠將可撓性賦 予膜狀接著劑，故能夠提高接著力。 除了上述成分之外，於膜狀接著劑中更含有橡膠改性 201038703 環氧樹脂。橡膠改性環氧樹脂係與該甲基丙烯酸環氧 同樣爲柔軟之成分，藉由組合橡膠改性環氧樹脂與甲 烯酸環氧丙酯共聚物而使用，能夠進一步提高膜狀接 之可撓性。相對於環氧樹脂及苯氧樹脂之合計量而言 膠改性環氧樹脂之摻合量較佳爲1重量％以上、30重 以下。 只要橡膠改性環氧樹脂爲骨架中具有橡膠及/或 ^ 之環氧樹脂的話，並未予以特別限定，具體而言，例 〇 可列舉：羧基改性丁二烯-丙烯腈彈性體與分子內化學 的環氧樹脂（CTBN改性環氧樹脂）、丙烯腈-丁二烯 改性環氧樹脂（NBR改性環氧樹脂）、胺甲酸酯改性 樹脂、矽氧烷改性環氧樹脂等之橡膠改性環氧樹脂。 橡膠改性環氧樹脂可以單獨使用，也可以倂用二種以 於上述橡膠改性環氧樹脂之中，若使用NBR改性 樹脂時，較佳爲與環氧樹脂及苯氧樹脂具優越之相溶 〇 甲基丙烯酸環氧丙酯共聚物之環氧當量較佳作成 以下。若環氧當量爲大的，亦即分子鏈中之環氧基數 少的時，與環氧樹脂之相溶性將變低。另外，分子鏈 環氧基能夠於硬化時與環氧樹脂進行反應而作成網 造’其結果，能夠抑制高溫高濕條件下之熱膨脹，具 之長期連接信賴性。若環氧當量較1 000爲大時，由於 氧樹脂之反應點爲少的，變得無法作成有效的網狀構 耐熱、耐濕性將變差。 丙酯 基丙 著劑 ，橡 量％ 聚醚 如， 鍵結 橡膠 環氧 此等 上。 環氧 性。 1000 目爲 中之 狀構 優越 與環 造， 201038703 甲基丙烯酸環氧丙酯共聚物之玻璃轉移溫度（Tg)較 佳爲較雙酚A型苯氧樹脂之玻璃轉移溫度爲低。一般而 言，爲了耐熱性及耐濕性之提高，必須提高膜狀接著劑中 所含之樹脂成分硬化後之玻璃轉移溫度。若玻璃轉移溫度 爲高的時，因爲高溫區域下之熱膨脹係數將減低，高溫/高 濕環境下之特性變化將變少。 爲了提高硬化後之玻璃轉移溫度的方法大多以玻璃轉 0 移溫度高的苯氧樹脂作爲樹脂成分所使用。膜狀接著劑係 被夾住於連接對象之間，予以加熱、加壓而接著連接對象， 於加熱、加壓時，由於玻璃轉移溫度高的苯氧樹脂不具有 充分的流動特性，將有於連接對象之電極間，樹脂成分殘 留必要量以上，所殘留的樹脂成分經硬化後之物形成絕緣 被覆而成爲接觸不良的原因之情形。因此，若使用玻璃轉 移溫度較苯氧基樹脂之玻璃轉移溫度爲低的甲基丙烯酸環 氧丙酯共聚物時，能夠使膜狀接著劑整體之流動特性提 0 高。還有，玻璃轉移溫度係使用動態黏彈性測定裝置（DMA ) 所測出的値。 甲基丙烯酸環氧丙酯共聚物係一種使甲基丙烯酸環氧 丙酯與其他之共聚合單體共聚合的聚合物，其他之共聚合 單體可列舉：丙烯酸、丙烯酸甲酯、丙烯酸乙酯等之丙稀 酸衍生物；富馬酸二甲酯、富馬酸二乙酯等之富馬酸衍生 物；另外，苯乙烯、α-甲基苯乙烯等之苯乙烯衍生物等。 若其他之共聚合單體使用丙烯酸衍生物時，能夠提高甲基 -10- 201038703 丙烯酸環氧丙醋共聚物與環氧樹脂及與苯氧樹脂之相'溶性 而較佳。 雖然甲基丙烯酸環氧丙酯共聚物之分子量並未予以特 別限制，若考量與環氧樹脂之相溶性時’ g量平均分子量 較佳爲1 〇萬以下。 相對於環氧樹脂及苯氧樹脂之合計量而言’甲基丙烯 酸環氧丙酯共聚物之含量較佳爲1重量％以上、30重量％ 以下。若甲基丙烯酸環氧丙酯共聚物樹脂之含量超過30重 C) 量％時，因此硬化後之耐熱性將變得不足。另外，若低於 1重量％時’充分之可撓性提高效果將無法得到’接著力 將降低。還有，此處所謂的樹脂成分係指環氧樹脂、苯氧 樹脂、甲基丙烯酸環氧丙酯共聚物、橡膠改性環氧樹脂等 之熱硬化性樹脂及熱硬化性樹脂。 使用於本發明之環氧樹脂係於加熱時，迅速與硬化劑 進行反應而發現接著性能。雖然環氧樹脂之種類，並未予 Q 以特別限定，除了以雙酚A、F、S、AD等作爲骨架之雙酚 型環氧樹脂等之外，尙可列舉：酚醛型環氧樹脂、雙酚型 環氧樹脂、二環戊二烯型環氧樹脂等。 環氧樹脂之分子量係作成5 00以下。藉由使用低分子 量之環氧樹脂，能夠使交聯密度提高而增高接著性能。另 外’於加熱時，由於與硬化劑迅速進行反應而使接著力提 高。 於該環氧樹脂之中，使用於本發明之苯氧樹脂係高分 -11 - 201038703
子量之物。於本發明中，使用分子量30,000以上之雙酚A 型苯氧樹脂。藉由使用高分子量之苯氧樹脂而使薄膜成形 性變高。另外，能夠提高連接溫度中之樹脂的溶解黏度， 具有不紊亂後述之導電性粒子之配向而能夠連接的效果。 如此方式，藉由組合低分子量之環氧樹脂與高分子量 之環氧樹脂而使用，採取膜狀接著劑之性能均衡性將成爲 可能。環氧樹脂與苯氧樹脂之摻合比較佳設爲環氧樹脂/苯 氧樹脂=10/90〜70/30。還有，分子量係指由THF展開的 〇 凝膠滲透層析儀（GPC )所求出的聚苯乙烯換算的重量平 均分子量。 使用於本發明之潛在性硬化劑能夠適當選擇習知之物 作爲環氧樹脂硬化劑而使用。潛在性硬化劑係於低溫中具 優越之貯藏安定性，於室溫中幾乎不引起硬化反應，若藉 由加熱等而設定既定之條件時，迅速進行硬化反應。潛在 性硬化劑可列舉：咪嗖系、醯肼系、三氟化硼-胺錯合物、 Q 胺醯亞胺、聚胺系、三級胺、烷基尿素系等之胺系、二胺 二醯胺等及此等之改性物，此等潛在性硬化劑能夠單獨使 用或作成二種以上之混合物而使用。 於該潛在性硬化劑之中，較佳使用咪唑系潛在性硬化 劑。咪唑系潛在性硬化劑能夠使用習知之咪唑系潛在性硬 化劑，具體而言，可列舉：與咪唑化合物之環氧樹脂的加 成物。咪唑化合物可列舉：咪唑、2 -甲基咪唑、2 -乙基咪 唑、2-丙基咪唑、2-十二烷基咪唑、2-苯基咪唑、2-苯基-4- -12- 201038703 甲基咪唑、4-甲基咪唑。 再者，利用聚胺甲酸酯系、聚酯系等之高分子物質， 或鎳、銅等之金屬薄膜及矽酸鈣等之無機物被覆此等之潛 在性硬化劑而微膠囊化之物，由於其更充分達成兼具長期 保存性與迅速硬化性之矛盾的特性而較佳。因而，微膠囊 型咪唑系潛在性硬化劑特別理想。 相對於樹脂成分之合計重量而言，該環氧樹脂、苯氧 ^ 樹脂、甲基丙烯酸環氧丙酯共聚物等之樹脂成分與潛在性 〇 硬化劑的摻合比例較佳爲5〜90重量％。潛在性硬化劑之 比例較5重量％爲少的情形，將有硬化速度降低，硬化變 得不足之情形。另外，較90重量％爲多的情形，將有未反 應的硬化劑變得容易殘留，使耐熱、耐濕性降低之情形。 於膜狀接著劑中，進一步更佳爲含有導電性粒子。含 有導電性粒子之膜狀接著劑係可能作爲異向導電性接著劑 而使用。導電性粒子可列舉：金、銀、銅、鎳及此等之合 Q 金等之金屬粒子、碳等。另外，也可以在非導電性之玻璃、 陶瓷、塑膠、金屬氧化物等核之表面，被覆金屬或ITO等 而形成導電層之物。導電性粒子之形狀並未予以特別限 定，能夠使用球狀粒子或細長的針狀粒子。 若導電性粒子使用直徑與長度之比（縱橫比）爲5以 上之導電性粒子時，較佳爲不增加導電性粒子之含量而能 夠降低連接電阻，能夠達成良好之電性連接，同時能夠更 高度保持面方向之絕緣電阻。如導電性粒子之縱橫比係藉 -13- 201038703 由CCD顯微鏡觀察等之方法而進行直接測定之第1(a)圖 所示，導電性粒子1之直徑R與長度L之比。導電性粒子 並無必定具有筆直形狀的必要，即使具有稍微之彎曲或分 枝也無問題而能夠使用。此情形係如第1 ( b )圖所示，將 導電性粒子之最大長度（圖中之箭號的長度）設爲長度L 而求出縱橫比。另外，所謂導電性粒子之直徑係垂直於長 邊方向之剖面的直徑。剖面爲非圓之情形係將剖面之最大 長度設爲導電性粒子之直徑。 〇 縱橫比爲5以上之導電性粒子能夠使用市售之針狀導 電性粒子。另外，較佳能夠使用連接許多個微細之金屬粒 子而形成針狀之物。縱橫比進一步更佳爲1〇〜100。另外， 若導電性粒子之直徑爲Ιμιη以下時，所謂的微細間距電極 之連接將成爲可能而較佳。 形成微細之金屬粒子的金屬可列舉：含有具有Fe、Ni、 Co等之強磁性的金屬單體或是含有強磁性的複合體。若使 Q 用具有強磁性的金屬時，能夠藉由其本身所具有的磁性而 配向，或是如後所述，能夠使用磁場而進行導電性粒子之 配向。 若上述之縱橫比爲5以上之導電性粒子配向於膜之厚 度方向時，因爲異向導電性將進一步提高而較佳。還有， 所謂在長邊方向之配向係指相對於膜面而言，導電性粒子 之長邊方向已成爲排列於垂直方向的狀態。第2圖係顯示 導電性粒子配向於膜厚度方向的狀態之剖面示意圖。針狀 -14- 201038703 之導電性粒子1係於膜狀接著劑之樹脂成分2之中，配向 膜厚度方向（圖中之箭號方向）。雖然使導電性粒子配向 於膜厚度方向的方法並未予以特別限定，可列舉較佳的下 列方法：使用具有如上所述之強磁性的導電性粒子之情 形，其係將導電性粒子分散於樹脂用溶液中，將所得到的 分散溶液塗布於與基底面成交叉之方向已外加磁場的基底 上，使該導電性粒子配向，藉由基底上之溶劑去除等，使 其固化、硬化而固定配向。 〇 相對於膜狀接著劑之全部體積而言，導電性粒子之含 量係由0.01〜30體積％之範圍所選出，依照用途而分別使 用，爲了防止因過剩之導電性粒子所造成的面方向之絕緣 性能降低，更佳爲設爲0.01〜10體積％。 於不損害本發明之主旨的範圍內，於本發明之膜狀接 著劑中，除了上述之必要成分以外，添加其他之熱硬化性 樹脂、熱可塑性樹脂等爲可能。另外，也可以含有硬化加 Q 速劑、聚合抑制劑、增感劑、矽烷耦合劑、難燃化劑、觸 變劑等之添加劑。 本發明之膜狀接著劑能夠藉由混合上述之各成分而得 到。由於使用於本發明之甲基丙烯酸環氧丙酯共聚物係與 環氧樹脂、苯氧樹脂具優越之相溶性，即使不使用特別之 攪拌裝置，容易地混合也爲可能。例如，藉由將該環氧樹 月旨、苯氧樹脂、甲基丙烯酸環氧丙酯共聚物、潛在性硬化 劑等與溶劑置入容器中，進行數分鐘之利用離心攪拌混合 -15- 201038703 機所導致的單純混合，能夠容易地作成樹脂成分之溶液。 利用輥塗布機等，塗布此溶液而形成薄膜，藉由經乾燥等 而去除其後之溶液，膜狀接著劑將可以得到。 使用導電性粒子之情形，能夠使用將導電性粒子添加 於樹脂成分之溶液中而使其分散的分散液，同樣地進行塗 布而形成膜，其後經乾燥等而除去溶劑後製作膜狀接著 劑。爲了使導電性粒子配向，也可以於膜之形成時，使其 通過施加於膜狀接著劑厚度方向的磁場之中。於通過磁場 C) 中之際，導電性粒子將配向，其後，於去除溶劑之步驟所 配向的導電性粒子之狀態將被固定化。雖然膜狀接著劑之 膜厚並未予以特別限制，通常爲1 〇〜5 0 μιη。 【實施例】 (實施例1 ) (塗布液之製作） 苯氧樹脂係使用雙酚Α型之環氧樹脂〔Japan Epoxy Ο Resin (股份）製）Epikotel256 (分子量約5萬、Tg約98 °C )〕、環氧樹脂係使用雙酚F型之液狀環氧樹脂〔Japan EpoxyResin (股份）製）Epikote 806(分子量約 350)〕、 甲基丙烯酸環氧丙酯共聚物係使用甲基丙烯酸環氧丙酯之 苯乙烯系共聚物〔日本油脂（股份）製、MarproofG-0250S (環氧當量310、分子量約2萬、Tg約74°C )〕、橡膠改 性環氧樹脂係使用NBR改性環氧樹脂〔DIC (股份） TSR960〕、潛在性硬化劑係使用微膠囊型咪唑系硬化劑〔旭 -16 - • 201038703
化成 Epoxy (股份）製、NOVACURE 50/20/1 5/1 5/30之比例，將卡必醇醋酸酯與 溶劑（混合比率係重量比1 : 1)加入此等 行3 0分鐘之利用離心攪拌混合機所導致 作固形物成分6 0 %之樹脂溶液。相對於固 (樹脂組成物+鎳粉末）而言，成爲0·2 將導電性粒子具有Ιμιη〜12μιη長度分布之 橫比：5〜6 0 )添加於此樹脂溶液中’進一 〇 攪拌混合機進行3分鐘之攪拌而均勻分散 之塗布溶液。 (膜狀接著劑之製作） 藉由在已脫模處理之PET膜上，使用 布上述所所調整的塗布溶液，於磁束密度 中，於60t乾燥30分鐘而予以固化，得妾 狀接著劑。 f} (連接電阻評估） 製備以50μιη間隔配列有124條之ί 16μιη鍍金之銅電路的FPC：、與以50μιη 150μιη之ΙΤΟ電路的玻璃基板。其後，使 之連接電阻形成可進行測定的菊鍊（dais 來相向對準而配置二者，於FPC與玻璃基 所得到的膜狀接著劑，加熱至1 90 °C，同陡 力加壓12秒鐘而予以接著，得到FPC與名 HX3932 〕係以 醋酸丁酯之混合 材料中之後，進 的單純混合而製 形物成分之總量 體積％之方式來 .針狀鎳粒子（縱 步藉由使用離心 ，調製接著劑用 塗膠用刮刀而塗 :100mT之磁場 U厚度20μπι之膜 ί度50μιη、高度 間隔形成有寬度 所連接的124處 y chain)之方式 :板之間夾住上述 争也以5MPa之壓 琶缺帶之接合體。 -17- 201038703 於此接合體中，利用四端子法而求出使ITO電極、膜狀接 著劑及鍍金之銅電路介於中間所連接的相連接之124處的 電阻値，且以124除以此値而求出每一處之連續電阻。 (耐熱/耐濕試驗） 將上述之FPC與玻璃基板的接合體置入已設定成溫度 85、濕度85%之恆溫恆濕槽內，經過100小時後取出，再 進行相同於上述之方式而測出連接電阻値。 (接著力評估） 〇 於上述之FPC與玻璃基板的接合體中，使用自動立體 測圖儀AG-5000G〔島津製作所（股）製〕而剝下FPC，測 定9 0°剝離強度。還有，接著力係以初期之物與耐濕/耐熱 試驗後之物二者進行。 , (比較例1 ) 除了不添加橡膠改性環氧樹脂，將各成分之摻合比例 設爲苯氧樹脂/環氧樹脂/甲基丙烯酸環氧丙酯共聚物/潛在 Q 性硬化劑=50/20/30/30以外，進行相同於實施例1之方式 而製作厚度20μϊη之膜狀接著劑，進行一連串之評估。 (比較例2 ) 除了不添加甲基丙烯酸環氧丙酯共聚物’將各成分之 摻合比例設爲苯氧樹脂/環氧樹脂/橡膠改性環氧樹脂/潛在 性硬化劑==50/20/3 0/30以外，進行相同於實施例1之方式 而製作厚度20μιη之膜狀接著劑，進行一連串之評估。 (比較例3 ) -18- 201038703 除了使用具有OH末端之丙烯酸橡膠〔根上工業（股 份）製AS-3000E〕以取代甲基丙烯酸環氧丙酯共聚物之 外’進行相同於實施例1之方式而嘗試膜狀接著劑之製 作’ 3分鐘離心攪拌之情形，環氧樹脂與丙烯酸橡膠並未 良好混合’樹脂溶液將分離而無法進行薄片之製作。將以 上之結果顯不於表1。 【表1】 連接電阻 (初期） 連接電阻 (100小時後） 接著力 (初期） 接著力 (100小時後） 實施例1 0.35 Ω 0.50 Ω 730g 520g 比較例1 0.48 Ω 1.3Ω 660g 460g 比較例2 0.42 Ω 0.76 Ω 540g 330g 比較例3 一 — 一 _ 於使用本發明之膜狀接著劑的實施例1中，連接電阻 爲低的，另外，高溫高濕之環境下，即使經過1 00小時後， Q 電阻値之上升並不大。另外，無論初期、高溫高濕後，接 著力皆爲良好。 於比較例1中，由於未添加橡膠改性環氧樹脂，認爲 反應速度降低，硬化未充分進行。因而，雖然連接電阻、 接著力之初期特性皆爲良好，但是於高溫高濕試驗後，特 性已降低。由於比較例2未添加甲基丙烯酸環氧丙酯共聚 物，接著劑之可撓性未能充分得到。因而，若與實施例1 作一比較時，初期、高溫高濕試驗後，接著力皆變低。 -19- 201038703 此次所揭示的實施形態與實施例應該被認爲全部的觀 點係例示，並無限制。本發明之範圍並非上述之說明，而 是藉由申請專利範圍所示，意圖包含與申請專利之範圍均 等的意義及範圍內的全部變更。 產業上利用之可能性 本發明膜狀接著劑係於電子機器之小型化、高機能化 所尋求的領域中，爲了進行構造零件中之連接端子的狹小 ^ 化，適用於用以接著基板或電子零件等，且進行電性連接。 Ο 【圖式簡單說明】 第1 ( a )圖與第1 ( b )圖係用以說明使用於本發明之 導電性粒子之縱橫比的測定方法之示意圖。 第2圖係顯示導電性粒子配向於膜厚度方向的狀態之 剖面示意圖。 【主要元件符號說明】 1 導電性粒子 Ο 2 樹脂成分 -20-

Claims (1)

  1. 201038703 七、申請專利範圍： 1· 一種膜狀接著劑’其係以分子量爲3〇,〇〇〇以上之雙酚A 型苯氧樹脂、分子量爲500以下之環氧樹脂、甲基丙烯 酸環氧丙醋共聚物、橡膠改性環氧樹脂、及潛在性硬化 劑作爲必要成分。 2. 如申請專利範圍第1項之膜狀接著劑，其中該甲基丙烯 酸環氧丙酯共聚物之環氧當量爲1000以下。 3. 如申請專利範圍第1項之膜狀接著劑，其中該甲基丙烯 I 1 酸環氧丙酯共聚物之玻璃轉移溫度較該雙酚Α型苯氧樹 脂之玻璃轉移溫度爲低。 4. 如申請專利範圍第2項之膜狀接著劑，其中該甲基丙烯 酸環氧丙酯共聚物之玻璃轉移溫度較該雙酚A型苯氧樹 脂之玻璃轉移溫度爲低。 5 ·如申請專利範圍第1至4項中任一項之膜狀接著劑，其 中更含有導電性粒子。 ^ 6 .如申請專利範圍第5項之膜狀接著劑，其中該導電性粒 ϋ 子之直徑與長度的比（縱橫比）爲5以上，且配向於膜 之厚度方向。 -21-
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