WO2015146596A1 - ダイシングシート用基材フィルム、当該基材フィルムを備えるダイシングシート、および当該基材フィルムの製造方法 - Google Patents
ダイシングシート用基材フィルム、当該基材フィルムを備えるダイシングシート、および当該基材フィルムの製造方法 Download PDFInfo
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
- B32B27/325—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polycycloolefins
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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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
- C09J7/00—Adhesives in the form of films or foils
- C09J7/20—Adhesives in the form of films or foils characterised by their carriers
-
- 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
- C09J7/00—Adhesives in the form of films or foils
- C09J7/20—Adhesives in the form of films or foils characterised by their carriers
- C09J7/29—Laminated material
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- 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
- B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
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- 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
- B32B2274/00—Thermoplastic elastomer material
-
- 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
- B32B2307/51—Elastic
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- 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
- B32B2307/54—Yield strength; Tensile strength
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- 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
- B32B2457/00—Electrical equipment
- B32B2457/14—Semiconductor wafers
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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
- C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
- C09J2203/326—Applications of adhesives in processes or use of adhesives in the form of films or foils for bonding electronic components such as wafers, chips or semiconductors
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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
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/10—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet
- C09J2301/16—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the structure of the carrier layer
-
- 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
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/10—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet
- C09J2301/16—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the structure of the carrier layer
- C09J2301/162—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the structure of the carrier layer the carrier being a laminate constituted by plastic layers only
-
- 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
- C09J2421/00—Presence of unspecified rubber
- C09J2421/006—Presence of unspecified rubber in the substrate
-
- 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
- C09J2423/00—Presence of polyolefin
- C09J2423/006—Presence of polyolefin in the substrate
-
- 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
- C09J2423/00—Presence of polyolefin
- C09J2423/04—Presence of homo or copolymers of ethene
- C09J2423/046—Presence of homo or copolymers of ethene in the substrate
-
- 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
- C09J2423/00—Presence of polyolefin
- C09J2423/10—Presence of homo or copolymers of propene
- C09J2423/106—Presence of homo or copolymers of propene in the substrate
Definitions
- the present invention relates to a dicing sheet to which the object to be cut is attached when the object to be cut such as a semiconductor wafer is cut and separated into element pieces, a base film used for the dicing sheet, and a manufacturing method thereof.
- semiconductor wafers such as silicon and gallium arsenide, substrates such as glass substrates and alumina substrates, and various packages (in this specification, these are collectively referred to as “objects to be cut”) are manufactured in a large diameter state, These are cut and separated (diced) into element pieces (hereinafter referred to as “chips”).
- the object to be cut attached to this dicing process is opposite to the side where the cutting tool for cutting is close in order to ensure the handleability of the object to be cut and the chips in the dicing process and subsequent processes.
- a polyolefin film or a polyvinyl chloride film is usually used as a base film, and an adhesive layer is provided on the base film.
- an object to be cut is cut by a rotating round blade.
- the pressure-sensitive adhesive layer may be cut, and a part of the base film may be cut to ensure that the article to be cut to which the dicing sheet is stuck is cut.
- a cut piece made of the material constituting the pressure-sensitive adhesive layer and the base film is generated from the dicing sheet, and the obtained chip may be contaminated by the cut piece.
- One form of such a cutting piece is a thread-like cutting piece that adheres on the dicing line or near the cross section of the chip separated by dicing.
- a dicing blade with a thicker blade width is used than when dicing a semiconductor wafer, and dicing cuts are made.
- the depth also becomes deeper. For this reason, since the amount of the base film that is cut and removed during dicing increases as compared with the case of the semiconductor wafer, the generation amount of the thread-like cutting pieces also tends to increase.
- Patent Document 1 discloses an invention in which a polyolefin film irradiated with an electron beam or ⁇ (gamma) ray of 1 to 80 Mrad is used as a base film of a dicing sheet. Is disclosed. In the said invention, it is thought that resin which comprises a base film bridge
- Patent Document 1 polyethylene, polypropylene, polymethylpentene, ethylene-vinyl acetate copolymer, ethylene- (meth) acrylic acid copolymer, ethylene-methyl are used as polyolefin films irradiated with electron beams or ⁇ rays.
- Examples include (meth) acrylic acid ester copolymers, ethylene-ethyl (meth) acrylic acid copolymers, ethylene-ionomer copolymers, ethylene-vinyl alcohol copolymers, and polybutenes.
- (meth) acrylic acid in the present specification means both acrylic acid and methacrylic acid. The same applies to other similar terms.
- the object to be cut is separated into pieces by dicing processing, and a plurality of chips are arranged close to each other on the dicing sheet. Then, for the purpose of separating these chips from each other, tension is applied to the dicing sheet to form the dicing sheet.
- An expanding step of extending in the main surface direction is performed. In this expanding step, in the dicing sheet in which the dicing object is attached to the center and the ring frame is attached to the outer peripheral area, the dicing object is located between the area where the dicing object is attached and the area where the ring frame is attached.
- tension is applied to the dicing sheet.
- variation of said relative position of the perpendicular direction is performed by pulling down a ring claim with respect to a ring-shaped member.
- the dicing pitch may be reduced with the miniaturization of the chip, and in this case, in the expanding process, in the main surface of the dicing sheet in order to ensure a sufficient gap between the chips after the expanding process.
- the tension applied to the dicing sheet tends to increase so that the amount of expansion (expansion amount) increases.
- the dicing sheet used for such applications is required not to break even when a higher tension is applied than in the past.
- the base film that is one of the constituent elements of the dicing sheet the base film that does not easily break even when the amount of the expand increases as described above is also referred to as “base film excellent in expandability”.
- the “dicing pitch” means a distance between the center lines of two dicing lines that are parallel to each other and are most proximal among the dicing lines formed by dicing.
- the feed width of the dicing blade in the direction orthogonal to the rotating direction of the dicing blade is the dicing pitch.
- the dicing sheet immediately after the expansion work may be loosened so as to affect subsequent processes. Specifically, if the amount of loosening due to the expanding work (the vertical separation distance of the bottom surface of the dicing sheet with respect to the lower surface of the portion attached to the ring frame in the dicing sheet) is excessively large, In addition, the slack bottom surface of the dicing sheet or the vicinity thereof easily collides with foreign matter, and the handling property when using the dicing sheet is lowered.
- the dicing sheet is partially heated, and the base film constituting the dicing sheet is thermally contracted to reduce the amount of slackness of the dicing sheet.
- the phenomenon in which the amount of slackness of the dicing sheet is reduced based on the heat shrinkage of the base film is also referred to as “restoration”, and the dicing sheet has at least one of the property that this restoration is likely to occur and the property that the restoration amount is large.
- the base film capable of imparting the above property is also referred to as “a base film excellent in restorability”.
- the present invention is difficult to generate a cutting piece in the dicing process, and even when the amount of expansion in the expanding process is large, the base film excellent in expandability and recoverability, the dicing sheet provided with the base film, and the It aims at providing the manufacturing method of a base film.
- the base film is provided with a cutting piece suppressing layer (A) and an expanded layer (B) including at least one resin-based unit layer, Of the at least one resin-based unit layer, the resin-based unit layer (B1) arranged closest to the cutting piece suppressing layer (A) is a unit layer containing linear polyethylene, polypropylene, and a thermoplastic elastomer.
- a substrate film of a dicing sheet wherein the substrate film is a cutting piece suppressing layer (A) and an expanded layer (B) laminated on one main surface of the cutting piece suppressing layer (A).
- the expanded layer (B) includes at least one resin-based unit layer, and is disposed closest to the cutting piece suppression layer (A) among the at least one resin-based unit layer.
- the resin-based unit layer (B1) contains linear polyethylene, polypropylene, and a thermoplastic elastomer
- the cutting piece suppressing layer (A) is a thermoplastic having at least one of an aromatic ring and an aliphatic ring.
- a base film comprising a ring-containing resin (a1) which is a resin and an acyclic olefin-based resin (a2) which is an olefin-based thermoplastic resin other than the ring-containing resin (a1).
- thermoplastic elastomer contained in the resin unit layer (B1) is an olefin elastomer.
- the thickness of the expanded layer (B) is such that the ratio to the thickness of the base film is 30% or more and 80% or less, and the thickness of the expanded layer (B) of the resin-based unit layer (B1).
- the expanded layer (B) includes a plurality of the resin-based unit layers, and the resin-based resin layer that is disposed farthest from the cutting piece suppressing layer (A) among the plurality of resin-based unit layers.
- the above (1) comprising a resin-based unit layer (B2) different from the unit layer (B1), wherein the resin-based unit layer (B2) comprises a layer containing an ethylene- (meth) acrylic acid copolymer.
- the base film according to any one of to (7).
- a dicing comprising: the base film according to any one of (1) to (8) above; and an adhesive layer disposed on the cutting piece suppressing layer (A) of the film. Sheet.
- the resin composition ((alpha)) for forming the said cutting piece suppression layer (A) and the said resin-type unit layer (B1) are formed.
- Three or more types of resin compositions including a resin composition ( ⁇ 1) for forming the resin-based unit layer (B2) and a resin composition ( ⁇ 2) for forming the resin-based unit layer (B2),
- a base film having excellent expandability and restoration property is provided. Moreover, the dicing sheet provided with said base film is also provided by this invention. Furthermore, according to the manufacturing method of this invention, it is possible to manufacture said base film efficiently.
- a dicing sheet 1 includes a pressure-sensitive adhesive layer 3 disposed on a base film 2 as a basic configuration.
- This base film 2 includes a cutting piece suppression layer (A) and an expanded layer (B) laminated on one main surface of the cutting piece suppression layer (A).
- the base film 2 may be composed of a cutting piece suppression layer (A) and an expanded layer (B), or another layer may be laminated.
- A cutting piece suppression layer
- B expanded layer
- the pressure-sensitive adhesive layer 3 is disposed on the main surface.
- the cutting piece suppression layer (A) includes a ring-containing resin (a1) that is a thermoplastic resin having at least one of an aromatic ring and an aliphatic ring, and an olefin-based thermoplastic resin other than the ring-containing resin (a1). And an acyclic olefin-based resin (a2).
- the ring-containing resin (a1) is different from the acyclic olefin-based resin (a2) in that the polymer constituting each resin substantially has a chemical structure (cyclic structure) having a cyclic skeleton.
- the physical properties such as density, tensile modulus, softening point, fluidization temperature, melt mass flow rate (MFR) are different.
- the content of the ring-containing resin (a1) in the cutting piece suppression layer (A) is preferably more than 3.0% by mass and 60% by mass or less, and more preferably 3.5% by mass or more and 55% by mass or less. More preferably, it is preferably 5.0% by mass or more and 55% by mass or less, and more preferably 10% by mass or more and 45% by mass or less.
- the content of the ring-containing resin (a1) in the cutting piece suppression layer (A) exceeds 3.0% by mass, the effect of suppressing the generation of cutting pieces (hereinafter, also referred to as “cutting piece suppression effect”). Can be obtained stably.
- the content of the ring-containing resin (a1) in the cutting piece suppression layer (A) is 60% by mass or less, it is possible to effectively suppress a decrease in workability of the cutting piece suppression layer (A). Can do.
- the ring-containing resin (a1) is a thermoplastic resin having at least one of an aromatic ring and an aliphatic ring.
- An aromatic ring is a chemical structure having at least one cyclic skeleton (this chemical structure is referred to as “cyclic structure” in this specification), and at least one of the cyclic skeletons satisfies the Hückel rule and is cyclic.
- the one having an electron that is delocalized is referred to as an aromatic ring.
- Aromatic rings are roughly classified into single rings such as benzene rings and condensed rings such as naphthalene rings.
- the skeleton atom forming the aromatic ring may be composed of carbon alone, or may be a heterocyclic ring in which one or more of the skeleton atoms are elements other than carbon, such as pyridine, furan, thiophene and the like. Furthermore, non-benzenoid aromatic rings such as cyclopentadienide anions are also included in the aromatic ring according to this embodiment.
- the number of atoms constituting the skeleton of the aromatic ring according to this embodiment is not limited, and a functional group such as a methyl group or a hydroxyl group may be bonded to one or more atoms forming this skeleton. In this case, the functional group bonded to the aromatic ring such as tetrahydronaphthalene may have a cyclic structure.
- aliphatic ring refers to a cyclic structure in which any of the cyclic skeletons does not have an electron that is delocalized in the ring of the aromatic ring.
- the aliphatic ring is a cyclic structure composed of a cyclic skeleton other than the aromatic ring.
- the cyclic skeleton forming the aliphatic ring include a monocyclic ring such as cyclohexane, a bridged ring such as norbornane and adamantane, a condensed ring such as decalin, and a spiro ring such as spiro [4,5] decane. .
- bonds forming the cyclic skeleton of the aliphatic ring such as norbornene may be unsaturated bonds, and some of the atoms forming the cyclic skeleton of the aliphatic ring such as tetrahydrofuran are other than carbon. May be used.
- a functional group such as a methyl group or a hydroxyl group may be substituted for one or more of hydrogen bonded to the atoms forming the cyclic skeleton of the aliphatic ring.
- the skeleton atom may form a carbonyl group, such as a cyclic ketone such as cyclohexanone or a lactone such as ⁇ -butyrolactone.
- the position of the aromatic ring and the aliphatic ring in the thermoplastic resin (hereinafter sometimes referred to as polymer) constituting the ring-containing resin (a1) is arbitrary.
- a part of the main chain in the polymer constituting the ring-containing resin (a1) may be formed, or the main chain or side chain of this polymer as a functional group having a cyclic structure (for example, phenyl group, adamantyl group, etc.) May be bonded to.
- the polymer in which the aromatic ring forms a part of the main chain include polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyimide, polyamideimide, and polyaryl ketone.
- cycloolefin polymer As a polymer in which an aliphatic ring is part of the main chain, cycloolefin polymer, cycloolefin copolymer, norbornene resin using norbornene as a monomer, copolymer containing norbornene and ethylene, tetracyclododecene and ethylene as monomers And copolymers containing dicyclopentadiene and ethylene as monomers.
- the functional group having a cyclic structure include groups consisting of a ring assembly such as a fluorene group and a biphenyl group in addition to the above phenyl group and adamantyl group.
- An aromatic ring and an aliphatic ring may be contained in one polymer, and in that case, both of them may form part of the main chain, or one or both of them may be main. It may be bonded as a functional group to a chain or a side chain. Examples of the latter include those having a naphthalene ring structure as a functional group, although the portion forming a part of the main chain is an aliphatic ring, such as an acenaphthylene copolymer.
- a preferred structure of the ring-containing resin (a1) is a structure in which an aliphatic ring including a ring of a bridged ring skeleton constitutes at least a part of the main chain of the polymer constituting the resin, and has such a structure
- the resin include a ring-opening metathesis polymer hydrogenated polymer of a norbornene-based monomer (specifically, available as ZEONEX (registered trademark) series manufactured by ZEON Corporation), a copolymer of norbornene and ethylene (specifically, poly Available as Plastics TOPAS (registered trademark) series), copolymers based on ring-opening polymerization of dicyclopentadiene and tetracyclopentadene (specifically, ZEONOR (registered trademark) series manufactured by Nippon Zeon Co., Ltd.) ), A copolymer of ethylene and tetracyclododecene (specifically, Mitsui Chemicals, Inc.) A
- the ring-containing resin (a1) preferably has a structure in which an aromatic ring constitutes at least a part of a main chain of a polymer constituting the resin.
- a resin having such a structure a styrene-butadiene copolymer (specifically, Asaflex (registered trademark) series manufactured by Asahi Kasei Chemicals Corporation, Clearen (registered trademark) series manufactured by Denki Kagaku Kogyo Co., Ltd.), K manufactured by Chevron Phillips Co., Ltd.
- Asaflex (registered trademark) series manufactured by Asahi Kasei Chemicals Corporation, Clearen (registered trademark) series manufactured by Denki Kagaku Kogyo Co., Ltd.) K manufactured by Chevron Phillips Co., Ltd.
- the resin series, the BASF Styrolux series, and the Atofina Finaclear series are available.
- the polymer constituting the ring-containing resin (a1) may be one type or a blend of a plurality of types of polymers.
- the types of polymers are different from each other in terms of branching state (that is, polymer architecture), molecular weight, blending balance of monomers constituting the polymer, and monomers constituting the polymer. It means that the composition and combinations thereof differ to such a degree that they have a great influence on physical properties and the like.
- the ring-containing resin (a1) may have a crosslinked structure.
- the kind of the crosslinking agent that brings about the crosslinked structure is arbitrary, and a compound having an organic peroxide such as dicumyl peroxide or an epoxy group is typical.
- the cross-linking agent may be cross-linked between the same type of polymers constituting the ring-containing resin (a1), or may be cross-linked between different types of polymers.
- the bonding site of the crosslinking agent is also arbitrary.
- the ring-containing resin (a1) may be crosslinked with atoms constituting the main chain in the polymer, or may be crosslinked with atoms constituting other than the main chain such as side chains and functional groups.
- the degree of crosslinking is arbitrary, but if the degree of crosslinking proceeds excessively, the workability (particularly formability) of the cutting piece suppressing layer (A) containing the ring-containing resin (a1) is excessively reduced, or the cutting piece Since there is a concern that the surface property of the suppression layer (A) is excessively deteriorated or the brittleness resistance of the cutting piece suppression layer (A) is lowered, it should be kept in a range where such a problem does not occur.
- the ring-containing resin (a1) may be crystalline or non-crystalline.
- the ring-containing resin (a1) is preferably non-crystalline from the viewpoint of mixing with the acyclic olefin resin (a2) and molding on the film.
- the acyclic olefin-based resin (a2) is a material other than the above-mentioned ring-containing resin (a1), that is, substantially both of an aromatic ring and an aliphatic ring. It consists of an olefinic thermoplastic resin that does not exist.
- the olefin-based thermoplastic resin is, as described above, homopolymers and copolymers having olefins as monomers, and copolymers having monomers other than olefins and molecules other than olefins, after polymerization. It means a general term for thermoplastic resins in which the mass ratio of the portion based on olefin units in the resin is 1.0 mass% or more.
- the polymer constituting the acyclic olefin-based resin (a2) according to this embodiment may be linear or may have a side chain. Moreover, you may have an acyclic functional group and the kind and substitution density are arbitrary. A functional group having low reactivity such as an alkyl group may be used, or a functional group having high reactivity such as a carboxylic acid group may be used.
- the acyclic olefin-based resin (a2) includes at least one acyclic polyolefin (in the present specification, “acyclic polyolefin” means a homopolymer having an olefin having no cyclic structure as a monomer and It means the generic name of copolymer.
- acyclic polyolefin means a homopolymer having an olefin having no cyclic structure as a monomer and It means the generic name of copolymer.
- acyclic olefin resin (a2) examples include polyethylene (linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene), ethylene-olefin copolymer (ethylene and olefin other than ethylene) ), Ethylene-vinyl acetate copolymer, ethylene- (meth) acrylic acid copolymer, ethylene- (meth) acrylic acid ester copolymer, and other ethylene-based copolymers, polypropylene, polybutene And polymethylpentene.
- the polymer constituting the acyclic olefin resin (a2) may be one kind or a blend of a plurality of kinds of polymers.
- polyethylene linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene
- ethylene-olefin copolymer ethylene-vinyl acetate copolymer
- ethylene -It is preferably an ethylene copolymer such as (meth) acrylic acid copolymer, ethylene- (meth) acrylic acid ester copolymer, polyethylene (low density polyethylene, medium density polyethylene, high density polyethylene), ethylene -More preferred is an olefin copolymer.
- Examples of the olefin constituting the ethylene-olefin copolymer include propylene such as propylene, 1-butene, 1-hexene, 1-octene and 4-methyl-1-pentene, and ⁇ -olefin having 4 to 18 carbon atoms. And monomers.
- the mass ratio of the portion based on ethylene units in the polymerized resin may be 1.0% by mass or more. If the mass ratio of the portion based on the ethylene unit is in the above range, the cutting piece suppressing effect is easily obtained stably.
- the ethylene unit in the resin after polymerization described above 20 mass% or more is preferable, 50 mass% or more is more preferable, and 70 mass% or more is further more preferable.
- the acyclic olefin resin (a2) may have a crosslinked structure.
- the kind of the crosslinking agent that brings about the crosslinked structure is arbitrary, and a compound having an organic peroxide such as dicumyl peroxide or an epoxy group is typical.
- the crosslinking agent may be crosslinked between one type of polymer constituting the acyclic olefin resin (a2), or may be crosslinked between different types of polymers.
- the bonding site of the crosslinking agent is also arbitrary.
- the crosslinking agent may be crosslinked with atoms constituting the main chain in the polymer constituting the acyclic olefin resin (a2), or may be crosslinked with atoms constituting other than the main chain such as side chains and functional groups.
- the degree of cross-linking is arbitrary, but if the degree of cross-linking progresses excessively, the difference in physical properties between the acyclic olefin resin (a2) and the ring-containing resin (a1) is reduced, and the generation of cutting pieces is suppressed. It is feared that the function to perform tends to decrease. Therefore, the degree of cross-linking should be kept in a range where such a problem does not occur.
- the preferable degree of thermoplasticity in the acyclic olefin resin (a2) according to the present embodiment is shown in the range of melt mass flow rate (190 ° C., 2.16 kgf), 0.5 g / 10 min to 10 g / 10 min. It is more preferable if it is 2.0 g / 10 min or more and 7 g / 10 min or less.
- the melt mass flow rate of the acyclic olefin-based resin (a2) is equal to or higher than the melt mass flow rate of the ring-containing resin (a1). Is preferred.
- the acyclic olefin resin (a2) may be amorphous or may have crystallinity.
- the cutting piece suppression layer (A) contains other components in addition to the ring-containing resin (a1) and the acyclic olefin resin (a2). You may contain. Examples of such other components include thermoplastic elastomer resins such as isoprene rubber, nitrile rubber, acrylic rubber, urethane rubber, butadiene rubber, and copolymers thereof.
- the content of these other components in the cutting piece suppressing layer (A) is preferably set in a range in which the cutting piece suppressing effect of the cutting piece suppressing layer (A) can be obtained.
- the expanded layer (B) includes at least one resin-based unit layer. That is, the expanded layer (B) may have a single layer structure or a laminated structure.
- the expanded layer (B) includes a resin-based unit layer (B1) as a unit layer disposed closest to the cutting piece suppressing layer (A) among at least one resin-based unit layer included in the layer. .
- the expanded layer (B) is composed of a resin-based unit layer (B1).
- Resin-based unit layer (B1) The resin-based unit layer (B1) disposed closest to the cutting piece suppressing layer (A) contains linear polyethylene, polypropylene, and a thermoplastic elastomer.
- linear polyethylene means a copolymer of ethylene and ⁇ -olefin (alkene having 4 or more carbon atoms having an ethylenically unsaturated bond at the ⁇ -position).
- the specific structure of the linear polyethylene is not particularly limited. Examples of the ⁇ -olefin serving as a monomer that gives a linear polyethylene include 1-butene, 1-hexene, 1-octene, and the like.
- the linear polyethylene may be composed of one type of polymer or a mixture of a plurality of types of polymers.
- the resin-based unit layer (B1) contains linear polyethylene, it is possible to obtain a base film 2 that is excellent in expandability and restorability.
- the resin unit layer (B1) preferably contains 10% by mass or more of linear polyethylene, and contains 15% by mass or more. It is more preferable to contain 20% by mass or more.
- the content of linear polyethylene in the resin-based unit layer (B1) may be even higher, 30% by mass or more, 40% by mass or more, or 50% by mass or more. May be.
- the upper limit of the content of linear polyethylene in the resin-based unit layer (B1) is within a range in which the content of other components (polypropylene, thermoplastic elastomer, etc.) contained in the resin-based unit layer (B1) is not excessively reduced. I just need it.
- the content of linear polyethylene in the resin unit layer (B1) may be 90% by mass or less, 80% by mass or less, or 70% by mass or less.
- the density at 23 ° C. of the linear polyethylene (in the present specification, “density” unless otherwise specified means the density at 23 ° C.) is not particularly limited.
- the density of the linear polyethylene is preferably 860 kg / m 3 or more and less than 940 kg / m 3 , and 870 kg / m 3 or more. more preferably less than 935 kg / m 3, more preferably less than 890 kg / m 3 or more 930 kg / m 3, particularly preferably less than 910 kg / m 3 or more 930 kg / m 3.
- the degree of thermoplasticity of the linear polyethylene is not particularly limited. If the preferable degree of thermoplasticity is shown in the range of melt mass flow rate (measurement conditions: temperature 190 ° C., load 2.16 kgf, the same shall apply hereinafter), it is 0.5 g / 10 min or more and 10 g / 10 min or less. It is more preferable if it is 0 g / 10 min or more and 7 g / 10 min or less.
- polypropylene means a general term for homopolymers and copolymers of monomers containing propylene. Polypropylene may be composed of one type of polymer or a mixture of multiple types of polymers. When the resin-based unit layer (B1) contains polypropylene, it is possible to obtain the base film 2 that is excellent in expandability and restorability.
- polypropylene includes a copolymer
- the type of monomer other than propylene related to the copolymer is not limited.
- examples of such monomers include ⁇ -olefins having 4 to 18 carbon atoms such as ethylene, 1-butene, 1-hexene and 1-octene.
- the content of the structural unit derived from propylene in the copolymer is usually 75 masses as the mass ratio of propylene with respect to the whole monomer for forming the copolymer. % To 99.9% by mass, preferably 80% to 99% by mass, more preferably 85% to 99% by mass, and still more preferably 90% to 99% by mass. is there.
- polypropylene contains a copolymer
- the specific mode of the copolymer is not particularly limited, and may be any of a random copolymer, a block copolymer, and a graft copolymer. You may contain these 2 or more types of copolymers.
- the resin-based unit layer (B1) preferably contains 5% by mass or more of polypropylene, and preferably contains 10% by mass or more. More preferably, it is particularly preferably 12% by mass or more.
- the content of polypropylene in the resin-based unit layer (B1) may be higher, 15% by mass or more, or 30% by mass or more.
- the upper limit of the content of polypropylene in the resin-based unit layer (B1) is within a range in which the content of other components (such as linear polyethylene and thermoplastic elastomer) contained in the resin-based unit layer (B1) is not excessively reduced. I just need it. 70 mass% or less may be sufficient as content of the polypropylene in a resin system unit layer (B1), 60 mass% or less may be sufficient, and less than 50 mass% may be sufficient.
- Polypropylene is preferably a thermoplastic resin from the viewpoint of facilitating the production of the resin-based unit layer (B1).
- the polypropylene is not crosslinked or the degree of crosslinking is appropriately controlled.
- the melt mass flow rate (MFR) is preferably 0.5 g / 10 min or more and 10 g / 10 min or less, and is 2.0 g / 10 min or more and 7 g / 10 min or less. It is more preferable.
- thermoplastic elastomer is still thermoplastic even when repeatedly heated and cooled within the temperature range specific to the material during processing and use, and has rubber-like elasticity at room temperature.
- a high molecular weight substance indicates the tendency of a substance that, after being deformed considerably by a weak stress and then removing the stress, rapidly returns to its original size and shape. This tendency is mainly due to a decrease in entropy due to deformation. Due to When the resin-based unit layer (B1) contains the thermoplastic elastomer, it is possible to obtain the base film 2 that is excellent in expandability and restoration property.
- thermoplastic elastomers The following are the specific physical properties of thermoplastic elastomers. That is, when the external force is removed, it returns to its original size almost instantaneously.
- the tensile elastic modulus is about 0.1 MPa to about 100 MPa.
- the elongation at break is about 100% to about 800%.
- the tensile strength is about 5 MPa to 40 MPa.
- the specific type of thermoplastic elastomer is not limited. Examples of thermoplastic elastomers include olefin elastomers, styrene elastomers, urethane elastomers, and the like.
- an olefin elastomer a copolymer of propylene and an ⁇ olefin; an ⁇ olefin polymer (a polymer formed by polymerizing an ⁇ olefin, which may be either a homopolymer or a copolymer);
- ethylene-propylene rubbers such as ethylene-propylene rubber (EPM) and ethylene-propylene-diene rubber (EPDM); chlorosulfonated polyethylene (CSM) and the like.
- TAFMER registered trademark
- AFFINITY registered trademark
- ENGAGE registered trademark
- EXACT manufactured by ExxonMobil Corporation Product names such as (Registered Trademark) series and Exelen (Registered Trademark) FX series manufactured by Sumitomo Chemical Co., Ltd.
- the styrene elastomer is made of a copolymer containing structural units derived from styrene or a derivative thereof (styrene compound), and has rubber-like elasticity and thermoplasticity in a temperature range including normal temperature.
- styrenic elastomers include styrene-conjugated diene copolymers and styrene-olefin copolymers.
- styrene-conjugated diene copolymers include styrene-butadiene copolymers, styrene-butadiene-styrene copolymers (SBS), styrene-butadiene-butylene-styrene copolymers, styrene-isoprene copolymers, styrene.
- SBS styrene-butadiene-styrene copolymers
- SBS styrene-butadiene-styrene copolymers
- styrene-isoprene copolymers styrene-isoprene copolymers
- styrene-conjugated diene copolymers such as isoprene-styrene copolymer (SIS) and styrene-ethylene-isoprene-styrene copolymer; styrene-ethylene / propylene-styrene copolymer (SEPS, styrene-isoprene) -Hydrogenated styrene-conjugated diene copolymers such as -styrene copolymer water additives) and styrene-ethylene-butylene-styrene copolymers (SEBS, hydrogenated styrene-butadiene copolymers).
- SIS isoprene-styrene copolymer
- SEPS styrene-ethylene / propylene-styrene copolymer
- SEBS hydrogenated styrene-butad
- thermoplastic elastomer may be composed of one kind of polymer or a mixture of plural kinds of polymers.
- thermoplastic elastomers olefin elastomers are preferable from the viewpoint of enhancing compatibility with other components contained in the resin unit layer (B1), particularly linear polyethylene and polypropylene.
- the resin-based unit layer (B1) preferably contains 1% by mass or more of the thermoplastic elastomer, and contains 2% by mass or more. It is more preferable to contain 5% by mass or more.
- the upper limit of the content of the thermoplastic elastomer in the resin-based unit layer (B1) is within a range in which the content of other components (such as linear polyethylene and polypropylene) contained in the resin-based unit layer (B1) does not decrease excessively. I just need it.
- the content of the thermoplastic elastomer in the resin-based unit layer (B1) may be 60% by mass or less, 50% by mass or less, or 40% by mass or less.
- the resin-based unit layer (B1) may contain a resin other than the above-mentioned resin (this resin is also referred to as “sub resin” in the present specification).
- this resin is also referred to as “sub resin” in the present specification.
- LDPE low density polyethylene
- VLDPE very low density polyethylene
- EVA ethylene-vinyl acetate copolymer
- EBA ethylene-vinyl acetate-maleic anhydride copolymer
- EBA ethylene- (meth) acrylic acid copolymer
- EBA ethylene-butyl acrylate copolymer
- the secondary resin may be composed of one type of resin or a plurality of types of resins.
- the breaking elongation of the resin-based unit layer (B1) is not limited, but is preferably large. It is preferably 100% or more, more preferably 200% or more, and particularly preferably 500% or more.
- the breaking elongation of the resin-based unit layer (B1) may have anisotropy due to the manufacturing process.
- the thickness of the resin unit layer (B1) is not particularly limited. If the resin-based unit layer (B1) is excessively thin, the significance of providing the resin-based unit layer (B1) may be lost. If the resin-based unit layer (B1) is excessively thick, it will be described later. It may be set as appropriate considering that the significance of providing the resin-based unit layer (B2) may be lost.
- the thickness of the resin-based unit layer (B1) is usually preferably 5 ⁇ m or more and 150 ⁇ m or less, more preferably 10 ⁇ m or more and 100 ⁇ m or less, and particularly preferably 15 ⁇ m or more and 60 ⁇ m or less.
- the ratio of the thickness of the resin-based unit layer (B1) to the thickness of the expanded layer (B) is not particularly limited.
- the ratio is 100%.
- the ratio is preferably 5% to 70%, more preferably 10% to 60%, and more preferably 20% or more. It is particularly preferable that it is 50% or less.
- the expanded layer (B) preferably includes a resin-based unit layer (B2) containing an ethylene- (meth) acrylic acid copolymer.
- the resin-based unit layer (B2) is disposed more distal to the cutting piece suppressing layer (A) than the resin-based unit layer (B1), It is preferable that the cutting piece restraining layer (A) is disposed most distally.
- ethylene- (meth) acrylic acid copolymer means a copolymer of ethylene and one or more compounds selected from the group consisting of (meth) acrylic acid and (meth) acrylic acid ester. Means coalescence.
- (meth) acrylic acid esters include methyl (meth) acrylate, ethyl (meth) acrylate, hydroxyethyl (meth) acrylate, and butyl (meth) acrylate.
- the molar ratio of the structural unit derived from ethylene to the entire structural unit of the ethylene- (meth) acrylic acid copolymer is preferably 89% or more, more preferably 90% or more, and 91% or more. It is particularly preferred that
- the ethylene- (meth) acrylic acid copolymer contained in the resin-based unit layer (B2) may be composed of one type of polymer, or may be composed of a plurality of types of polymers.
- the ethylene- (meth) acrylic acid copolymer content contained in the resin-based unit layer (B2) is preferably 50% by mass or more based on the total resin constituting the resin-based unit layer (B2). 70 mass% or more is more preferable, and 90 mass% or more is particularly preferable.
- the resin unit layer (B2) may be made of an ethylene- (meth) acrylic acid copolymer.
- the resin unit layer (B2) may contain an ethylene resin (b1) other than the ethylene- (meth) acrylic acid copolymer.
- the “ethylene-based resin (b1)” means a thermoplastic resin whose main component is a polymer containing a structural unit derived from ethylene.
- the molar ratio of the structural unit derived from ethylene to the entire structural unit of the ethylene-based resin (b1) is preferably 60% by mass or more and 100% by mass or less, and 70% by mass or more and 99.5% by mass or less. It is more preferable.
- Examples of the ethylene-based resin (b1) include low-density polyethylene (LDPE, density: 910 kg / m 3 or more and less than 930 kg / m 3 ), very low-density polyethylene (VLDPE, density: 880 kg / m 3 or more, 910 kg / m). 3 ), ethylene-propylene copolymer, ethylene-vinyl acetate copolymer (EVA), ethylene-vinyl acetate-maleic anhydride copolymer, and the like.
- the ethylene resin (b1) may be composed of one type of resin or may be composed of a plurality of types of resins.
- the resin unit layer (B2) may contain a resin other than the ethylene- (meth) acrylic acid copolymer and the ethylene resin (b1).
- a resin include polypropylene and styrene elastomer.
- the thickness of the resin unit layer (B2) is not particularly limited. If the resin-based unit layer (B2) is excessively thin, the physical properties of the entire expanded layer (B) are dominated by the resin-based unit layer (B1), and the significance of providing the resin-based unit layer (B2) may be lost. If the resin-based unit layer (B2) is excessively thick, the thickness of the resin-based unit layer (B1) becomes too thin, and the significance of providing the resin-based unit layer (B1) is lost. It may be set appropriately considering that there is a risk of being damaged.
- the thickness of the resin-based unit layer (B2) is usually preferably 15 ⁇ m or more and 200 ⁇ m or less, more preferably 25 ⁇ m or more and 150 ⁇ m or less, and particularly preferably 35 ⁇ m or more and 100 ⁇ m or less.
- the ratio of the thickness of the resin-based unit layer (B2) to the thickness of the expanded layer (B) is not particularly limited. The ratio is usually preferably 30% or more and 95% or less, more preferably 40% or more and 90% or less, and particularly preferably 50% or more and 80% or less.
- the expanded layer (B) may be composed of the resin-based unit layer (B1), or the resin-based unit layer (B1) and the resin-based layer. You may be comprised from the unit layer (B2). As long as a predetermined function can be fulfilled as the expanded layer (B), unit layers other than these unit layers may be provided.
- the thickness of the base film 2 which concerns on this embodiment is 40 micrometers or more and 300 micrometers or less normally, Preferably they are 60 micrometers or more and 200 micrometers or less.
- the thickness of the cut piece suppressing layer (A) is usually 20 ⁇ m or more and 120 ⁇ m or less, and preferably 30 ⁇ m or more and 100 ⁇ m or less. If the cutting piece suppressing layer (A) has the above thickness, the cutting piece suppressing effect can be obtained more stably.
- the thickness of the expanded layer (B) is usually 20 ⁇ m or more and 280 ⁇ m or less, preferably 40 ⁇ m or more and 200 ⁇ m or less. When the expanded layer (B) is excessively thin, it may be difficult to obtain the base film 2 having excellent expandability even if the expanded layer (B) has the above-described compositional characteristics.
- the ratio of the thickness of the expanded layer (B) to the thickness of the base film 2 is preferably 30% or more and 80% or less. When this ratio is too low, as a result, the expanded layer (B) becomes excessively thin, and there is a possibility that it is difficult to obtain the base film 2 having excellent expandability as described above. On the other hand, when said ratio is too high, there exists a possibility that the cutting piece suppression layer (A) may become excessively thin as a result, and it may become difficult to acquire the cutting piece suppression effect stably.
- the ratio of the thickness of the expanded layer (B) to the thickness of the base film 2 is more preferably 33% or more and 77% or less, more preferably 35% or more and 75% or less, and 40% or more and 70. % Or less is particularly preferable.
- the tensile elastic modulus of the base film 2 is preferably 80 MPa or more and 300 MPa or less.
- the tensile elastic modulus is less than 80 MPa, when the wafer is bonded to the dicing sheet 1 and then fixed to the ring frame, the base film 2 is soft and may be loosened, which may cause a conveyance error.
- the tensile elastic modulus of the base film 2 exceeds 300 MPa, the load applied during the expanding process becomes large, which may cause problems such as the dicing sheet 1 itself peeling off from the ring frame.
- the base film 2 when the expanded layer (B) is composed only of the resin-based unit layer (B1), that is, the base film 2 is composed of the cutting piece suppressing layer (A) and the resin-based unit.
- the layer (B1) when composed of the layer (B1), from the above formula (I) or (II) using the tensile modulus values measured for the cutting piece suppression layer (A) and the resin-based unit layer (B1), respectively.
- the calculated tensile modulus ratio ⁇ is preferably 1.0 to 3.0.
- the base film 2 when the expanded layer (B) is composed of the resin-based unit layer (B1) and the resin-based unit layer (B2), that is, the base film 2 is the cutting piece suppression layer.
- the tensile modulus measured for each of the cutting piece suppressing layer (A) and the resin-based unit layer (B1) It is preferable that the tensile modulus ratio ⁇ calculated from the above formula (I) or (II) by using the value is 1.0 to 3.0.
- the measuring method of the tensile elasticity modulus in each layer which comprises the base film 2 is as showing in the test example mentioned later.
- the manufacturing method of base film 2 is not particularly limited. Examples include melt extrusion methods such as a T-die method and a round die method; calendar methods; solution methods such as a dry method and a wet method, and any method may be used. From the viewpoint of producing the base film 2 with high productivity, it is preferable to employ a melt extrusion method or a calendar method. Among these, in the case of producing by the melt extrusion method, the components constituting the cutting piece suppressing layer (A) and the expanded layer (B) were kneaded, respectively, and pellets were produced directly or once from the obtained kneaded material. Thereafter, the film may be formed using a known extruder.
- constituent elements in the dicing sheet As constituent elements other than the base film 2 in the dicing sheet 1, of the two main surfaces of the base film 2, closer to the cutting piece suppression layer (A) than the expanded layer (B)
- the pressure-sensitive adhesive layer 3 arranged on the main surface of the other side, and the surface opposite to the side facing the base film 2 of the pressure-sensitive adhesive layer 3, that is, the surface to be attached to the object to be cut are protected. An example of the release sheet for this is shown.
- Adhesive layer 3 It does not specifically limit as an adhesive which comprises the adhesive layer 3, What is normally used as a dicing sheet can be used, for example, adhesives, such as rubber type, an acryl type, a silicone type, a polyvinyl ether type, are used. It may also be an energy ray curable (including ultraviolet curable), heat foamed or heat curable adhesive. In addition, when the dicing sheet 1 in the present embodiment is used as a dicing die bonding sheet, an adhesive, a thermoplastic adhesive, a B stage adhesive, etc. that simultaneously have a wafer fixing function and a die bonding function. Is used.
- the thickness of the pressure-sensitive adhesive layer 3 is usually about 3 ⁇ m to 100 ⁇ m, preferably about 5 ⁇ m to 80 ⁇ m.
- release sheet for protecting the adhesive layer 3 is arbitrary.
- release sheets include polyethylene film, polypropylene film, polybutene film, polybutadiene film, polymethylpentene film, polyvinyl chloride film, vinyl chloride copolymer film, polyethylene terephthalate film, polyethylene naphthalate film, polybutylene terephthalate film, polyurethane Film, ethylene vinyl acetate film, ionomer resin film, ethylene- (meth) acrylic acid copolymer film, ethylene- (meth) acrylic acid ester copolymer film, polystyrene film, polycarbonate film, polyimide film, fluororesin film, etc. Can be used. Moreover, you may use these bridge
- the release surface of the release sheet (particularly the surface in contact with the pressure-sensitive adhesive layer 3) is preferably subjected to a release treatment.
- the release agent used for the release treatment include alkyd, silicone, fluorine, unsaturated polyester, polyolefin, and wax release agents.
- it does not specifically limit about the thickness of a peeling sheet, Usually, it is about 20 micrometers-about 150 micrometers.
- Manufacturing method of dicing sheet 1 The manufacturing method of the dicing sheet 1 which consists of laminated bodies, such as said base film 2 and the adhesive layer 3, and a peeling sheet used as needed, is not specifically limited.
- Some examples of the manufacturing method of the dicing sheet 1 are as follows.
- the pressure-sensitive adhesive layer 3 is formed on the release sheet, and the base film 2 is pressure-bonded and laminated on the pressure-sensitive adhesive layer 3.
- the formation method of the adhesive layer 3 is arbitrary.
- An example of a method for forming the pressure-sensitive adhesive layer 3 is as follows. A coating agent containing a pressure-sensitive adhesive composition for forming the pressure-sensitive adhesive layer 3 and, if desired, a solvent is prepared. More than the expanded layer (B) of the two main surfaces of the base film 2 by a coating machine such as a roll coater, knife coater, roll knife coater, air knife coater, die coater, bar coater, gravure coater, curtain coater, etc.
- the pressure-sensitive adhesive layer 3 is formed by drying the layer made of the coating agent on the base film 2. As an example other than the above method, the pressure-sensitive adhesive layer 3 separately formed in a sheet shape may be attached to the base film 2.
- the base film 2 is formed, the pressure-sensitive adhesive layer 3 is formed thereon, and a release sheet is further laminated as necessary.
- the formation method of the adhesive layer 3 at this time is arbitrary as described above.
- a pressure-sensitive adhesive layer 3 separately formed in a sheet shape may be attached to the base film 2.
- Chip Manufacturing Method A chip manufacturing method using the dicing sheet according to the present embodiment will be described.
- the surface of the pressure-sensitive adhesive layer 3 of the dicing sheet 1 according to this embodiment is attached to one main surface of the object to be cut.
- the surface of the pressure-sensitive adhesive layer 3 may be exposed by peeling off the release sheet.
- the dicing sheet 1 is attached to the object to be cut using an attaching device, the dicing sheet 1 is usually attached to the ring frame. In this way, a laminated structure in which the object to be cut adhered to the dicing sheet 1 is located in the opening of the ring frame is obtained.
- the above laminated structure is placed on a dicing table, and dicing is performed from the surface opposite to the side facing the adhesive layer 3 of the object to be cut, so that the object to be cut is separated into pieces.
- dicing process By passing through the above-mentioned dicing process, on the dicing sheet 1, a plurality of chips formed by dividing the object to be cut are arranged in a state of being close to each other. In this state, when one chip is picked up, the chip may come into contact with a chip adjacent to the chip. If such chip contact occurs, the pick-up is not performed properly or the chip is missing. There is a high possibility that quality problems will occur. Therefore, after the dicing process, an expanding process for applying tension to the dicing sheet 1 is performed. When tension is applied to the dicing sheet 1, the dicing sheet 1 extends in the main surface direction and the distance between the chips increases.
- the amount of expansion is usually defined as the amount of dicing sheet that is drawn down, but this amount of drawing may be about 10 mm to 20 to 40 mm in recent years. Even in such a case, if the dicing sheet 1 including the base film 2 according to the present embodiment is used, the base film 2 is hardly broken. Therefore, when the dicing sheet 1 provided with the base film 2 according to the present embodiment is used, even if the amount of the expansion is large, it is difficult to cause problems in the expanding process.
- the base film 2 according to the present embodiment is also excellent in restoration properties.
- the dicing sheet 1 provided with the base film 2 having excellent resilience can be easily reduced in slackness by heating at a temperature of about 50 ° C. to 70 ° C. for 30 seconds to several minutes after the expanding operation.
- Example 1 Preparation of base film
- 30 parts by mass of cycloolefin copolymer manufactured by Polyplastics, product name: TOPAS (registered trademark) 8007) as ring-containing resin (a1) and low-density polyethylene (Sumitomo) as acyclic olefin resin (a2) Chemical Co., Ltd., product name: Sumikasen (registered trademark) L705)
- 70 parts by mass was melt-kneaded at 210 ° C. with a twin-screw kneader (Toyo Seiki Seisakusho Co., Ltd., Labo Plast Mill), and a cutting piece suppression layer (A
- a resin composition ( ⁇ ) To obtain a resin composition ( ⁇ ).
- the resin composition ( ⁇ 1) for forming the resin-based unit layer (B1) was obtained by melt-kneading at 210 ° C. with a biaxial kneader (manufactured by Toyo Seiki Seisakusho, Labo Plast Mill).
- the obtained resin composition ( ⁇ ) and resin composition ( ⁇ 1) were used for co-extrusion molding by a small T-die extruder (manufactured by Toyo Seiki Seisakusho, Labo Plast Mill).
- a small T-die extruder manufactured by Toyo Seiki Seisakusho, Labo Plast Mill.
- an expanded layer (B) composed of a resin-based unit layer (B1) having a thickness of 60 ⁇ m, and a 40 ⁇ m-thick cutting piece suppressing layer (A) laminated on one main surface of the resin-based unit layer (B1).
- a base film having a thickness of 100 ⁇ m and a two-layer structure was obtained.
- the obtained energy ray-curable pressure-sensitive adhesive composition was applied on a silicone-treated release film (manufactured by Lintec Corporation, SP-PET3811 (S)) so that the film thickness after drying was 10 ⁇ m, and the coating was carried out at 100 ° C. It dried for 1 minute and formed the laminated body which consists of an adhesive layer and a peeling film. Next, this laminate was bonded to the main surface of the base film on the side of the cut piece suppressing layer (A), and the pressure-sensitive adhesive layer in the laminate was transferred onto the base film, which was used as a dicing sheet.
- a silicone-treated release film manufactured by Lintec Corporation, SP-PET3811 (S)
- Example 2 In Example 1, except that the resin composition ( ⁇ 1) was obtained by melt-kneading 40 parts by mass of linear polyethylene, 30 parts by mass of polypropylene, and 30 parts by mass of an olefin elastomer, the same as in Example 1. A dicing sheet provided with a base film having a two-layer structure was produced.
- Example 3 In Example 1, except that the resin composition ( ⁇ 1) was obtained by melt-kneading 20 parts by mass of linear polyethylene, 50 parts by mass of polypropylene, and 30 parts by mass of an olefin elastomer, the same as in Example 1. A dicing sheet provided with a base film having a two-layer structure was produced.
- Example 4 The polypropylene used to form the resin composition ( ⁇ 1) is changed to another type of polypropylene (manufactured by Prime Polymer Co., Ltd., product name: Prime Polypro (registered trademark) F-704LB, density: 900 kg / m 3 ). Except for the above, a dicing sheet including a base film having a two-layer structure was produced in the same manner as in Example 2.
- Example 5 The polypropylene used to form the resin composition ( ⁇ 1) is changed to another type of polypropylene (manufactured by Prime Polymer Co., Ltd., product name: Prime Polypro (registered trademark) F-704NP, density: 900 kg / m 3 ). Except for the above, a dicing sheet including a base film having a two-layer structure was produced in the same manner as in Example 2.
- Example 6 The resin composition ( ⁇ 1) was obtained by melting and kneading 65 parts by mass of linear polyethylene, 30 parts by mass of polypropylene, and 5 parts by mass of an olefin elastomer, in the same manner as in Example 1, and having a two-layer structure. A dicing sheet provided with a base film was produced.
- Example 7 The resin composition ( ⁇ 1) was obtained by melt-kneading 30 parts by mass of linear polyethylene, 30 parts by mass of polypropylene, and 40 parts by mass of an olefin elastomer, in the same manner as in Example 1, and having a two-layer structure. A dicing sheet provided with a base film was produced.
- Example 8 30 parts by mass of cycloolefin copolymer (manufactured by Polyplastics, product name: TOPAS (registered trademark) 8007) as ring-containing resin (a1) and low-density polyethylene (Sumitomo) as acyclic olefin resin (a2) Chemical Co., Ltd., product name: Sumikasen (registered trademark) L705) 70 parts by mass was melt-kneaded at 210 ° C. with a twin-screw kneader (Toyo Seiki Seisakusho Co., Ltd., Labo Plast Mill), and a cutting piece suppression layer (A To obtain a resin composition ( ⁇ ).
- a biaxial kneader containing 100 parts by mass of an ethylene-methacrylic acid copolymer (Mitsui DuPont, manufactured by Polychemical Co., Ltd., product name: Nucrel (registered trademark) N0903HC), which is one of ethylene- (meth) acrylic acid copolymers. (Toyo Seiki Seisakusho Co., Ltd., Labo Plast Mill) was melt-kneaded at 210 ° C. to obtain a resin composition ( ⁇ 2) for forming the resin-based unit layer (B2).
- the obtained resin composition ( ⁇ ), resin composition ( ⁇ 1), and resin composition ( ⁇ 2) were used for coextrusion molding by a small T-die extruder (manufactured by Toyo Seiki Seisakusho Co., Ltd., Labo Plast Mill).
- a resin-based unit layer (B1) having a thickness of 30 ⁇ m, a cutting piece suppressing layer (A) having a thickness of 40 ⁇ m laminated on one main surface of the resin-based unit layer (B1), and a resin-based unit layer ( B1) is composed of a resin-based unit layer (B2) having a thickness of 30 ⁇ m laminated so as to be in contact with the other main surface, in other words, a 40 ⁇ m cutting piece suppression layer (A) and a cutting piece suppression layer (A ) And a 60 ⁇ m expanded layer (B) laminated on one main surface, and the expanded layer (B) has a 30 ⁇ m thick resin-based unit layer (B1) and a 30 ⁇ m thick resin-based unit layer (B2).
- a substrate film having a three-layer structure having a thickness of 100 ⁇ m was obtained. Thereafter, the same operation as in Example 1 was performed to manufacture a dicing sheet.
- Example 9 The resin composition ( ⁇ 1) was obtained by melt-kneading 20 parts by mass of linear polyethylene, 50 parts by mass of polypropylene, and 30 parts by mass of an olefin elastomer, in the same manner as in Example 8, and having a three-layer structure. A dicing sheet provided with a base film was produced.
- Example 10 Dicing provided with a base film having a three-layer structure in the same manner as in Example 8, except that the resin composition ( ⁇ 1) was changed to one having the composition of the resin composition ( ⁇ 1) prepared in Example 4. A sheet was produced.
- Example 11 Dicing provided with a base film having a three-layer structure in the same manner as in Example 8, except that the resin composition ( ⁇ 1) was changed to one having the composition of the resin composition ( ⁇ 1) prepared in Example 5. A sheet was produced.
- Example 1 A dicing sheet comprising a base film having a two-layer structure in the same manner as in Example 1 except that the resin composition ( ⁇ 1) was obtained by melt-kneading 60 parts by mass of linear polyethylene and 40 parts by mass of polypropylene. Manufactured.
- a resin composition ( ⁇ 1) is provided with a base film having a two-layer structure in the same manner as in Example 1 except that 60 parts by mass of linear polyethylene and 40 parts by mass of an olefin elastomer are melt-kneaded. A dicing sheet was manufactured.
- tip was peeled by irradiating an ultraviolet-ray (160mJ / cm ⁇ 2 >) from the base film side.
- an ultraviolet-ray 160mJ / cm ⁇ 2 >
- digital microscope Keyence, VHX-100, magnification: 100 times
- the measured number of cutting pieces was evaluated according to the following evaluation criteria.
- C The number of cutting pieces is 16 or more A and B are judged to be good, and C is judged to be bad did.
- the results are shown in Table 1.
- Dicing size 10 mm ⁇ 10 mm ⁇ Dicing condition 2> ⁇ Work size: 6 inch diameter, thickness 350 ⁇ m ⁇ Dicing blade: 27HECC manufactured by DISCO ⁇ Blade rotation speed: 30,000rpm Dicing speed: 100 mm / sec. Depth of cut: Cut the base film from the interface with the adhesive layer to a depth of 40 ⁇ m. Dicing size: 10 mm ⁇ 10 mm
- Test Example 3 (Restorability evaluation) In Test Example 2, dicing was performed under dicing condition 1, and hot air having a temperature of 50 ° C. to 70 ° C. was supplied for 1 minute by a dryer to the dicing sheet after the expanding process was performed under expanding condition 1. Thereafter, the amount of slackness of the dicing sheet (the distance in the vertical direction of the bottom surface of the dicing sheet based on the portion of the dicing sheet attached to the ring frame) was measured. The measured amount of slack was evaluated according to the following criteria.
- the amount of slack is 1.5 mm or less
- B The amount of slack is more than 1.5 mm and 3 mm or less
- C The amount of slack is more than 3 mm A and B were judged to be good, and C was judged to be bad. The results are shown in Table 1.
- the obtained resin film was cut into 15 mm ⁇ 140 mm test pieces, and the tensile elastic modulus at 23 ° C. was measured in accordance with JIS K7161-1: 2014 and JIS K7127: 1999. Specifically, after setting the above test piece to a chuck distance of 100 mm with a tensile tester (manufactured by Shimadzu Corporation, Autograph AG-IS 500N), a tensile test was performed at a speed of 200 mm / min, and tensile elasticity was obtained. The rate (MPa) was measured. The tensile modulus was measured only in the direction of extrusion (MD) during molding of the resin film.
- MD direction of extrusion
- the tensile modulus of the cut piece suppression layer (A) is E1
- the tensile modulus of the resin unit layer (B1) is E2
- the tensile modulus ratio ⁇ E2 / E1 (II)
- the tensile elastic modulus of the resin-based unit layer (B1) was E1
- the tensile elastic modulus of the resin-based unit layer (B2) was E2.
- the tensile modulus ratio ⁇ for the combination of the resin-based unit layer (B1) and the resin-based unit layer (B2) was also calculated.
- E1 ⁇ E2 the value obtained by dividing the tensile elastic modulus of the resin-based unit layer (B1) by the tensile elastic modulus of the resin-based unit layer (B2) from the above formula (I) is expressed as the tensile elastic modulus ratio ⁇ . did.
- the obtained tensile modulus ratio is shown in Table 1.
- the substrate film for dicing sheet and the dicing sheet according to the present invention are suitably used for dicing semiconductor wafers and various packages.
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Abstract
Description
(1)ダイシングシートの基材フィルムであって、前記基材フィルムは、切削片抑制層(A)と、前記切削片抑制層(A)の一方の主面上に積層されたエキスパンド層(B)とを備え、前記エキスパンド層(B)は少なくとも1層の樹脂系単位層を備え、前記少なくとも1層の樹脂系単位層のうち前記切削片抑制層(A)に最も近位に配置される樹脂系単位層(B1)は、直鎖状ポリエチレン、ポリプロピレンおよび熱可塑性エラストマーを含有し、前記切削片抑制層(A)は、芳香族系環および脂肪族系環の少なくとも1種を有する熱可塑性樹脂である環含有樹脂(a1)と、当該環含有樹脂(a1)以外のオレフィン系熱可塑性樹脂である非環式オレフィン系樹脂(a2)とを含有することを特徴とする基材フィルム。
E1≧E2のとき、引張弾性率比ε=E1/E2 ・・・ (I)
E1<E2のとき、引張弾性率比ε=E2/E1 ・・・ (II)
から得られる引張弾性率比εが1.0~3.0となる上記(1)に記載の基材フィルム。
1.基材フィルム
図1に示されるように、本発明の一実施形態に係るダイシングシート1は、基本構成として、基材フィルム2上に配置された粘着剤層3を備える。この基材フィルム2は、切削片抑制層(A)と、切削片抑制層(A)の一方の主面上に積層されたエキスパンド層(B)とを備えるものである。図1に示されるダイシングシート1のエキスパンド層(B)は、本実施形態の一例として、切削片抑制層(A)に近位に配置される樹脂系単位層(B1)および切削片抑制層(A)に対して遠位に配置される樹脂系単位層(B2)を備えている。
切削片抑制層(A)は芳香族系環および脂肪族系環の少なくとも1種を有する熱可塑性樹脂である環含有樹脂(a1)と、この環含有樹脂(a1)以外のオレフィン系熱可塑性樹脂である非環式オレフィン系樹脂(a2)とを含有する。
(1-1)環含有樹脂(a1)
環含有樹脂(a1)は芳香族系環および脂肪族系環の少なくとも1種を有する熱可塑性樹脂である。
非環式オレフィン系樹脂(a2)は、上記の環含有樹脂(a1)以外の、つまり、芳香族系環および脂肪族系環のいずれも実質的に有さないオレフィン系熱可塑性樹脂からなる。本実施形態において、オレフィン系熱可塑性樹脂とは、前述のとおり、オレフィンを単量体とするホモポリマーおよびコポリマー、ならびにオレフィンとオレフィン以外の分子とを単量体とするコポリマーであって重合後の樹脂におけるオレフィン単位に基づく部分の質量比率が1.0質量%以上である熱可塑性樹脂の総称を意味する。
切削片抑制層(A)は上記の環含有樹脂(a1)および非環式オレフィン系樹脂(a2)に加えて、他の成分を含有してもよい。そのような他の成分として、イソプレンゴムやニトリルゴム、アクリルゴム、ウレタンゴム、ブタジエンゴム、またはその共重合体などの熱可塑性エラストマー樹脂が例示される。これらの他の成分の切削片抑制層(A)中の含有量は、切削片抑制層(A)の切削片抑制効果が得られる範囲に設定することが好ましい。
エキスパンド層(B)は、少なくとも1層の樹脂系単位層を備える。すなわち、エキスパンド層(B)は単層構造を有してもよいし、積層構造を有してもよい。エキスパンド層(B)は、当該層が備える少なくとも1層の樹脂系単位層のうち、切削片抑制層(A)に最も近位に配置される単位層として、樹脂系単位層(B1)を備える。エキスパンド層(B)が単層構造の場合にはエキスパンド層(B)は樹脂系単位層(B1)から構成される。
切削片抑制層(A)に最も近位に配置される樹脂系単位層(B1)は、直鎖状ポリエチレン、ポリプロピレンおよび熱可塑性エラストマーを含有する。
エキスパンド層(B)が複数の単位層から構成される場合には、エキスパンド層(B)は、エチレン-(メタ)アクリル酸類共重合体を含有する樹脂系単位層(B2)を備えることが好ましい。エキスパンド層(B)における樹脂系単位層(B2)の配置に関し、樹脂系単位層(B2)は樹脂系単位層(B1)よりも切削片抑制層(A)に対して遠位に配置され、切削片抑制層(A)に対して最も遠位に配置されることが好ましい。本明細書において、「エチレン-(メタ)アクリル酸類共重合体」とは、エチレンと、(メタ)アクリル酸および(メタ)アクリル酸エステルからなる群から選ばれる1種以上の化合物との共重合体を意味する。(メタ)アクリル酸エステルとしては、(メタ)アクリル酸メチル、(メタ)アクリル酸エチル、(メタ)アクリル酸ヒドロキシエチル、(メタ)アクリル酸ブチルなどが例示される。このような樹脂系単位層(B2)をエキスパンド層(B)が備えることにより、復元性により優れる基材フィルム2が得られやすくなる。
エキスパンド層(B)は、上記の樹脂系単位層(B1)から構成されていてもよいし、樹脂系単位層(B1)および樹脂系単位層(B2)から構成されていてもよい。エキスパンド層(B)として所定の機能を果たすことができる限り、これらの単位層以外の単位層を備えていてもよい。
本実施形態に係る基材フィルム2の厚さは、通常40μm以上300μm以下であり、好ましくは60μm以上200μm以下である。切削片抑制層(A)の厚さは、通常20μm以上120μm以下であり、好ましくは30μm以上100μm以下である。切削片抑制層(A)が上記の厚さであれば、切削片抑制効果がより安定的に得られやすくなる。エキスパンド層(B)の厚さは、通常20μm以上280μm以下であり、好ましくは40μm以上200μm以下である。エキスパンド層(B)が過度に薄い場合には、エキスパンド層(B)が上記の組成上の特徴を有していても、エキスパンド性に優れる基材フィルム2が得られにくくなることもある。
E1≧E2のとき、引張弾性率比ε=E1/E2 ・・・ (I)
E1<E2のとき、引張弾性率比ε=E2/E1 ・・・ (II)
から得られる引張弾性率比εが1.0~3.0となることが好ましく、特に1.0~2.8となることが好ましく、さらには1.0~2.6となることが好ましい。
基材フィルム2の製造方法は特に限定されない。Tダイ法、丸ダイ法等の溶融押出法;カレンダー法;乾式法、湿式法等の溶液法などが例示され、いずれの方法でもよい。生産性高く基材フィルム2を製造する観点から、溶融押出法またはカレンダー法を採用することが好ましい。これらのうち、溶融押出法により製造する場合には、切削片抑制層(A)およびエキスパンド層(B)を構成する成分をそれぞれ混練し、得られた混練物から直接、または一旦ペレットを製造したのち、公知の押出機を用いて製膜すればよい。
ダイシングシート1における基材フィルム2以外の構成要素として、基材フィルム2の2つの主面のうち、エキスパンド層(B)よりも切削片抑制層(A)に近位な方の主面上に配置された粘着剤層3、およびこの粘着剤層3の基材フィルム2に対向する側と反対側の面、つまり被切断物に貼付されるための面を保護するための剥離シートが例示される。
粘着剤層3を構成する粘着剤としては、特に限定されず、ダイシングシートとして通常用いられるものを使用することができ、例えば、ゴム系、アクリル系、シリコーン系、ポリビニルエーテル系等の粘着剤が用いられ、また、エネルギー線硬化型(紫外線硬化型を含む)や加熱発泡型や加熱硬化型の粘着剤であってもよい。また、本実施形態におけるダイシングシート1がダイシング・ダイボンディングシートとして使用される場合には、ウェハ固定機能とダイ接着機能とを同時に兼ね備えた粘接着剤、熱可塑性接着剤、Bステージ接着剤等が用いられる。
粘着剤層3の厚さは、通常は3μmから100μm、好ましくは5μmから80μm程度である。
粘着剤層3を保護するための剥離シートは任意である。
剥離シートとして、例えば、ポリエチレンフィルム、ポリプロピレンフィルム、ポリブテンフィルム、ポリブタジエンフィルム、ポリメチルペンテンフィルム、ポリ塩化ビニルフィルム、塩化ビニル共重合体フィルム、ポリエチレンテレフタレートフィルム、ポリエチレンナフタレートフィルム、ポリブチレンテレフタレートフィルム、ポリウレタンフィルム、エチレン酢酸ビニルフィルム、アイオノマー樹脂フィルム、エチレン-(メタ)アクリル酸共重合体フィルム、エチレン-(メタ)アクリル酸エステル共重合体フィルム、ポリスチレンフィルム、ポリカーボネートフィルム、ポリイミドフィルム、フッ素樹脂フィルム等を用いることができる。また、これらの架橋フィルムを用いてもよい。さらに、これらのフィルムの複数が積層された積層フィルムであってもよい。
なお、剥離シートの厚さについては特に限定されず、通常、20μmから150μm程度である。
上記の基材フィルム2および粘着剤層3、ならびに必要に応じて用いられる剥離シート等の積層体からなるダイシングシート1の製造方法は特に限定されない。
(i)剥離シート上に粘着剤層3を形成し、その粘着剤層3上に基材フィルム2を圧着して積層する。このとき、粘着剤層3の形成方法は任意である。
粘着剤層3の形成方法の一例を挙げれば次のようになる。粘着剤層3を形成するための粘着剤組成物と、所望によりさらに溶媒とを含有する塗布剤を調製する。ロールコーター、ナイフコーター、ロールナイフコーター、エアナイフコーター、ダイコーター、バーコーター、グラビアコーター、カーテンコーター等の塗工機によって、基材フィルム2の2つの主面のうち、エキスパンド層(B)よりも切削片抑制層(A)に近位な方の主面に塗布する。基材フィルム2上の塗布剤からなる層を乾燥させることにより、粘着剤層3が形成される。
上記の方法以外の例として、別途シート状に形成した粘着剤層3を基材フィルム2に貼付してもよい。
上記(i)、(ii)の方法以外の例として、別途シート状に形成した粘着剤層3を基材フィルム2に貼付してもよい。
本実施形態に係るダイシングシートを用いてチップを製造する方法について説明する。
まず、本実施形態に係るダイシングシート1の粘着剤層3の面を、被切断物の一方の主面に貼付する。粘着剤層3の面が剥離シートにより保護されている場合には、その剥離シートをはがして粘着剤層3の面を表出させればよい。この被切断物へのダイシングシート1の貼付を、貼付装置を用いて行う場合には、通常、リングフレームに対するダイシングシート1の貼付も行われる。こうして、リングフレームの開口部内に、ダイシングシート1に貼着した被切断物が位置する積層構造体が得られる。
(基材フィルムの作製)
環含有樹脂(a1)としてのシクロオレフィン・コポリマー(ポリプラスチックス社製,製品名:TOPAS(登録商標)8007)30質量部と、非環式オレフィン系樹脂(a2)としての低密度ポリエチレン(住友化学社製,製品名:スミカセン(登録商標)L705)70質量部とを、二軸混練機(東洋精機製作所社製,ラボプラストミル)にて210℃で溶融混練し、切削片抑制層(A)を形成するための樹脂組成物(α)を得た。
n-ブチルアクリレート95質量部およびアクリル酸5質量部を共重合してなる共重合体(Mw:500,000)100質量部、ウレタンアクリレートオリゴマー(Mw:8000)120質量部、イソシアネート系硬化剤(日本ポリウレタン社,コロネートL)5質量部、光重合開始剤(チバスペシャリティケミカルズ社製,イルガキュア184)4質量部とを混合し、エネルギー線硬化型粘着剤組成物を得た。
実施例1において、樹脂組成物(β1)を、直鎖状ポリエチレン40質量部、ポリプロピレン30質量部およびオレフィン系エラストマー30質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
実施例1において、樹脂組成物(β1)を、直鎖状ポリエチレン20質量部、ポリプロピレン50質量部およびオレフィン系エラストマー30質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を形成するために用いたポリプロピレンを、別の種類のポリプロピレン(プライムポリマー社製,製品名:プライムポリプロ(登録商標)F-704LB,密度:900kg/m3)に変更する以外は、実施例2と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を形成するために用いたポリプロピレンを、別の種類のポリプロピレン(プライムポリマー社製,製品名:プライムポリプロ(登録商標)F-704NP,密度:900kg/m3)に変更する以外は、実施例2と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、直鎖状ポリエチレン65質量部、ポリプロピレン30質量部およびオレフィン系エラストマー5質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、直鎖状ポリエチレン30質量部、ポリプロピレン30質量部およびオレフィン系エラストマー40質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
環含有樹脂(a1)としてのシクロオレフィン・コポリマー(ポリプラスチックス社製,製品名:TOPAS(登録商標)8007)30質量部と、非環式オレフィン系樹脂(a2)としての低密度ポリエチレン(住友化学社製,製品名:スミカセン(登録商標)L705)70質量部とを、二軸混練機(東洋精機製作所社製,ラボプラストミル)にて210℃で溶融混練し、切削片抑制層(A)を形成するための樹脂組成物(α)を得た。
以下、実施例1と同様の操作を行い、ダイシングシートを製造した。
樹脂組成物(β1)を、直鎖状ポリエチレン20質量部、ポリプロピレン50質量部およびオレフィン系エラストマー30質量部を溶融混練して得たこと以外は、実施例8と同様にして、3層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、実施例4において用意した樹脂組成物(β1)の組成を有するものに変更したこと以外は、実施例8と同様にして、3層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、実施例5において用意した樹脂組成物(β1)の組成を有するものに変更したこと以外は、実施例8と同様にして、3層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、直鎖状ポリエチレン60質量部およびポリプロピレン40質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
樹脂組成物(β1)を、直鎖状ポリエチレン60質量部およびオレフィン系エラストマー40質量部を溶融混練して得たこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
低密度ポリエチレン(住友化学社製,製品名:スミカセン(登録商標)L705,密度:919kg/m3)40質量部と、ポリプロピレン(プライムポリマー社製,製品名:プライムポリプロ(登録商標)F-744NP,密度:900kg/m3)30質量部と、オレフィン系エラストマー(三井化学社製,製品名:タフマー(登録商標)DF640,密度:864kg/m3)30質量部とを、二軸混練機(東洋精機製作所社製,ラボプラストミル)にて210℃で溶融混練して得た樹脂組成物(β1)を用いたこと以外は、実施例1と同様にして、2層構造の基材フィルムを備えるダイシングシートを製造した。
表中では、実施例1から3、6から9ならびに比較例1および3に係るポリプロピレンを「ポリプロピレン1」、実施例4および10に係るポリプロピレンを「ポリプロピレン2」、実施例5および11に係るポリプロピレンを「ポリプロピレン3」と示した。
実施例および比較例で製造したダイシングシートの粘着剤層をBGA型パッケージモジュールに貼付した後、ダイシング装置(ディスコ社製,DFD-651)にセットし、以下の条件でダイシングを行った。
・ワークサイズ:6インチ径,厚さ350μm
・ダイシングブレード:ディスコ社製 Z1110LS3
・ブレード回転数:30,000rpm
・ダイシングスピード:10mm/秒
・切り込み深さ:基材フィルムを粘着剤層との界面から20μmの深さまで切り込み
・ダイシングサイズ:10mm×10mm
A:切削片の個数が0個以上10個以下
B:切削片の個数が11個以上15個以下
C:切削片の個数が16個以上
AおよびBについて良好と判定し、Cを不良と判定した。結果を表1に示す。
実施例および比較例で製造したダイシングシートの粘着剤層に6インチシリコンウエハを貼付した後、このダイシングシートをフラットフレームに装着し、ダイシング装置(ディスコ社製,DFD-651)にセットし、以下の2つの条件でそれぞれダイシングを行った。
<ダイシング条件1>
・ワークサイズ:6インチ径,厚さ350μm
・ダイシングブレード:ディスコ社製 27HECC
・ブレード回転数:30,000rpm
・ダイシングスピード:10mm/秒
・切り込み深さ:基材フィルムを粘着剤層との界面から20μmの深さまで切り込み
・ダイシングサイズ:10mm×10mm
<ダイシング条件2>
・ワークサイズ:6インチ径,厚さ350μm
・ダイシングブレード:ディスコ社製 27HECC
・ブレード回転数:30,000rpm
・ダイシングスピード:100mm/秒
・切り込み深さ:基材フィルムを粘着剤層との界面から40μmの深さまで切り込み
・ダイシングサイズ:10mm×10mm
B:エキスパンド条件1および2の一方において破断が確認された
C:エキスパンド条件1および2のいずれについても破断が確認された
AおよびBについて良好と判定し、Cを不良と判定した。結果を表1に示す。
試験例2において、ダイシング条件1にてダイシングを行い、エキスパンド条件1にてエキスパンド工程を行った後のダイシングシートに対して、ドライヤーにより温度は50℃~70℃の温風を1分間供給した。その後のダイシングシートの弛み量(ダイシングシートにおけるリングフレームに貼着する部分を基準とする、ダイシングシートの底面の鉛直方向の離間距離)を測定した。測定された弛み量について、次の基準で評価した。
A:弛み量が1.5mm以下
B:弛み量が1.5mm超3mm以下
C:弛み量が3mm超
AおよびBについて良好と判定し、Cを不良と判定した。結果を表1に示す。
実施例および比較例に係る基材フィルムを作製するために調製した樹脂組成物を、それぞれ単独で小型Tダイ押出機(東洋精機製作所社製、ラボプラストミル)によって押出成形した。これにより、厚さ100μmの単層構造の樹脂フィルムを得た。
E1≧E2のとき、引張弾性率比ε=E1/E2 ・・・ (I)
E1<E2のとき、引張弾性率比ε=E2/E1 ・・・ (II)
から、切削片抑制層(A)と樹脂系単位層(B1)との組み合わせについての引張弾性率比εを算出した。その結果、E1≧E2であったため上記式(I)から、切削片抑制層(A)の引張弾性率を樹脂系単位層(B1)の引張弾性率で除した値を引張弾性率比εとした。得られた引張弾性率比を表1に示す。
2…基材フィルム
(A)切削片抑制層
(B)エキスパンド層
(B1)樹脂系単位層
(B2)樹脂系単位層
3…粘着剤層
Claims (11)
- ダイシングシートの基材フィルムであって、
前記基材フィルムは、切削片抑制層(A)と、前記切削片抑制層(A)の一方の主面上に積層されたエキスパンド層(B)とを備え、前記エキスパンド層(B)は少なくとも1層の樹脂系単位層を備え、
前記少なくとも1層の樹脂系単位層のうち前記切削片抑制層(A)に最も近位に配置される樹脂系単位層(B1)は、直鎖状ポリエチレン、ポリプロピレンおよび熱可塑性エラストマーを含有し、
前記切削片抑制層(A)は、芳香族系環および脂肪族系環の少なくとも1種を有する熱可塑性樹脂である環含有樹脂(a1)と、当該環含有樹脂(a1)以外のオレフィン系熱可塑性樹脂である非環式オレフィン系樹脂(a2)とを含有することを特徴とする基材フィルム。 - 前記基材フィルムを構成する層のうち、隣接する2つの層の全ての組み合わせにおいて、当該2つの層が、引張弾性率E1を有する層および引張弾性率E2を有する層である場合に、次式(I)または(II)
E1≧E2のとき、引張弾性率比ε=E1/E2 ・・・ (I)
E1<E2のとき、引張弾性率比ε=E2/E1 ・・・ (II)
から得られる引張弾性率比εが1.0~3.0となる請求項1に記載の基材フィルム。 - 前記樹脂系単位層(B1)は、ポリプロピレンを5質量%以上70質量%以下含有する、請求項1または2に記載の基材フィルム。
- 前記樹脂系単位層(B1)は、熱可塑性エラストマーを1質量%以上60質量%以下含有する、請求項1~3のいずれか一項に記載の基材フィルム。
- 前記樹脂系単位層(B1)に含まれる熱可塑性エラストマーがオレフィン系エラストマーである、請求項1~4のいずれか一項に記載の基材フィルム。
- 前記エキスパンド層(B)の厚さは、前記基材フィルムの厚さに対する比率が30%以上80%以下であり、前記樹脂系単位層(B1)のエキスパンド層(B)の厚さに対する比率が30%以上である、請求項1~5のいずれか一項に記載の基材フィルム。
- 前記樹脂系単位層(B1)は、前記直鎖状ポリエチレンを10質量%以上90質量%以下含有する、請求項1~6のいずれか一項に記載の基材フィルム。
- 前記エキスパンド層(B)は前記樹脂系単位層を複数備え、
前記複数の樹脂系単位層のうち、切削片抑制層(A)に対して最も遠位に配置された、前記樹脂系単位層(B1)と異なる樹脂系単位層(B2)を有し、
前記樹脂系単位層(B2)がエチレン-(メタ)アクリル酸類共重合体を含有してなる層を備える、請求項1~7のいずれか一項に記載の基材フィルム。 - 請求項1~8のいずれか一項に記載される基材フィルムと、当該フィルムの前記切削片抑制層(A)上に配置された粘着剤層とを備えたことを特徴とするダイシングシート。
- 請求項1~7のいずれか一項に記載される基材フィルムの製造方法であって、
前記切削片抑制層(A)を形成するための樹脂組成物(α)および前記樹脂系単位層(B1)を形成するための樹脂組成物(β1)を含む2種以上の樹脂組成物を共押出成形して、前記切削片抑制層(A)と前記エキスパンド層(B)との積層体を得る共押出成形工程を備えることを特徴とする基材フィルムの製造方法。 - 請求項8に記載される基材フィルムの製造方法であって、
前記切削片抑制層(A)を形成するための樹脂組成物(α)、前記樹脂系単位層(B1)を形成するための樹脂組成物(β1)および前記樹脂系単位層(B2)を形成するための樹脂組成物(β2)を含む3種以上の樹脂組成物を共押出成形して、前記切削片抑制層(A)と前記エキスパンド層(B)との積層体を得る共押出成形工程を備えることを特徴とする基材フィルムの製造方法。
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JP2016510219A JPWO2015146596A1 (ja) | 2014-03-28 | 2015-03-11 | ダイシングシート用基材フィルム、当該基材フィルムを備えるダイシングシート、および当該基材フィルムの製造方法 |
KR1020167027645A KR20160138446A (ko) | 2014-03-28 | 2015-03-11 | 다이싱 시트용 기재 필름, 당해 기재 필름을 구비하는 다이싱 시트, 및 당해 기재 필름의 제조 방법 |
CN201580016730.3A CN106133879A (zh) | 2014-03-28 | 2015-03-11 | 切割片用基材膜、具备该基材膜的切割片及该基材膜的制造方法 |
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EP3147936A4 (en) * | 2014-06-18 | 2018-01-24 | Lintec Corporation | Dicing-sheet base film and dicing sheet |
TWI734782B (zh) * | 2016-05-12 | 2021-08-01 | 日商三菱化學股份有限公司 | 聚乙烯醇系薄膜及其製造方法與利用此聚乙烯醇系薄膜之偏光膜 |
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EP3125276A4 (en) | 2017-11-22 |
EP3125276A1 (en) | 2017-02-01 |
CN106133879A (zh) | 2016-11-16 |
TW201542375A (zh) | 2015-11-16 |
US20170036431A1 (en) | 2017-02-09 |
JPWO2015146596A1 (ja) | 2017-04-13 |
KR20160138446A (ko) | 2016-12-05 |
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