WO2006126820A1 - Plastic sheet having enhanced formability for carrier tape - Google Patents
Plastic sheet having enhanced formability for carrier tape Download PDFInfo
- Publication number
- WO2006126820A1 WO2006126820A1 PCT/KR2006/001926 KR2006001926W WO2006126820A1 WO 2006126820 A1 WO2006126820 A1 WO 2006126820A1 KR 2006001926 W KR2006001926 W KR 2006001926W WO 2006126820 A1 WO2006126820 A1 WO 2006126820A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- plastic sheet
- styrene
- middle layer
- moiety
- carrier tapes
- Prior art date
Links
- 239000002985 plastic film Substances 0.000 title claims abstract description 62
- 229920005989 resin Polymers 0.000 claims abstract description 58
- 239000011347 resin Substances 0.000 claims abstract description 58
- 239000011256 inorganic filler Substances 0.000 claims abstract description 39
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 39
- 229920000642 polymer Polymers 0.000 claims abstract description 32
- 239000000203 mixture Substances 0.000 claims abstract description 23
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims abstract description 21
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims abstract description 18
- 239000010410 layer Substances 0.000 claims description 66
- 238000001125 extrusion Methods 0.000 claims description 33
- 239000002344 surface layer Substances 0.000 claims description 32
- 229920001577 copolymer Polymers 0.000 claims description 20
- 239000006229 carbon black Substances 0.000 claims description 13
- 239000002952 polymeric resin Substances 0.000 claims description 13
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 12
- 238000000576 coating method Methods 0.000 claims description 12
- 239000004793 Polystyrene Substances 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 9
- 229920005669 high impact polystyrene Polymers 0.000 claims description 9
- 239000004797 high-impact polystyrene Substances 0.000 claims description 9
- 229920002223 polystyrene Polymers 0.000 claims description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 239000007822 coupling agent Substances 0.000 claims description 7
- 239000002270 dispersing agent Substances 0.000 claims description 7
- 239000000945 filler Substances 0.000 claims description 7
- 229920000728 polyester Polymers 0.000 claims description 7
- 229920000570 polyether Polymers 0.000 claims description 7
- 229920005601 base polymer Polymers 0.000 claims description 6
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 6
- 125000000524 functional group Chemical group 0.000 claims description 6
- -1 polyethylene, ethylene copolymers Polymers 0.000 claims description 6
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 6
- 239000000454 talc Substances 0.000 claims description 6
- 229910052623 talc Inorganic materials 0.000 claims description 6
- 239000004417 polycarbonate Substances 0.000 claims description 5
- 229920000515 polycarbonate Polymers 0.000 claims description 5
- 229920006249 styrenic copolymer Polymers 0.000 claims description 5
- PAYRUJLWNCNPSJ-UHFFFAOYSA-N Aniline Chemical compound NC1=CC=CC=C1 PAYRUJLWNCNPSJ-UHFFFAOYSA-N 0.000 claims description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- KAESVJOAVNADME-UHFFFAOYSA-N Pyrrole Chemical compound C=1C=CNC=1 KAESVJOAVNADME-UHFFFAOYSA-N 0.000 claims description 4
- YTPLMLYBLZKORZ-UHFFFAOYSA-N Thiophene Chemical compound C=1C=CSC=1 YTPLMLYBLZKORZ-UHFFFAOYSA-N 0.000 claims description 4
- KAKZBPTYRLMSJV-UHFFFAOYSA-N butadiene group Chemical group C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- 239000002245 particle Substances 0.000 claims description 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 3
- 239000005977 Ethylene Substances 0.000 claims description 3
- 229920001609 Poly(3,4-ethylenedioxythiophene) Polymers 0.000 claims description 3
- FACXGONDLDSNOE-UHFFFAOYSA-N buta-1,3-diene;styrene Chemical compound C=CC=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 FACXGONDLDSNOE-UHFFFAOYSA-N 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 3
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 2
- 235000021355 Stearic acid Nutrition 0.000 claims description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical class [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims description 2
- 239000004917 carbon fiber Substances 0.000 claims description 2
- 125000005587 carbonate group Chemical group 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 150000002148 esters Chemical group 0.000 claims description 2
- 125000001033 ether group Chemical group 0.000 claims description 2
- 229910021485 fumed silica Inorganic materials 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims description 2
- 229910003437 indium oxide Inorganic materials 0.000 claims description 2
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052742 iron Inorganic materials 0.000 claims description 2
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical class CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 claims description 2
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 claims description 2
- 238000006116 polymerization reaction Methods 0.000 claims description 2
- 150000004756 silanes Chemical class 0.000 claims description 2
- 229910052709 silver Inorganic materials 0.000 claims description 2
- 239000004332 silver Substances 0.000 claims description 2
- 125000003011 styrenyl group Chemical group [H]\C(*)=C(/[H])C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 claims description 2
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 claims description 2
- 229930192474 thiophene Natural products 0.000 claims description 2
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 claims description 2
- 229910001887 tin oxide Inorganic materials 0.000 claims description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N urethane group Chemical group NC(=O)OCC JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims 2
- 239000004480 active ingredient Substances 0.000 claims 1
- 239000004927 clay Substances 0.000 claims 1
- 229910052570 clay Inorganic materials 0.000 claims 1
- 239000007791 liquid phase Substances 0.000 claims 1
- 239000010445 mica Substances 0.000 claims 1
- 229910052618 mica group Inorganic materials 0.000 claims 1
- 239000011787 zinc oxide Substances 0.000 claims 1
- 238000012546 transfer Methods 0.000 abstract description 24
- 230000009975 flexible effect Effects 0.000 abstract description 2
- 238000000034 method Methods 0.000 description 21
- 230000008569 process Effects 0.000 description 17
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 14
- 238000004049 embossing Methods 0.000 description 12
- 239000000463 material Substances 0.000 description 10
- 229920003002 synthetic resin Polymers 0.000 description 10
- 230000015572 biosynthetic process Effects 0.000 description 6
- 230000007423 decrease Effects 0.000 description 5
- 230000007547 defect Effects 0.000 description 5
- 229920001890 Novodur Polymers 0.000 description 4
- 230000003247 decreasing effect Effects 0.000 description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- 229920006026 co-polymeric resin Polymers 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 229920000578 graft copolymer Polymers 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 229920013716 polyethylene resin Polymers 0.000 description 3
- 239000004065 semiconductor Substances 0.000 description 3
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 229920001940 conductive polymer Polymers 0.000 description 2
- 239000012050 conventional carrier Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 235000019441 ethanol Nutrition 0.000 description 2
- 239000003000 extruded plastic Substances 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 238000003856 thermoforming Methods 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000002730 additional effect Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- BXOUVIIITJXIKB-UHFFFAOYSA-N ethene;styrene Chemical group C=C.C=CC1=CC=CC=C1 BXOUVIIITJXIKB-UHFFFAOYSA-N 0.000 description 1
- RRUSYLYDWCIAGO-UHFFFAOYSA-N ethyl prop-2-enoate;styrene Chemical compound CCOC(=O)C=C.C=CC1=CC=CC=C1 RRUSYLYDWCIAGO-UHFFFAOYSA-N 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000012685 gas phase polymerization Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001955 polyphenylene ether Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920005990 polystyrene resin Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- YARNEMCKJLFQHG-UHFFFAOYSA-N prop-1-ene;styrene Chemical group CC=C.C=CC1=CC=CC=C1 YARNEMCKJLFQHG-UHFFFAOYSA-N 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
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- B32—LAYERED PRODUCTS
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- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
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- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- 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
- H01B1/06—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances
- H01B1/12—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances organic substances
- H01B1/124—Intrinsically conductive polymers
- H01B1/127—Intrinsically conductive polymers comprising five-membered aromatic rings in the main chain, e.g. polypyrroles, polythiophenes
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/546—Flexural strength; Flexion stiffness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2405/00—Adhesive articles, e.g. adhesive tapes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2509/00—Household appliances
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2553/00—Packaging equipment or accessories not otherwise provided for
Definitions
- the present invention relates to a plastic sheet for carrier tapes for use in carrying or transporting electronic parts and a carrier tape prepared therefrom. More particularly, the present invention relates to an antistatic plastic sheet which is so excellent in formability that it can be readily molded into carrier tapes without the local distortion attributable to poor heat transfer, and can be neatly punched to form holes, and a carrier tape prepared therefrom, which has well defined pockets.
- tape-and-reel is a process of packing devices by loading them into individual pockets comprising what is known as a carrier tape.
- a plastic sheet is molded at 150 ⁇ 250°C into pockets of the carrier tape under pressure and vacuum conditions.
- the pocket units are sealed in the carrier tape with a cover tape.
- the carrier tape is wound on a reel for convenient handling and transport. The reel is enclosed in a reel box before it is finally shipped to the customer.
- a carrier tape is manufactured by forming pockets in a mono- or trilayer plastic sheet 0.2 ⁇ 0.5mm thick which is extruded from a polymeric resin.
- Typical polymeric resins suitable for the carrier tape are styrene-based resins, exemplified by polystyrene (PS), high impact polystyrene (HIPS), acrylonitrile-butadiene-styrene copolymer (ABS), styrene-butadiene copolymer, styrene-acrylate copolymer, methacrylate-modified styrenic polymer, etc.
- Suitable polymeric materials which are selected from among them to meet the requirements of the carrier tape for mechanical properties, such as tensile strength and elongation, and optical properties, such as transparency, are extruded into mono- or trilayer structures.
- the middle layer is made from a resin having good mechanical properties, providing the mechanical strength required for the carrier tape while both the surface layers containing, for example, conductive carbon black, serve as antistatic layers. Thanks to their high mechanical properties, acrylonitrile- butadiene-styrene copolymers are prevalent over other materials for the middle layer.
- various styrenic polymers listed above, like polystyrene may be used, in combination, for the middle layer.
- Pat. No. 5,747,164 granted to Takeshi Miyakawa, disclose trilayer carrier tapes, manufactured by tri-extrusion, which show good mechanical strength and anti- statistic properties. They are described to have a middle layer of acrylonitrile-butadiene-styrene copolymer resin or styrenic resin sandwiched between two surface layers made of a conductive polymer compound containing a polymer selected from among acry- lonitrile-butadiene-styrene copolymer, polystyrene, polyphenylene ether resin and olefinic resin and conductive carbon black.
- the acrylonitrile-butadiene-styrene resin for the middle layer can be extruded at the highest efficiency at around 23O 0 C, whereas a temperature range from 190 to 200 0 C is known to be the most suitable in extruding the polystyrene or high impact polystyrene for the surface layers. Passing through a T- die, molten resin is extruded at different temperatures to form such a trilayer structure of plastic sheets.
- the extrusion temperature for the resin of the middle layer must be decreased to about 200 0 C or below.
- two strategies may be considered: one is to decrease the extrusion temperature of the acrylonitrile- butadiene-styrene copolymer resin for the middle layer by increasing its melt index; and the other is to employ a resin having an extrusion temperature as low as that of polystyrene or high impact polystyrene.
- both of these are confronted by difficulty.
- the acrylonitrile- butadiene-styrene copolymer resin must be modified to greatly decrease the melt index thereof.
- the increased melt index makes it difficult to extrude the resin, leading to a difficulty in modification.
- the employment of polystyrene or high impact polystyrene for the middle layer can prevent die drool, but provides poor mechanical properties for the middle layer, resulting in a mechanical failure of the carrier tape during use.
- the conventional trilayer plastic sheet for carrier tapes is faced with problems during embossing processes, such as an embossing process to form pockets and a punching process to form sprocket holes.
- embossing processes such as an embossing process to form pockets and a punching process to form sprocket holes.
- heat is efficiently transferred over the surface layers due to the presence of carbon black therein, but not over the middle layer because it is composed of polymeric resin.
- local temperature differences occur in the plastic sheet during a thermal forming process, causing regions of the resulting carrier tape to be distorted. This is one of the most frequently occurring defects in the carrier tapes.
- the plastic sheet composed of acrylonitrile-butadiene-styrene resin in the middle layer has toughness to retain elongational property during thermoforming process for forming pockets, this polymer, as shown in FIG. 1, is punched to form sprocket holes 10 beside pockets, they are not neat, but burrs 11 remain therein. This is also considered a defect.
- acrylonitrile-butadiene-styrene copolymers or styrenic resins used for the middle layer give frequent rise to defects upon extrusion due to the great difference in extrusion temperature from polymeric resins used for the surface layers, and cause the carrier tapes to be locally distorted upon an embossing process due to low heat transfer properties thereacross. Furthermore, the resin for the middle layer is not neatly punched, but its tough and flexible properties cause burrs to remain in the punched holes.
- an object of the present invention is to modify a base resin for use in the middle layer of a trilayer structure of a plastic sheet for carrier tapes, into a resin which decrease the extrusion temperature and improves in heat transfer rate so as to prevent the carrier tapes from being locally distorted upon an embossing process, and which yields neat punch holes therein.
- Another object of the present invention is to provide a plastic sheet for carrier tapes, which has high formability.
- the middle layer is modified to show high heat transfer property, thereby preventing local distortion attributed to poor heat transfer over the middle layer, and to improve a formability, thereby forming well defined pockets and neat holes.
- an aspect of the present invention provides an antistatic trilayer plastic sheet for carrier tapes, produced through triple layer co-extrusion, comprising: a middle layer made of a composition comprising a base polymer selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, and 2 to 50 parts by weight of an inorganic filler; and an upper surface layer and a lower surface layer, respectively laminated on or beneath the middle layer, each made from a base polymer resin selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, wherein each of the surface layers contains 1 to 50 parts by weight of electroconductive carbon black, or either or both of the surface layers have an antistatic coating made from an electro- conductive polymer thereon, whereby the plastic sheet is improved in formability and punchability.
- a middle layer made of a composition comprising a base polymer selected from
- the plastic sheet for carrier tapes in accordance with the present invention has a middle layer which is modified to show high heat transfer property, thereby preventing local distortion attributed to the poor heat transfer over the middle layer.
- an improvement in heat transfer property leads to high formability, so that the formation of pockets and holes in the plastic sheet can be readily conducted without creating burrs in the holes.
- FIG. 1 is a schematic perspective view illustrating a conventional carrier tape in which holes having burrs therein are punched.
- FIG. 2 is a schematic cross-sectional view of a plastic sheet for carrier tapes in accordance with an embodiment of the present invention.
- FIG. 3 is a schematic cross-sectional view of a plastic sheet for carrier tapes in accordance with another embodiment of the present invention.
- FIG. 4 is a schematic perspective view illustrating a carrier tape according to the present invention, in which neat holes having no burrs are produced.
- the middle layer of a trilayer plastic sheet for carrier tapes is made of a composition comprising an acrylonitrile- butadiene-styrene copolymer- or a styrenic copolymer-based composition containing 2-50 weight parts of a filler which does not reduce the melt fluidity of the base resin, and has a higher heat transfer rate than that of the base resin.
- any inorganic filler may be used in the present invention irrespective of its shape.
- the filler useful in the present invention include particulate fillers, such as calcium carbonate (CaCO ), several types of silica such as fumed silica and precipitated silica, talc, etc.; metal oxide particles such as titanium oxide, indium oxide, tin oxide, etc.; fiber fillers, such as glass fiber, carbon fiber, etc.; and metal powders, such as copper, iron, silver, etc.
- particulate fillers such as calcium carbonate (CaCO ), several types of silica such as fumed silica and precipitated silica, talc, etc.
- metal oxide particles such as titanium oxide, indium oxide, tin oxide, etc.
- fiber fillers such as glass fiber, carbon fiber, etc.
- metal powders such as copper, iron, silver, etc.
- the content of the inorganic filler ranges from 2 to 50 parts by weight and preferably from 5 to 30 parts by weight (based on 100 parts by weight of the middle layer).
- inorganic filler may be used in a large amount if it is small in size.
- a large amount of inorganic filler is not acceptable if it has a large size or is poorly compatible with a resin for the middle layer.
- the inorganic filler preferably ranges in size from 0.02 to 5 microns. For example, when the concentration of inorganic filler is less than 2 parts by weight, only an insignificant improvement in formability is obtained because the increase in heat transfer property is trivial.
- the inorganic filler greatly increases the heat transfer rate of the resin, but reduces the melt fluidity of the resin upon extrusion as well as degrading the mechanical properties of the resin.
- a coupling agent and/or a dispersant may be used in order to increase the in- terfacial adhesion between the inorganic filler and the base resin as well as to improve the dispersion of the inorganic filler in the base resin.
- the coupling agent useful in the present invention may be based on silanes or titanates, and examples of the dispersant include fatty acids, such as stearic acids or stearates.
- the coupling agent and/or the dispersant are preferably used in an amount from 0.01 to 5 parts by weight based on the total weight of the filler. For example, almost no effect can be obtained from less than 0.01 parts by weight of the coupling agent and the dispersant. On the other hand, if used in an amount greater than 5 parts by weight, no further increase in interfacial adhesion or dispersibility is obtained, and those additives may degrade the mechanical properties of the base resin.
- the inorganic filler is used in the following way.
- the production of a plastic sheet for carrier tapes starts with subjecting polymeric resins to an extrusion process in which the resins are processed in heat and under pressure.
- the polymeric resins After being introduced into an extruder, the polymeric resins are melted between the barrel and screw of the extruder by the heat provided from a heater located outside the barrel.
- the molten resin is allowed to proceed to an extrusion die.
- frictional heat is generated between the molten resin and the barrel.
- the frictional heat and the heat externally provided from the heater are not uniformly transferred throughout the resin, although in a molten state, because of its low heat transfer rate.
- the base resin for the middle layer is provided with mechanical strength such as modulus, which makes it possible to punch holes neatly in the plastic sheet, by the inorganic filler.
- Another additional effect of the inorganic filler is as follows. Because they are further extended during the embossing process, sides of the pocket walls are thinner than other portions in a carrier tape. In a conventional carrier tape, the thin portion becomes faded in color to the extent of having a transparent appearance. In the carrier tape of the present invention, the inorganic filler scatters light, so that the pockets appear to be the same color as other portions.
- An acrylonitrile-butadiene-styrene copolymer is useful as the base resin for the middle layer of the carrier tape in the present invention.
- styrenic copolymers can be used as the polymeric resin compatible with the inorganic filler in the present invention, exemplified by styrene polymers with butadiene, isoprene, or acrylate, (e.g., styrene-butadiene copolymer, styrene-butadiene- styrene copolymer, styrene-ethylene-butylene-styrene copolymer, styrene-isoprene-styrene copolymer, styrene-acrylate copolymer, styrene-methacrylate copolymer), and styrene polymers with olefin such as ethylene or propylene (
- polystyrenes, polycarbonates, polyesters, olefinic polymers, polyethers, and blends of styrenic resin therewith may be used alone or in combination to form the middle layer of the carrier tape in accordance with the present invention.
- examples of the base resin for the middle layer of the carrier tape in accordance with the present invention include polystyrene; high impact polystyrene; styrenic copolymers, such as styrene-butadiene copolymers, styrene-acrylate copolymers, styrene-methacrylate copolymers, styrene -butadiene- styrene copolymers, styrene-isoprene-styrene copolymers, styrene-ethylene-butylene-styrene copolymers, aery lonitrile-butadiene- styrene copolymers; polyethylene or ethylene copolymers; polypropylene or propylene copolymers; polyesters; polyethers; and combinations thereof.
- styrene such as styrene-butadiene copolymers, st
- the surface layers Positioned on the opposite sides of the middle layer made from the polymeric composition containing the inorganic filler, the surface layers, also serving as antistatic layers, may be prepared as disclosed in the conventional patents.
- a composition containing 100 parts by weight of a styrene copolymer and 5-50 parts by weight of electroconductive carbon black is used to form both of the surface layers while the composition of the present invention is used as a material for the middle layer of the trilayer carrier tape.
- a trilayer plastic sheet for carrier tapes comprises a middle layer 120 made from the composition of the present invention sandwiched between two surface layers 110 and 130 made from an electroconductive composition including a styrene polymer and electroconductive carbon black 111.
- a composite plastic sheet for carrier tapes as shown in FIG. 3, in which surface layers 110 and 130 are formed from a styrene copolymer underneath and on top of, respectively, a middle layer and both or either of the surface layers is coated with an antistatic layer 150 based on a conductive material.
- the present invention is more effective for the electroconductive polymer coating than for the resin containing carbon black.
- the electroconductive coating does not disperse the heat provided upon thermoforming, but is likely to be degenerated by the heat because of its low heat transfer rate.
- the inorganic filler of the middle layer can disperse the heat applied to the surface layer into and across the middle layer, thereby solving the problem.
- the surface layers are preferably made of a polymer having a functional group selected from among a styrene moiety, an ethylene moiety, a butylene moiety, a butadiene moiety, a propylene moiety, a carbonate moiety, an ester moiety, an urethane moiety, an acryl moiety, a phenyl moiety, an ether moiety, and combinations thereof, or is a blend of polymers having the functional groups.
- a styrene moiety an ethylene moiety, a butylene moiety, a butadiene moiety, a propylene moiety, a carbonate moiety, an ester moiety, an urethane moiety, an acryl moiety, a phenyl moiety, an ether moiety, and combinations thereof, or is a blend of polymers having the functional groups.
- the trilayer plastic sheet preferably has a thickness ratio of upper surface laye ⁇ middle laye ⁇ lower surface layer 1-30 : 98-40 : 1-30.
- the electroconductive polymer for the antistatic coating may be preferably a polymer having a functional group selected from among thiophene, pyrrole, and aniline, or a modified electroconductive polymer derived from above those, such as polyethylene dioxythiophene.
- the antistatic coating may be preferably formed to a thickness from 0.02 to 5 microns using a solution coating process or a direct polymerization process such as liquid- or gas-phase polymerization.
- the middle layer has a white color due to the inorganic filler present therein.
- the scratched portion appears white.
- the scratches although having no significant influence on the function of the carrier tapes, may be a factor causing the carrier tapes to have a defective appearance.
- carbon black may be added, along with the inorganic filler, in an amount from 0.005 to 5 parts by weight, based on 100 parts by weight of the middle layer materials, and preferably in an amount from 0.01 to 0.1 parts by weight to the styrene resin for the middle layer.
- the middle layer is tinted pale gray to dark gray, which prevents the scratched portions from appearing white.
- the present invention is most useful for, but is not limited to, trilayer antistatic carrier tapes.
- a monolayer plastic sheet made from a styrene resin mixed with electroconductive carbon black needs no additional inorganic fillers because the electroconductive carbon black itself has high heat transfer properties as well as being antistatic.
- fillers having high thermal transfer efficiency such as nanosized diamond (less than 90 nm in diameter) can be mixed at a concentration of 0.05-5 parts by weight to the total weight of resin. The concentration below 0.05 parts by weight gives only a minor improvement, whereas the concentration higher than 5 parts by weight raises the material cost too much.
- a trilayer plastic sheet comprising a middle layer made from an acrylonitrile- butadiene-styrene copolymer (Kumho Petrochemical Co. Ltd., Korea, grade: ABS770), and two surface layers, laminated on and beneath the middle layer, each made from a mixture of 70:30 high impact polystyrene (Kumho Petrochemical Co. Ltd., Korea. Grade: HI425) and electroconductive carbon black was prepared using a triple layerco- extrusion technique, in which the thickness of each of the antistatic surface layer was 15% of the total thickness.
- the plastic sheet was subjected to an embossing process to form pockets about 2.0 mm deep which were observed to be more transparent at pocket corners and edges than at other portions. On punching process, the holes were observed to have burrs therein, as shown in FIG. 1.
- compositions comprising 70-90 parts by weight of a blend of polystyrene (PS) and styrene-butadiene copolymer (SB) and 10-30 parts by weight of an inorganic filler such as calcium carbonate or talc, as materials for the middle layer, slightly reduces the tensile strength, but greatly decreases the extrusion temperature, compared to the use of 100 parts by weight of acrylonitrile- butadiene-styrene resin, thereby curtailing loss upon extrusion.
- plastic sheets were found to be improved in punchability and formability and to undergo no distortion after the formation of pockets.
- the antistatic plastic sheets were subjected to an embossing process. They were observed to show good punchability and to undergo no distortion after the formation of pockets therein. Particularly, they were measured to have a surface resistivity of 10E(6-7) at both the inner and the outer surface of the pockets, which was optimal for antistatic properties.
- the plastic sheet for carrier tapes in accordance with the present invention can be produced without die drool, thereby avoiding loss upon extrusion.
- the presence of the inorganic filler in the middle layer improves the formability of the plastic sheet because it effectively transfers the heat throughout the middle layer.
- the carrier tapes from the plastic sheet which function to carry or transport electronic parts safe from static electricity, undergo little distortion and allow holes to be effectively punched therein without the generation of burrs.
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Abstract
Herein an antistatic trilayer plastic sheet for carrier tapes, which shows high formability and punchability, is disclosed. In the trilayer structure of the plastic sheet, the middle layer is made from a composition comprising acrylonitrile-butadiene-styrene or a blend of styrenic polymers, and an inorganic filler. The presence of the inorganic filler in the middle layer increases the heat transfer rate, thereby improving the formability of the plastic sheet. The carrier tapes from the plastic sheet undergo little distortion and have well defined edges and corners thanks to the high formability. In addition to its inherent flexible and tough properties, the base resin for the middle layer is provided with mechanical strength such as modulus, which makes it possible to punch holes neatly in the plastic sheet, by the inorganic filler.
Description
Description
PLASTIC SHEET HAVING ENHANCED FORMABILITY FOR
CARRIER TAPE
Technical Field
[1] The present invention relates to a plastic sheet for carrier tapes for use in carrying or transporting electronic parts and a carrier tape prepared therefrom. More particularly, the present invention relates to an antistatic plastic sheet which is so excellent in formability that it can be readily molded into carrier tapes without the local distortion attributable to poor heat transfer, and can be neatly punched to form holes, and a carrier tape prepared therefrom, which has well defined pockets. Background Art
[2] Usually, various electronic parts, including semiconductor integrated circuit chips, light emitting devices, etc., are carried or transported by way of tape-and-reel, which is a process of packing devices by loading them into individual pockets comprising what is known as a carrier tape. A plastic sheet is molded at 150~250°C into pockets of the carrier tape under pressure and vacuum conditions. The pocket units are sealed in the carrier tape with a cover tape. The carrier tape is wound on a reel for convenient handling and transport. The reel is enclosed in a reel box before it is finally shipped to the customer.
[3] Generally, a carrier tape is manufactured by forming pockets in a mono- or trilayer plastic sheet 0.2~0.5mm thick which is extruded from a polymeric resin. Typical polymeric resins suitable for the carrier tape are styrene-based resins, exemplified by polystyrene (PS), high impact polystyrene (HIPS), acrylonitrile-butadiene-styrene copolymer (ABS), styrene-butadiene copolymer, styrene-acrylate copolymer, methacrylate-modified styrenic polymer, etc. Suitable polymeric materials which are selected from among them to meet the requirements of the carrier tape for mechanical properties, such as tensile strength and elongation, and optical properties, such as transparency, are extruded into mono- or trilayer structures.
[4] Almost all of the carrier tapes for semiconductor parts currently in use have trilayer structures which are adopted to overcome the low mechanical strength of monolayer structures. In a trilayer structure, the middle layer is made from a resin having good mechanical properties, providing the mechanical strength required for the carrier tape while both the surface layers containing, for example, conductive carbon black, serve as antistatic layers. Thanks to their high mechanical properties, acrylonitrile- butadiene-styrene copolymers are prevalent over other materials for the middle layer. In addition to acrylonitrile-butadiene-styrene resin, various styrenic polymers listed
above, like polystyrene may be used, in combination, for the middle layer.
[5] For example, U. S. Pat. No. 6,759,130 B2, granted to Kazuhiro Kosugi, and U. S.
Pat. No. 5,747,164, granted to Takeshi Miyakawa, disclose trilayer carrier tapes, manufactured by tri-extrusion, which show good mechanical strength and anti- statistic properties. They are described to have a middle layer of acrylonitrile-butadiene-styrene copolymer resin or styrenic resin sandwiched between two surface layers made of a conductive polymer compound containing a polymer selected from among acry- lonitrile-butadiene-styrene copolymer, polystyrene, polyphenylene ether resin and olefinic resin and conductive carbon black.
[6] In fact, these trilayer carrier tapes, usually manufactured by way of co-extrusion, are now used to carry semiconductor integrated circuit chips all over the world because of their superb mechanical strength and anti-static property.
[7] However, during processes of extrusion of trilayer carrier tape sheets, various problems arise.
[8] First, a so-called "die drool phenomenon" occurs upon extrusion due to the difference in extrusion temperature between an acrylonitrile-butadiene-styrene resin, usually employed for the middle layer, and polystyrene or high impact polystyrene, usually employed for the opposite surface layers, causing protrusions on the extruded plastic sheet. Although somewhat depending on melt index, the extrusion property of resin is largely determined by temperature. The acrylonitrile-butadiene-styrene resin for the middle layer can be extruded at the highest efficiency at around 23O0C, whereas a temperature range from 190 to 2000C is known to be the most suitable in extruding the polystyrene or high impact polystyrene for the surface layers. Passing through a T- die, molten resin is extruded at different temperatures to form such a trilayer structure of plastic sheets. When there is a large difference in extrusion temperature between the middle layer resin and the surface layer resin, some of the polystyrene resin for the surface layers slowly builds up at the die exit and eventually attaches itself to the opening(die lip) of the T-die through which the resin is extruded, which is called die drool. The resin stuck on the die lip is carbonized because it is continuously heated during the extrusion. If the die drool is not removed, the extruded plastic sheet has carbonized residues as lumps thereon. Since they have already been carbonized, these lumps refuse to be further extended or molded, and thus remain as protrusions on the final sheet. Upon product inspection, the sheet is determined to be defective. Usually, a computerized post-inspection system is employed to find and remove the protrusions, resulting in a loss amounting to about 30 to 50% in extreme cases.
[9] In order to avoid such problems, the extrusion temperature for the resin of the middle layer must be decreased to about 2000C or below. In this regard, two strategies may be considered: one is to decrease the extrusion temperature of the acrylonitrile-
butadiene-styrene copolymer resin for the middle layer by increasing its melt index; and the other is to employ a resin having an extrusion temperature as low as that of polystyrene or high impact polystyrene. However, both of these are confronted by difficulty.
[10] In order to decrease the extrusion temperature by as much as 3O0C, the acrylonitrile- butadiene-styrene copolymer resin must be modified to greatly decrease the melt index thereof. However, the increased melt index makes it difficult to extrude the resin, leading to a difficulty in modification. The employment of polystyrene or high impact polystyrene for the middle layer can prevent die drool, but provides poor mechanical properties for the middle layer, resulting in a mechanical failure of the carrier tape during use.
[11] Besides the problems upon extrusion, the conventional trilayer plastic sheet for carrier tapes is faced with problems during embossing processes, such as an embossing process to form pockets and a punching process to form sprocket holes. In a thermal process for forming the trilayer plastic sheet into a carrier tape, heat is efficiently transferred over the surface layers due to the presence of carbon black therein, but not over the middle layer because it is composed of polymeric resin. Thus, local temperature differences occur in the plastic sheet during a thermal forming process, causing regions of the resulting carrier tape to be distorted. This is one of the most frequently occurring defects in the carrier tapes.
[12] In addition, since the plastic sheet composed of acrylonitrile-butadiene-styrene resin in the middle layer has toughness to retain elongational property during thermoforming process for forming pockets, this polymer, as shown in FIG. 1, is punched to form sprocket holes 10 beside pockets, they are not neat, but burrs 11 remain therein. This is also considered a defect.
[13] In conventional trilayer plastic sheets for carrier tapes, as described hereinbefore, acrylonitrile-butadiene-styrene copolymers or styrenic resins used for the middle layer give frequent rise to defects upon extrusion due to the great difference in extrusion temperature from polymeric resins used for the surface layers, and cause the carrier tapes to be locally distorted upon an embossing process due to low heat transfer properties thereacross. Furthermore, the resin for the middle layer is not neatly punched, but its tough and flexible properties cause burrs to remain in the punched holes.
[14] Therefore, there is a need for a novel resin composition for use in the middle layer of a trilayer plastic sheet in order to overcome the problems occurring in the extrusion and embossing processes, and for a plastic sheet for carrier tapes, which employs more easily embossable and punchable resin compositions for the middle layer.
Disclosure of Invention
Technical Problem
[15] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to modify a base resin for use in the middle layer of a trilayer structure of a plastic sheet for carrier tapes, into a resin which decrease the extrusion temperature and improves in heat transfer rate so as to prevent the carrier tapes from being locally distorted upon an embossing process, and which yields neat punch holes therein.
[16] Another object of the present invention is to provide a plastic sheet for carrier tapes, which has high formability.
[17] In the present invention, the middle layer is modified to show high heat transfer property, thereby preventing local distortion attributed to poor heat transfer over the middle layer, and to improve a formability, thereby forming well defined pockets and neat holes. Technical Solution
[18] In order to accomplish the above objects, an aspect of the present invention provides an antistatic trilayer plastic sheet for carrier tapes, produced through triple layer co-extrusion, comprising: a middle layer made of a composition comprising a base polymer selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, and 2 to 50 parts by weight of an inorganic filler; and an upper surface layer and a lower surface layer, respectively laminated on or beneath the middle layer, each made from a base polymer resin selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, wherein each of the surface layers contains 1 to 50 parts by weight of electroconductive carbon black, or either or both of the surface layers have an antistatic coating made from an electro- conductive polymer thereon, whereby the plastic sheet is improved in formability and punchability.
Advantageous Effects
[19] The plastic sheet for carrier tapes in accordance with the present invention has a middle layer which is modified to show high heat transfer property, thereby preventing local distortion attributed to the poor heat transfer over the middle layer. In addition, an improvement in heat transfer property leads to high formability, so that the formation of pockets and holes in the plastic sheet can be readily conducted without creating burrs in the holes. Brief Description of the Drawings
[20] The above and other objects, features and advantages of the present invention will
be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[21] FIG. 1 is a schematic perspective view illustrating a conventional carrier tape in which holes having burrs therein are punched.
[22] FIG. 2 is a schematic cross-sectional view of a plastic sheet for carrier tapes in accordance with an embodiment of the present invention.
[23] FIG. 3 is a schematic cross-sectional view of a plastic sheet for carrier tapes in accordance with another embodiment of the present invention.
[24] FIG. 4 is a schematic perspective view illustrating a carrier tape according to the present invention, in which neat holes having no burrs are produced. Mode for the Invention
[25] In accordance with the present invention, the middle layer of a trilayer plastic sheet for carrier tapes is made of a composition comprising an acrylonitrile- butadiene-styrene copolymer- or a styrenic copolymer-based composition containing 2-50 weight parts of a filler which does not reduce the melt fluidity of the base resin, and has a higher heat transfer rate than that of the base resin.
[26] As long as its heat transfer rate is higher than that of the base resin for the middle layer, that is, an acrylonitrile-butadiene-styrene copolymer or a styrenic copolymer, any inorganic filler may be used in the present invention irrespective of its shape. Examples of the filler useful in the present invention include particulate fillers, such as calcium carbonate (CaCO ), several types of silica such as fumed silica and precipitated silica, talc, etc.; metal oxide particles such as titanium oxide, indium oxide, tin oxide, etc.; fiber fillers, such as glass fiber, carbon fiber, etc.; and metal powders, such as copper, iron, silver, etc. These inorganic fillers may be used alone or in combination.
[27] Although varying with the size, type, and compatibility with polymer resin thereof, the content of the inorganic filler ranges from 2 to 50 parts by weight and preferably from 5 to 30 parts by weight (based on 100 parts by weight of the middle layer). For instance, inorganic filler may be used in a large amount if it is small in size. On the other hand, a large amount of inorganic filler is not acceptable if it has a large size or is poorly compatible with a resin for the middle layer. In the present invention, the inorganic filler preferably ranges in size from 0.02 to 5 microns. For example, when the concentration of inorganic filler is less than 2 parts by weight, only an insignificant improvement in formability is obtained because the increase in heat transfer property is trivial. On the other hand, more than 50 parts by weight of the inorganic filler greatly increases the heat transfer rate of the resin, but reduces the melt fluidity of the resin upon extrusion as well as degrading the mechanical properties of the resin.
[28] When the inorganic filler is mixed with the base polymeric resin for the middle layer, a coupling agent and/or a dispersant may be used in order to increase the in- terfacial adhesion between the inorganic filler and the base resin as well as to improve the dispersion of the inorganic filler in the base resin. The coupling agent useful in the present invention may be based on silanes or titanates, and examples of the dispersant include fatty acids, such as stearic acids or stearates. Whether alone or in combination, the coupling agent and/or the dispersant are preferably used in an amount from 0.01 to 5 parts by weight based on the total weight of the filler. For example, almost no effect can be obtained from less than 0.01 parts by weight of the coupling agent and the dispersant. On the other hand, if used in an amount greater than 5 parts by weight, no further increase in interfacial adhesion or dispersibility is obtained, and those additives may degrade the mechanical properties of the base resin.
[29] In the present invention, the inorganic filler is used in the following way. Typically, the production of a plastic sheet for carrier tapes starts with subjecting polymeric resins to an extrusion process in which the resins are processed in heat and under pressure. After being introduced into an extruder, the polymeric resins are melted between the barrel and screw of the extruder by the heat provided from a heater located outside the barrel. The molten resin is allowed to proceed to an extrusion die. When the resin starts to melt, frictional heat is generated between the molten resin and the barrel. However, the frictional heat and the heat externally provided from the heater are not uniformly transferred throughout the resin, although in a molten state, because of its low heat transfer rate. Thus, different temperatures can be measured in the molten resin that proceeds to the extrusion die, a much higher temperature at the region around the barrel than the other regions of the resin. As a rule, the local temperature difference throughout the molten resin results in decreasing the temperature of the resin below the predetermined extrusion temperature, which gives rise to poor extrusion. If the extrusion temperature is set to be high in order to raise the temperature of the resin, the local temperature difference is aggravated, which may lead to carbonization of the resin in extreme cases. Accordingly, the addition of inorganic filler capable of increasing the heat transfer rate of the resin is the most effective alternative for conducting the extrusion at relatively low temperatures. Also, the low extrusion temperature of the base resin for the middle layer contributes to preventing defects from being generated due to die drool.
[30] The effect of inorganic filler on the heat transfer rate of polymeric resin is absolutely apparent upon resin processing with a kneader. For example, when a polyethylene resin is melted alone, it takes about five minutes to increase the temperature of the polyethylene resin to 15O0C. When a polyethylene resin is used in combination with inorganic filler, only two minutes is required to reach the same
temperature. In mixture with a resin, thus, an inorganic filler functions to increase the heat transfer rate of the resin.
[31] Moreover, efficient heat transfer through the inorganic filler throughout the middle layer improves the formability of the entire sheet materials. That is, the heat provided for the surface layers in the embossing process for forming pockets is well conducted through the inorganic filler to the middle layer and uniformly distributed throughout the middle layer. Accordingly, the carrier tapes according to the present invention do not undergo the local distortion described above. Also, the pockets have well-defined edges thanks to the uniformly distributed heat. In addition to its inherent properties of flexibility and toughness, which inhibit the formation of neat holes in the plastic sheet, the base resin for the middle layer is provided with mechanical strength such as modulus, which makes it possible to punch holes neatly in the plastic sheet, by the inorganic filler.
[32] Another additional effect of the inorganic filler is as follows. Because they are further extended during the embossing process, sides of the pocket walls are thinner than other portions in a carrier tape. In a conventional carrier tape, the thin portion becomes faded in color to the extent of having a transparent appearance. In the carrier tape of the present invention, the inorganic filler scatters light, so that the pockets appear to be the same color as other portions.
[33] An acrylonitrile-butadiene-styrene copolymer is useful as the base resin for the middle layer of the carrier tape in the present invention. In addition, almost all styrenic copolymers can be used as the polymeric resin compatible with the inorganic filler in the present invention, exemplified by styrene polymers with butadiene, isoprene, or acrylate, (e.g., styrene-butadiene copolymer, styrene-butadiene- styrene copolymer, styrene-ethylene-butylene-styrene copolymer, styrene-isoprene-styrene copolymer, styrene-acrylate copolymer, styrene-methacrylate copolymer), and styrene polymers with olefin such as ethylene or propylene (e.g., styrene-ethylene graft copolymer, styrene -propylene graft copolymer, styrene-ethylacrylate graft copolymer).
[34] Collectively, polystyrenes, polycarbonates, polyesters, olefinic polymers, polyethers, and blends of styrenic resin therewith may be used alone or in combination to form the middle layer of the carrier tape in accordance with the present invention. In more detail, examples of the base resin for the middle layer of the carrier tape in accordance with the present invention include polystyrene; high impact polystyrene; styrenic copolymers, such as styrene-butadiene copolymers, styrene-acrylate copolymers, styrene-methacrylate copolymers, styrene -butadiene- styrene copolymers, styrene-isoprene-styrene copolymers, styrene-ethylene-butylene-styrene copolymers, aery lonitrile-butadiene- styrene copolymers; polyethylene or ethylene copolymers; polypropylene or propylene copolymers; polyesters; polyethers; and combinations
thereof.
[35] Positioned on the opposite sides of the middle layer made from the polymeric composition containing the inorganic filler, the surface layers, also serving as antistatic layers, may be prepared as disclosed in the conventional patents. For example, a composition containing 100 parts by weight of a styrene copolymer and 5-50 parts by weight of electroconductive carbon black is used to form both of the surface layers while the composition of the present invention is used as a material for the middle layer of the trilayer carrier tape.
[36] The present invention is applicable to composite plastic films for carrier tapes irrespective of the materials. As shown in FIG. 2, a trilayer plastic sheet for carrier tapes comprises a middle layer 120 made from the composition of the present invention sandwiched between two surface layers 110 and 130 made from an electroconductive composition including a styrene polymer and electroconductive carbon black 111. Alternatively, provided is a composite plastic sheet for carrier tapes, as shown in FIG. 3, in which surface layers 110 and 130 are formed from a styrene copolymer underneath and on top of, respectively, a middle layer and both or either of the surface layers is coated with an antistatic layer 150 based on a conductive material. The present invention is more effective for the electroconductive polymer coating than for the resin containing carbon black. In contrast to the resin containing carbon black, the electroconductive coating does not disperse the heat provided upon thermoforming, but is likely to be degenerated by the heat because of its low heat transfer rate. Thus, the inorganic filler of the middle layer can disperse the heat applied to the surface layer into and across the middle layer, thereby solving the problem. For use in this structure of the composite plastic sheet, the surface layers are preferably made of a polymer having a functional group selected from among a styrene moiety, an ethylene moiety, a butylene moiety, a butadiene moiety, a propylene moiety, a carbonate moiety, an ester moiety, an urethane moiety, an acryl moiety, a phenyl moiety, an ether moiety, and combinations thereof, or is a blend of polymers having the functional groups.
[37] In accordance with the present invention, the trilayer plastic sheet preferably has a thickness ratio of upper surface layeπmiddle layeπlower surface layer 1-30 : 98-40 : 1-30. The electroconductive polymer for the antistatic coating may be preferably a polymer having a functional group selected from among thiophene, pyrrole, and aniline, or a modified electroconductive polymer derived from above those, such as polyethylene dioxythiophene. The antistatic coating may be preferably formed to a thickness from 0.02 to 5 microns using a solution coating process or a direct polymerization process such as liquid- or gas-phase polymerization.
[38] The middle layer has a white color due to the inorganic filler present therein. When the surface layer is scratched during handling, the scratched portion appears white. The
scratches, although having no significant influence on the function of the carrier tapes, may be a factor causing the carrier tapes to have a defective appearance. In order to prevent this appearance defect, carbon black may be added, along with the inorganic filler, in an amount from 0.005 to 5 parts by weight, based on 100 parts by weight of the middle layer materials, and preferably in an amount from 0.01 to 0.1 parts by weight to the styrene resin for the middle layer. In the presence of carbon black, the middle layer is tinted pale gray to dark gray, which prevents the scratched portions from appearing white.
[39] The present invention is most useful for, but is not limited to, trilayer antistatic carrier tapes. For example, a monolayer plastic sheet made from a styrene resin mixed with electroconductive carbon black needs no additional inorganic fillers because the electroconductive carbon black itself has high heat transfer properties as well as being antistatic. However, when higher heat transfer efficiency is required, fillers having high thermal transfer efficiency such as nanosized diamond (less than 90 nm in diameter) can be mixed at a concentration of 0.05-5 parts by weight to the total weight of resin. The concentration below 0.05 parts by weight gives only a minor improvement, whereas the concentration higher than 5 parts by weight raises the material cost too much.
[40] As seen in FIG. 4, no burrs are found in the sprocket holes 10 formed in the plastic sheet for carrier tapes in accordance with the present invention.
[41] A better understanding of the present invention may be obtained in light of the following examples which are set forth to illustrate, but are not to be construed to limit the present invention.
[42]
[43] [COMPARATIVE EXAMPLE 1]
[44] A trilayer plastic sheet comprising a middle layer made from an acrylonitrile- butadiene-styrene copolymer (Kumho Petrochemical Co. Ltd., Korea, grade: ABS770), and two surface layers, laminated on and beneath the middle layer, each made from a mixture of 70:30 high impact polystyrene (Kumho Petrochemical Co. Ltd., Korea. Grade: HI425) and electroconductive carbon black was prepared using a triple layerco- extrusion technique, in which the thickness of each of the antistatic surface layer was 15% of the total thickness.
[45] Good sheet formation was obtained at an average T-die temperature of 23O0C.
When the T-die temperature was decreased to 200-2100C, the extruded sheet had a rough surface because of too low T-die temperature.
[46] The plastic sheet extruded through a T-die fixed at 23O0C was cut to a proper size and molded using an embossing machine (SungHwan Tech, Korea). When the molding temperature was set at 190-2300C, normal pockets were formed, but distortion was
observed around the pockets. At a molding temperature less than 19O0C, edges and corners of the pockets were sharply formed, or very poor embossing was found, although no distortion was found therearound.
[47] The plastic sheet was subjected to an embossing process to form pockets about 2.0 mm deep which were observed to be more transparent at pocket corners and edges than at other portions. On punching process, the holes were observed to have burrs therein, as shown in FIG. 1.
[48] [49] [EXAMPLES 1 TO 6] [50] The same procedure as in Comparative Example 1 was repeated, with the exception of using compounds of 70-90 parts by weight of acrylonitrile-butadiene-styrene (ABS) copolymer combined with 10-30 parts by weight of calcium carbonate (CaCO ) or talc, instead of 100 parts by weight of acrylonitrile-butadiene-styrene (ABS) copolymer, as materials for the middle layer, to produce trilayer plastic sheets for carrier tapes.
[51] Compositions and test results of the plastic sheets obtained in Examples 1 to 6 are summarized in Tables 1 and 2. As seen in these tables, the use of 10 to 30 parts by weight of inorganic filler, such as calcium carbonate or talc, decreased the extrusion temperature by 10 to 3O0C and thus the set temperature of the T-die, resulting in a significant reduction in die drool- attributed loss. After being cut to proper sizes, the plastic sheets prepared in Examples 1 to 3 were subjected to an embossing process to form pockets which were found to undergo no distortion and have well defined edges. Even when the pockets were formed to a depth of 2.0 mm, their edges and corners did not differ in transparency to light relative to other portions. In addition, almost no burrs were found in the holes punched in the plastic sheets. After the formation of pockets, the surface layers of the carrier tapes thus formed were measured to have a resistance of 10E6 ohm/sq.
[52] Table 1
[53]
[54] Table 2
[55] x poor, Δ: moderate, o: good [56] [EXAMPLES 7 TO 12] [57] The same procedure as in Comparative Example 1 was repeated, with the exception that blends of styrenic resin were used, in combination with an inorganic filler such as calcium carbonate or talc as listed in Table 3, as materials for the middle layer.
[58] As seen in Table 4, the use of compositions comprising 70-90 parts by weight of a blend of polystyrene (PS) and styrene-butadiene copolymer (SB) and 10-30 parts by weight of an inorganic filler such as calcium carbonate or talc, as materials for the middle layer, slightly reduces the tensile strength, but greatly decreases the extrusion temperature, compared to the use of 100 parts by weight of acrylonitrile- butadiene-styrene resin, thereby curtailing loss upon extrusion. In addition, plastic sheets were found to be improved in punchability and formability and to undergo no distortion after the formation of pockets.
[59] Table 3
[60] Table 4
[61] [62] [EXAMPLES 13 TO 15] [63] The same procedures as in Examples 1 to 3 were conducted to produce plastic sheets for carrier tapes, with the exception that an electroconductive polymer solution was applied to both of the surface layers by way of a roll coating process and dried to provide a surface resistivity of 10E5 Ω/D for the plastic sheets. The electroconductive polymer coating solution was prepared by dissolving 4 g of a dispersion of 3,4-polyethylenedioxythiophene in water (H.C. Starck, Germany), 9 g of a urethane- based binder having a molecular weight of 10,000, 0.01 g of a Zonyl additive (Du Pount), 0.2 g of ethylene glycole, 0.2 g of l-methyl-2-pyrrolidinone in 25 g of a mixture of 1: 1 ethyl alcohol dsopropyl alcohol.
[64] After being cut to proper sizes, the antistatic plastic sheets were subjected to an
embossing process. They were observed to show good punchability and to undergo no distortion after the formation of pockets therein. Particularly, they were measured to have a surface resistivity of 10E(6-7) at both the inner and the outer surface of the pockets, which was optimal for antistatic properties.
[65] [66] Table 5
[67] Table 6
[68]
Industrial Applicability [69] Thanks to the increased heat transfer rate in the middle layer, as described hereinbefore, the plastic sheet for carrier tapes in accordance with the present invention can be produced without die drool, thereby avoiding loss upon extrusion.
[70] Also, the presence of the inorganic filler in the middle layer improves the formability of the plastic sheet because it effectively transfers the heat throughout the middle layer. Thus, the carrier tapes from the plastic sheet, which function to carry or transport electronic parts safe from static electricity, undergo little distortion and allow holes to be effectively punched therein without the generation of burrs.
[71] Although a preferred embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications,
additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
Claims
[1] An antistatic trilayer plastic sheet for carrier tapes, produced through triple layer co-extrusion, comprising: a middle layer made from a composition comprising a base polymer selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, and 2 to 50 parts by weight of an inorganic filler, based on 100 parts by weight thereof; and an upper surface layer and a lower surface layer, respectively laminated on top of and underneath the middle layer, each made from a base polymer resin selected from a group consisting of styrenic polymers, olefinic polymers, polyesters, polyethers, polycarbonates, and combinations thereof, wherein each of the surface layers contains electroconductive carbon black in an amount from 1 to 50 parts by weight based on 100 parts by weight thereof, or both or either of the surface layers has an antistatic coating made from an electroconductive polymer thereon, whereby the plastic sheet is improved in formability and punchability.
[2] The plastic sheet for carrier tapes according to claim 1, wherein the base polymer resin is selected from among polystyrene, high impact polystyrene, styrenic copolymers including styrene-butadiene copolymers, styrene-acrylate copolymers, styrene-methacrylate copolymers, styrene-butadiene-styrene copolymers, styrene-isoprene-styrene copolymers, styrene- ethylene-butylene-styrene copolymers, and acrylonitrile-butadiene-styrene copolymers, polyethylene, ethylene copolymers, polypropylene, propylene copolymers, polyesters, polyethers, and combinations thereof.
[3] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the inorganic filler ranges in size from 0.02 to 5 microns and is selected from a group consisting of calcium carbonate, clay, talc, mica, titanium oxide, zinc oxide, indium oxide, tin oxide, fumed silica, precipitated silica, glass fiber, carbon fiber, copper particles, iron particles, silver particles and combinations thereof.
[4] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the composition for the middle layer further comprises carbon black in an amount from 0.005 to 5 parts by weight, based on 100 parts by weight of the middle layer.
[5] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the composition for the middle layer further comprises a coupling agent and/or a dispersant in an amount from 0.01 to 5 parts by weight based on 100 parts by weight of total fillers, said coupling agent being based on silanes or titanates,
said dispersant being stearic acids or stearates, said coupling agent and said dispersant functioning to increase the interfacial adhesion between the inorganic filler and the base resin and to improve the dispersion of the inorganic filler in the base resin.
[6] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the base polymer for the surface layer is a polymer having a functional group selected from among a styrene moiety, an ethylene moiety, a butylene moiety, a butadiene moiety, a propylene moiety, a carbonate moiety, an ester moiety, an urethane moiety, an acryl moiety, a phenyl moiety, an ether moiety, and combinations thereof, or is a blend of polymers having the functional groups.
[7] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the total surface layers and middle layer have a thickness ratio of 2-60:98:40.
[8] The antistatic plastic sheet for carrier tapes according to claim 1 or 2, wherein the antistatic coating contains the electroconductive polymer as an active ingredient and is formed to a thickness from 0.02 to 5 microns using a solution coating process or a direct polymerization process in a gas or liquid phase.
[9] The antistatic plastic sheet for carrier tapes according to claim 1 or 8, wherein the electroconductive polymer of the antistatic coating is a polymer having a functional group selected from among thiophene, pyrrole, and aniline, or modified electroconductive polymer derived from above those such as polyethylene dioxythiophene.
[10] A carrier tape prepared from the antistatic sheet of claim 1 or 2.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR1020050042878A KR100695503B1 (en) | 2005-05-23 | 2005-05-23 | Plastic Sheet Having Enhanced Formability for Carrier Tape |
| KR10-2005-0042878 | 2005-05-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2006126820A1 true WO2006126820A1 (en) | 2006-11-30 |
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ID=37257973
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/KR2006/001926 WO2006126820A1 (en) | 2005-05-23 | 2006-05-23 | Plastic sheet having enhanced formability for carrier tape |
Country Status (2)
| Country | Link |
|---|---|
| KR (1) | KR100695503B1 (en) |
| WO (1) | WO2006126820A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110699000A (en) * | 2019-10-11 | 2020-01-17 | 上海固柯胶带科技有限公司 | Film material for grinding and packaging semiconductor |
| CN113402833A (en) * | 2020-08-27 | 2021-09-17 | 天津斯坦利新型材料有限公司 | Conductive composition, preparation method and carrier tape |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100649887B1 (en) * | 2005-12-19 | 2006-11-27 | 서광석 | Sheet for using in extreme environments and tray for electronic parts produced therefrom |
| KR100715550B1 (en) * | 2005-12-24 | 2007-05-10 | 광 석 서 | Strong carrier tape sheet |
| KR100837424B1 (en) * | 2006-02-20 | 2008-06-12 | 주식회사 엘지화학 | Conductive styrene based thermoplastic resin composition and career tape sheet comprising the same |
| KR100776041B1 (en) * | 2006-11-07 | 2007-11-29 | 에이앤티엔지니어링(주) | Transparent polycarbonate composite sheet having excellent heat-resistance and formability |
| KR101662368B1 (en) | 2013-07-26 | 2016-10-04 | 롯데첨단소재(주) | Conductive Sheet Composition |
| JP6292607B2 (en) * | 2013-12-26 | 2018-03-14 | 株式会社 東京ウエルズ | Carrier tape, manufacturing method thereof and manufacturing apparatus thereof |
| KR102240735B1 (en) * | 2018-09-03 | 2021-04-16 | 세원정공 주식회사 | Sheet comprising inline-laminated antistatic PMMA film and manufacturing method thereof |
| KR102240718B1 (en) * | 2018-09-03 | 2021-04-15 | 하현대 | Antistatic multi-layer sheet and manufacturing method thereof |
| KR102201978B1 (en) | 2020-05-28 | 2021-01-11 | 박동진 | Apparatus and method for manufacturing carrier tape using air press |
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| JPS59122525A (en) * | 1982-12-28 | 1984-07-16 | Takiron Co Ltd | Antistatic plastic sheet or film |
| JPH02295732A (en) * | 1989-05-09 | 1990-12-06 | Asai Bussan Kk | Antistatic plastic sheet |
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| CN110699000A (en) * | 2019-10-11 | 2020-01-17 | 上海固柯胶带科技有限公司 | Film material for grinding and packaging semiconductor |
| CN113402833A (en) * | 2020-08-27 | 2021-09-17 | 天津斯坦利新型材料有限公司 | Conductive composition, preparation method and carrier tape |
| CN113402833B (en) * | 2020-08-27 | 2022-05-17 | 天津斯坦利新型材料有限公司 | Conductive composition, preparation method and carrier tape |
Also Published As
| Publication number | Publication date |
|---|---|
| KR20050067112A (en) | 2005-06-30 |
| KR100695503B1 (en) | 2007-03-16 |
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