WO2016080346A1 - 半導体装置及びその製造方法、並びに可撓性樹脂層形成用樹脂組成物 - Google Patents
半導体装置及びその製造方法、並びに可撓性樹脂層形成用樹脂組成物 Download PDFInfo
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/22—Secondary treatment of printed circuits
- H05K3/28—Applying non-metallic protective coatings
- H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
- G01P1/00—Details of instruments
- G01P1/12—Recording devices
- G01P1/127—Recording devices for acceleration values
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
- H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
- H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/18—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof the devices being of types provided for in two or more different subgroups of the same main group of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0393—Flexible materials
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/22—Secondary treatment of printed circuits
- H05K3/28—Applying non-metallic protective coatings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
- H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
- H01L21/561—Batch processing
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
- H01L23/3107—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
- H01L23/3121—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation
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- H—ELECTRICITY
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- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
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- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/10—Details of semiconductor or other solid state devices to be connected
- H01L2924/11—Device type
- H01L2924/12—Passive devices, e.g. 2 terminal devices
- H01L2924/1204—Optical Diode
- H01L2924/12041—LED
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/10—Details of semiconductor or other solid state devices to be connected
- H01L2924/11—Device type
- H01L2924/14—Integrated circuits
- H01L2924/141—Analog devices
- H01L2924/142—HF devices
- H01L2924/1421—RF devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/10—Details of semiconductor or other solid state devices to be connected
- H01L2924/11—Device type
- H01L2924/14—Integrated circuits
- H01L2924/143—Digital devices
- H01L2924/1434—Memory
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0104—Properties and characteristics in general
- H05K2201/0108—Transparent
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0104—Properties and characteristics in general
- H05K2201/0129—Thermoplastic polymer, e.g. auto-adhesive layer; Shaping of thermoplastic polymer
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0104—Properties and characteristics in general
- H05K2201/0133—Elastomeric or compliant polymer
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0154—Polyimide
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0158—Polyalkene or polyolefin, e.g. polyethylene [PE], polypropylene [PP]
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0162—Silicon containing polymer, e.g. silicone
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10098—Components for radio transmission, e.g. radio frequency identification [RFID] tag, printed or non-printed antennas
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10151—Sensor
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0011—Working of insulating substrates or insulating layers
- H05K3/0044—Mechanical working of the substrate, e.g. drilling or punching
- H05K3/0052—Depaneling, i.e. dividing a panel into circuit boards; Working of the edges of circuit boards
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
Definitions
- the present invention relates to a semiconductor device and a manufacturing method thereof.
- the present invention also relates to a resin composition and a resin film used for forming a flexible resin layer, and a semiconductor device using these.
- Patent Document 1 discloses a method of obtaining an in-mold product with built-in electronic component components using a printed wiring board on which components such as an IC are mounted and a long fiber reinforced resin. This method enables downsizing by incorporating a plurality of component built-in modules in a resin.
- a wearable device used on a curved surface a device in which a hard portion and a flexible portion are mixed has been developed.
- Patent Document 2 describes a method of obtaining a flexible component built-in module by forming a recess in a flexible substrate and sealing an electronic component mounted inside the recess with a long fiber reinforced resin.
- an object of the present invention is to provide a method capable of efficiently obtaining a semiconductor device that can be used along a curved surface and has sufficient flexibility so that poor connection is not likely to occur even if it is detached.
- a semiconductor device obtained by the method is provided.
- the main object of the present invention is to provide a resin composition capable of forming a flexible resin layer excellent in flexibility and transparency with good step embedding.
- One aspect of the present disclosure includes a flexible substrate, a circuit component mounted on the flexible substrate, and a flexible resin layer (flexible member) that seals the circuit component.
- a method for manufacturing a semiconductor device including a circuit board includes a step of sealing the circuit component with the sealing material by laminating a sealing material (sealing member) on the flexible substrate, and curing the sealing material to allow the sealing. Forming a flexible resin layer (flexible member).
- a method according to another aspect of the present disclosure includes a step of sealing the circuit component with the sealing material by printing a sealing material (sealing member) on the flexible substrate, and the sealing material. To obtain the circuit board having the flexible resin layer (flexible member).
- a method according to another aspect of the present disclosure includes a step of sealing the circuit component with the sealing material by immersing the flexible substrate in a sealing material (sealing member) and drying the method. Obtaining the circuit board having the flexible member by curing a sealing material.
- the sealing material can be cured by heating and / or exposure.
- the semiconductor device obtained by the method according to the present disclosure can be used while being installed along a curved surface by using a flexible substrate and a flexible resin layer (flexible member) (for example, a body or the like). It can be attached to a curved surface) and can be flexible even if it is detached. According to the method according to the present disclosure, such a semiconductor device can be obtained efficiently. For example, the semiconductor device can be obtained with a small number of manufacturing steps. Further, according to some methods, when a plurality of circuit components are used, the electronic components can be reduced in size by sealing the plurality of circuit components with a flexible resin layer (flexible member). You can also.
- the method for manufacturing a semiconductor device according to the present disclosure may further include a step of cutting the circuit board. By performing this process, a plurality of semiconductor devices can be manufactured in a large area at a time, and the manufacturing process can be further reduced.
- the flexible resin layer may include at least one selected from the group consisting of a polyimide resin, an acrylic resin, a silicone resin, a urethane resin, an epoxy resin, and a polyethylene glycol resin.
- the flexible substrate and the flexible resin layer may be transparent in the visible range. Since the flexible substrate and the flexible resin layer are transparent in the visible range, a semiconductor device that does not greatly impair the design of the applied device can be obtained. For example, it is possible to avoid the problem that the substrate surface is particularly visible as it is in a device using a transparent casing, which greatly impairs the design. As an electronic component used for a wearable device, a natural component that melts into the body and the surroundings is desirable even when the device to be applied is worn. Therefore, the design of the device itself and electronic components that do not impair the design are required.
- the circuit parts may be two or more types. By providing various functions in the circuit board with two or more types of circuit components, it is easy to reduce the size of the electronic components.
- thermoplastic polyurethane or styrene-based elastomer (B) a polymerizable compound, and (C) a resin composition containing a polymerization initiator. It discovered that the said subject relevant to level
- a semiconductor that can be used along a curved surface and has a flexibility that is unlikely to cause a connection failure even if it is attached or detached, and the electronic component is made transparent as much as possible, so that the design of an applied device is not greatly impaired.
- a method for manufacturing a semiconductor device capable of efficiently obtaining the device and a semiconductor device obtained by the manufacturing method can be provided.
- a semiconductor device obtained by a method according to some embodiments can have excellent stretchability.
- the resin composition and the resin film of the present invention are excellent in flexibility and can form a flexible resin layer having high transparency with good step embedding.
- FIG. 1 is a cross-sectional view schematically showing the semiconductor device according to the present embodiment.
- the semiconductor device 100 according to the present embodiment includes a flexible substrate 1 having flexibility, a circuit component 2, and a flexible resin layer having flexibility (a flexible layer or a flexible member). There is also a circuit board composed of 3).
- the flexible substrate 1 may be transparent in the visible range.
- the flexible substrate 1 is, for example, a flexible substrate that may be transparent in the visible range.
- the circuit component 2 is mounted on the flexible substrate 1.
- the flexible resin layer 3 seals the flexible substrate 1 and the circuit component 2 and protects the surface of the circuit substrate.
- being transparent in the visible region means that the light transmittance in the visible light region of 400 nm to 750 nm is 90% or more when converted to a thickness of 50 ⁇ m.
- being transparent in the visible range means that the light transmittance is satisfied in a state after curing.
- polyimide resin As a constituent material of the flexible substrate 1 that may be transparent in the visible region, polyimide resin, acrylic resin, silicone resin, urethane resin, epoxy resin, polyethylene glycol resin, or the like is used depending on the purpose. These can be transparent materials in the visible range.
- the constituent material of the flexible substrate 1 is a polyimide resin, an acrylic resin, a silicone resin, a urethane resin, or a long-chain alkyl chain (for example, carbon) having a siloxane structure, an aliphatic ether structure, or a diene structure from the viewpoint of further excellent stretchability.
- a bismaleimide resin having 1 to 20 alkyl chains It may be at least one selected from the group consisting of a bismaleimide resin having 1 to 20 alkyl chains), an epoxy resin, and a polyethylene glycol resin having a rotaxane structure, and may be a siloxane structure, an aliphatic ether structure, or a diene. It may be at least one selected from the group consisting of a polyimide resin having a structure, a silicone resin, a urethane resin, and a bismaleimide resin having a long-chain alkyl chain. These can be used individually by 1 type or in combination of 2 or more types.
- the conductive material that is the wiring portion is not necessarily transparent in the visible range.
- the constituent material of the flexible substrate 1 may be at least one selected from the group consisting of polyimide resin, acrylic resin, silicone resin, urethane resin, bismaleimide resin, epoxy resin and polyethylene glycol resin.
- the constituent material of the flexible substrate 1 is a polyimide resin, an acrylic resin, a silicone resin, a urethane resin, a long alkyl chain (having a siloxane structure, an aliphatic ether structure, or a diene structure (
- it may be at least one selected from the group consisting of a bismaleimide resin having 1 to 20 carbon atoms), an epoxy resin, and a polyethylene glycol resin having a rotaxane structure.
- the constituent material of the flexible substrate 1 is a polyimide resin, a silicone resin, a urethane resin having a siloxane structure, an aliphatic ether structure or a diene structure, and a bismaleimide resin having a long alkyl chain. It may be at least one selected from the group consisting of The constituent material of the flexible substrate 1 can be used alone or in combination of two or more.
- the circuit component 2 is a mounting component including a semiconductor element such as a memory chip, a light emitting diode (LED), an RF tag (RFID), a temperature sensor, an acceleration sensor, and the like.
- a semiconductor element such as a memory chip, a light emitting diode (LED), an RF tag (RFID), a temperature sensor, an acceleration sensor, and the like.
- One type of circuit component 2 may be mounted, or two or more types of circuit components 2 may be mixed and mounted.
- One circuit component 2 may be mounted, or a plurality of circuit components 2 may be mounted.
- the flexible resin layer 3 is, for example, a cured resin layer, and is obtained by curing the sealing material.
- the flexible resin layer 3 can be formed by, for example, using a resin composition described later or a resin film produced therefrom as a sealing material and curing them.
- the sealing material which forms the flexible resin layer (flexible layer) 3 and the flexible resin layer 3 for example, polyimide resin, acrylic resin, silicone resin, urethane resin, epoxy Resins, polyethylene glycol resins, and the like can be used depending on the purpose. These can be transparent materials in the visible range.
- the constituent material of the flexible resin layer 3 is a polyimide resin, an acrylic resin, a silicone resin, a urethane resin, a long-chain alkyl chain (for example, having a siloxane structure, an aliphatic ether structure, or a diene structure, from the viewpoint of further excellent stretchability.
- It may be at least one selected from the group consisting of a bismaleimide resin having 1 to 20 carbon atoms), an epoxy resin, and a polyethylene glycol resin having a rotaxane structure, and may be a siloxane structure or an aliphatic ether structure or It may be at least one selected from the group consisting of a polyimide resin having a diene structure, a silicone resin, a urethane resin, and a bismaleimide resin having a long chain alkyl chain. These can be used individually by 1 type or in combination of 2 or more types.
- Examples of the shape of the sealing material that becomes the flexible resin layer 3 include a film shape and a liquid state. From the viewpoint of excellent handleability at the time of embedding for sealing and flatness of the flexible resin layer formed while embedding steps, the encapsulant may be in the form of a film.
- the cured flexible resin layer 3 exhibits a low elastic modulus and a high elongation characteristic, and may have a high bending resistance. Thereby, since the flexibility is further improved, it is possible to more easily obtain the flexibility that can be used along the curved surface and that does not easily cause a connection failure even if it is detached.
- the flexible resin layer 3 is preferably excellent in water resistance and sweat resistance from the viewpoint of being easily worn on the body.
- the method for manufacturing the semiconductor device according to the present embodiment includes, for example, a mounting process, a sealing process, a curing process, and a cutting process in this order.
- the circuit component 2 is mounted on the flexible substrate 1.
- the plurality of circuit components 2 to be mounted may be one type or a combination of two or more types.
- One or a plurality of circuit components 2 may be mounted.
- the flexible substrate 1 and the circuit component 2 are sealed with a resin composition or a resin film as a sealing material.
- the flexible substrate 1 and the circuit component 2 are formed by, for example, laminating a film-like sealing material (resin film) on the flexible substrate 1 and printing the sealing material (resin composition) on the flexible substrate 1. It can be sealed by immersing the flexible substrate 1 in a sealing material (resin composition) and drying. Sealing can be performed by heating press, roll lamination, vacuum lamination, printing method, dipping method, or the like. Among these, the method that can be used in the Roll to Roll process can shorten the manufacturing process.
- the sealing material in the sealing step by heating press, roll lamination, vacuum lamination, etc., it is preferable to laminate the sealing material (resin film) under reduced pressure.
- the pressure for pressure bonding may be about 0.1 to 150 MPa (about 1 to 1500 kgf / cm 2 ).
- the sealing material for sealing, the sealing material (sealing resin) may be heated to 50 to 170 ° C. There are no particular restrictions on these conditions.
- the sealing material can be cured by heat curing by heating, photocuring by exposure, or a combination thereof.
- the sealing material may be a material (resin composition) that cures at a low temperature as long as it is thermosetting.
- the sealing material may be a photocuring material (resin composition) from the viewpoint of being curable at room temperature.
- the method for manufacturing a semiconductor device can include a step of obtaining a plurality of semiconductor devices having circuit components by cutting and separating the circuit board as necessary, for example, as shown in FIG. As a result, a plurality of semiconductor devices can be manufactured in a large area at a time, and the manufacturing process can be easily reduced.
- a resin composition for forming flexible resin layer includes (A) an elastomer including at least one of thermoplastic polyurethane or styrene-based elastomer, (B) a polymerizable compound, and (C) a polymerization initiator, and includes a flexible resin layer. Is used to form This resin composition can be cured by irradiation with actinic rays and / or heating.
- thermoplastic polyurethane those generally used as an elastomer or a thermoplastic elastomer can be used.
- Commercially available products of thermoplastic polyurethane include, for example, BASF Japan Ltd. “Elaston Series”, Tosoh Corp. “Milactolan Series”, DIC Bayer Polymer Ltd. “PANDEX Series”, “Desmopan Series”, “Texin” Series ".
- the thermoplastic polyurethane may be a polyether-based thermoplastic polyurethane which is a reaction product of polyether diol and diisocyanate from the viewpoint of water resistance.
- examples of commercially available polyether-based thermoplastic polyurethanes include “Elaston ET385” manufactured by BASF Japan. From the viewpoint of transparency and weather resistance, a so-called non-yellowing type thermoplastic polyurethane may be used.
- An example of a commercially available non-yellowing type thermoplastic polyurethane is Tosoh Corporation “Milactolan XN-2001”, which is a reaction product of hexamethylene diisocyanate and polycarbonate diol.
- the weight average molecular weight of the thermoplastic polyurethane may be 10,000 to 200,000, 20,000 to 175,000, or 30,000 to 150,000 from the viewpoint of coating properties.
- the weight average molecular weight (Mw) may be a standard polystyrene equivalent value by gel permeation chromatography (GPC).
- Styrenic elastomer has as its basic unit structure a copolymer containing polystyrene as a hard segment and a diene elastomer containing an unsaturated double bond selected from polyethylene, polybutylene, polyisoprene and the like as a soft segment. It is an elastomer.
- Examples of commercially available styrene elastomers include JSR Corporation “Dynalon SEBS Series”, Kraton Polymer Japan Corporation “Clayton D Polymer Series”, and Aron Kasei Corporation “AR Series”.
- the hydrogenated styrene elastomer is produced by adding hydrogen to an unsaturated double bond of a diene elastomer as a soft segment. According to the hydrogenated styrene-based elastomer, effects such as improved weather resistance can be expected.
- Examples of commercially available hydrogenated styrene-based elastomers include JSR Co., Ltd. “Dynalon HSBR Series”, Kraton Polymer Japan Co., Ltd. “Clayton G Polymer Series”, and Asahi Kasei Chemicals Corporation “Tough Tech Series”.
- the weight average molecular weight of the styrene elastomer may be 30,000 to 200,000, 50,000 to 150,000, or 75,000 to 125,000 from the viewpoint of coating properties.
- the content of the component (A) (elastomer) may be 50 to 90% by mass with respect to the total amount of the component (A) and the component (B) (polymerizable compound).
- the content of the component (A) is 50% by mass or more, particularly good flexibility is easily obtained.
- the content of the component (A) is 90% by mass or less, since the elastomer is easily entangled with the polymerizable compound at the time of curing, the resin composition can be particularly easily cured.
- the content of the component (A) may be 60 to 85% by mass, or 70 to 80% by mass.
- the polymerizable compound of component (B) is not particularly limited as long as it is a compound that is polymerized by heating or irradiation with ultraviolet rays, but from the viewpoint of material selectivity and availability, for example, an ethylenically unsaturated group or the like.
- a compound having a polymerizable substituent may be used.
- the polymerizable compound examples include (meth) acrylate, vinylidene halide, vinyl ether, vinyl ester, vinyl pyridine, vinyl amide and arylated vinyl. From the viewpoint of transparency, the polymerizable compound may contain (meth) acrylate and / or arylated vinyl.
- the (meth) acrylate may be monofunctional, bifunctional, or polyfunctional (trifunctional or higher), but may be a bifunctional or polyfunctional (meth) acrylate in order to easily obtain sufficient curability. Good.
- Examples of the monofunctional (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth) acrylate, butoxyethyl (meth) acrylate, Isoamyl (meth) acrylate, hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, heptyl (meth) acrylate, octylheptyl (meth) acrylate, nonyl (meth) acrylate, decyl (meth) acrylate, undecyl (meth) acrylate , Lauryl (meth) acrylate, tridecyl (meth) acrylate, tetradecyl (meth) acrylate, pentadecyl (meth) acrylate,
- bifunctional (meth) acrylate examples include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, and polyethylene glycol di (meth) acrylate.
- Examples of the trifunctional or higher polyfunctional (meth) acrylate include trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) acrylate, and ethoxylated propoxylated tri Methylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, ethoxylated pentaerythritol tri (meth) acrylate, propoxylated pentaerythritol tri (meth) acrylate, ethoxylated propoxylated pentaerythritol tri (meth) acrylate, pentaerythritol Tetra (meth) acrylate, ethoxylated pentaerythritol tetra (meth) acrylate, propoxylated pentaerythri
- These compounds can be used alone or in combination of two or more, and can also be used in combination with other polymerizable compounds.
- the content of the polymerizable compound of the component (B) may be 10 to 50% by mass with respect to the total amount of the component (A) and the component (B).
- the content of the component (B) is 10% by mass or more, it is particularly easy to cure together with the elastomer (A).
- the content of the component (B) is 50% by mass or less, sufficient strength and flexibility of the cured product can be easily obtained.
- the content of the component (B) may be 15 to 40% by mass.
- the polymerization initiator for the component (C) is not particularly limited as long as it is a compound that initiates polymerization by heating or irradiation with ultraviolet rays.
- a polymerization initiator can be a thermal radical polymerization initiator or a photoradical polymerization initiator. Since the curing speed is high and room temperature curing is possible, the component (C) may contain a radical photopolymerization initiator.
- thermal radical polymerization initiator examples include ketone peroxides such as methyl ethyl ketone peroxide, cyclohexanone peroxide, and methylcyclohexanone peroxide; 1,1-bis (t-butylperoxy) cyclohexane, 1,1-bis (t-Butylperoxy) -2-methylcyclohexane, 1,1-bis (t-butylperoxy) -3,3,5-trimethylcyclohexane, 1,1-bis (t-hexylperoxy) cyclohexane, 1,1- Peroxyketals such as bis (t-hexylperoxy) -3,3,5-trimethylcyclohexane; hydroperoxides such as p-menthane hydroperoxide; ⁇ , ⁇ ′-bis (t-butylperoxy) diisopropylbenzene , Dicumyl peroxide, t-butylcumylpa Dial
- radical photopolymerization initiators include benzoinketals such as 2,2-dimethoxy-1,2-diphenylethane-1-one; 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropane- ⁇ -hydroxy ketones such as 1-one, 1- [4- (2-hydroxyethoxy) phenyl] -2-hydroxy-2-methyl-1-propan-1-one; 2-benzyl-2-dimethylamino-1 ⁇ -amino ketones such as-(4-morpholinophenyl) -butan-1-one, 1,2-methyl-1- [4- (methylthio) phenyl] -2-morpholinopropan-1-one; Oxime esters such as (4-phenylthio) phenyl] -1,2-octadion-2- (benzoyl) oxime; bis (2,4,4) Phosphine oxides such as 6-trimethylbenzoyl) phenylphosphine oxide, bis
- the aryl group substituents at the two triarylimidazole sites may give the same and symmetric compounds, or differently give asymmetric compounds.
- a thioxanthone compound and a tertiary amine may be combined, such as a combination of diethylthioxanthone and dimethylaminobenzoic acid.
- ⁇ -hydroxyketone and phosphine oxide are particularly excellent in terms of curability, transparency, and heat resistance.
- heat and photo radical polymerization initiators can be used alone or in combination of two or more. Further, it can be combined with an appropriate sensitizer.
- the content of the polymerization initiator of the component (C) may be 0.1 to 10 parts by mass with respect to 100 parts by mass of the total amount of the components (A) and (B).
- the content of the component (C) is 0.1 parts by mass or more, the resin composition tends to be sufficiently cured.
- the content of component (C) is 10 parts by mass or less, a flexible resin layer having sufficient light transmittance tends to be easily formed.
- the content of the component (B) may be 0.3 to 7 parts by mass, or 0.5 to 5 parts by mass.
- additives such as antioxidants, yellowing inhibitors, ultraviolet absorbers, visible light absorbers, colorants, plasticizers, stabilizers, fillers, and the like are added to the resin composition as necessary. You may add in the range which does not impair the effect of this invention substantially.
- the resin composition according to one embodiment may be diluted with an organic solvent and used as a resin varnish.
- the organic solvent used here is not particularly limited as long as it can dissolve the resin composition.
- the organic solvent include aromatic hydrocarbons such as toluene, xylene, mesitylene, cumene, and p-cymene; cyclic ethers such as tetrahydrofuran and 1,4-dioxane; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, 4-hydroxy Ketones such as -4-methyl-2-pentanone; esters such as methyl acetate, ethyl acetate, butyl acetate, methyl lactate, ethyl lactate and ⁇ -butyrolactone; carbonates such as ethylene carbonate and propylene carbonate; N, N-dimethylformamide Amides such as N, N-dimethylacetamide and N-methyl
- toluene and N, N-dimethylacetamide can be selected from the viewpoints of solubility and boiling point.
- These organic solvents can be used alone or in combination of two or more.
- the solid content concentration in the resin varnish may be 20 to 80% by mass.
- the elastic modulus of a flexible resin layer formed by curing a resin composition containing (A) an elastomer, (B) a polymerizable compound, and (C) a polymerization initiator is 0.1 MPa to 1000 MPa. Also good. When the elastic modulus is 0.1 MPa or more and 1000 MPa or less, handleability and flexibility as a film can be obtained. From this viewpoint, the elastic modulus may be 0.3 MPa to 100 MPa, or 0.5 MPa to 50 MPa.
- the elongation at break of the flexible resin layer may be 100% or more. If the breaking elongation is 100% or more, more excellent stretchability can be obtained. From the same viewpoint, the elongation at break may be 300% or more, or 500% or more.
- the recovery rate may be 80% or more.
- the recovery rate can be measured with X as 50%.
- FIG. 4 is a stress-strain curve showing an example of measuring the recovery rate. If the recovery rate is 80% or more, the resistance to repeated use can be further enhanced. From the same viewpoint, the recovery rate may be 85% or more, or 90% or more.
- the flexible resin layer formed from the resin composition has at least one characteristic selected from a total light transmittance of 80% or more, a Yellowness Index of 5.0 or less, and a haze of 5.0% or less. You may have. These can be measured using, for example, a spectral haze meter (Spectral haze meter “SH7000” manufactured by Nippon Denshoku Industries Co., Ltd.). If these characteristics are in the above range, sufficient transparency is easily obtained. From the same viewpoint, the total light transmittance may be 85% or more, the Yellowness Index may be 4.0 or less, the haze may be 4.0% or less, the total light transmittance may be 90% or more, and the Yellowness Index is 3.0. Hereinafter, the haze may be 3.0% or less.
- the resin film according to one embodiment is made of the above resin composition.
- the resin film can contain (A) an elastomer, (B) a polymerizable compound, and (C) a polymerization initiator.
- This resin film is obtained by, for example, applying a resin varnish containing (A) an elastomer, (B) a polymerizable compound, (C) a polymerization initiator, and an organic solvent for dissolving them to a base film, It can be easily manufactured by removing.
- polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate, and polyethylene naphthalate
- Polyolefins such as polyethylene and a polypropylene
- Polycarbonate polyamide, a polyimide, polyamideimide, polyetherimide
- Examples include polyether sulfide, polyether sulfone, polyether ketone, polyphenylene ether, polyphenylene sulfide, polyarylate, polysulfone, or liquid crystal polymer films.
- the base film is polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polypropylene, polycarbonate, polyamide, polyimide, polyamideimide, polyphenylene ether, polyphenylene sulfide, polyarylate, Alternatively, it may be a polysulfone film.
- the thickness of the base film may be appropriately changed depending on the intended flexibility, but may be 3 to 250 ⁇ m. When the thickness of the base film is 3 ⁇ m or more, sufficient film strength is easily obtained, and when the thickness of the base film is 250 ⁇ m or less, sufficient flexibility is easily obtained. From the same viewpoint, the thickness of the base film may be 5 to 200 ⁇ m, or 7 to 150 ⁇ m. From the viewpoint of improving releasability from the resin film, the surface of the base film may be subjected to a mold release treatment with a silicone compound, a fluorine-containing compound, or the like.
- a protective film may be attached on the resin film to form a laminated film having a three-layer structure including a base film, a resin film, and a protective film.
- the protective film include polyesters such as butylene terephthalate and polyethylene naphthalate; polyolefin films such as polyethylene and polypropylene.
- the protective film may be a polyester film such as polyethylene terephthalate; or a polyolefin film such as polyethylene or polypropylene.
- the surface of the protective film may be subjected to a mold release treatment with a silicone compound, a fluorine-containing compound, or the like.
- the thickness of the protective film may be appropriately changed depending on the intended flexibility, but may be 10 to 250 ⁇ m. When the thickness of the protective film is 10 ⁇ m or more, sufficient film strength is easily obtained, and when the thickness of the protective film is 250 ⁇ m or less, sufficient flexibility is easily obtained. From the same viewpoint, the thickness of the protective film may be 15 to 200 ⁇ m, or 20 to 150 ⁇ m.
- the thickness of the resin film after drying is not particularly limited, but may be 5 to 1000 ⁇ m. There exists a tendency for a resin film or its hardened
- Resin film can be easily stored, for example, by winding it into a roll.
- a roll-shaped film can be cut into a suitable size and stored in a sheet-like state.
- the resin composition according to one embodiment can be used as a sealing material for forming a flexible sealing member of a wearable device.
- the resin film which concerns on one Embodiment can be used as a resin sealing film for forming the flexible sealing member of a wearable apparatus.
- Example 1 [Preparation of resin varnish VU1]
- component (A) 80 parts by mass of a polyether-based thermoplastic polyurethane (BASF Japan “Elaston ET385A”), and as the component (B), ethylene oxide-modified bisphenol A dimethacrylate (manufactured by Hitachi Chemical Co., Ltd., “Fan”).
- component (Cryl FA-321M ) 20 parts by mass, as component (C) 1.5 parts by mass of bis (2,4,6-trimethylbenzoyl) phenylphosphine oxide (" Irgacure 819 "manufactured by BASF), and toluene 125
- the resin varnish VU1 was obtained by mixing the mass parts while stirring.
- a surface release-treated PET film (“Purex A31” manufactured by Teijin DuPont Films Ltd., thickness 25 ⁇ m) was prepared as a base film. Resin varnish VU1 was applied onto the release-treated surface of this PET film using a knife coater (“SNC-350” manufactured by Yasui Seiki Co., Ltd.) and then a dryer (“MSO-80TPS” manufactured by Futaba Kagaku Co., Ltd.). A resin film was formed by drying at 100 ° C. for 20 minutes, and the same surface release treatment PET film as that of the base film was pasted on the formed resin film so that the release treatment surface was on the resin film side. At this time, the thickness of the resin film can be arbitrarily adjusted by adjusting the gap of the coating machine so that the thickness of the cured resin film becomes 100 ⁇ m in this embodiment. Adjusted.
- Each resin film was irradiated with 5000 mJ / cm 2 of ultraviolet rays (wavelength 365 nm) with an ultraviolet exposure machine (Mikasa Co., Ltd. “ML-320FSAT”) to cure the resin film, thereby forming a flexible resin layer. .
- ML-320FSAT ultraviolet exposure machine
- a laminated film having a length of 40 mm and a width of 10 mm was cut out, the base film and the protective film were removed, and a measurement sample of the flexible resin layer was obtained.
- the stress-strain curve of the measurement sample was measured using an autograph (Shimadzu Corporation “EZ-S”), and the elastic modulus and elongation were determined from the stress-strain curve.
- the distance between chucks at the time of measurement was 20 mm, and the pulling speed was 50 mm / min.
- the value at a load of 0.5 to 1.0 N was measured as the elastic modulus, and the value (breaking elongation) when the sample was broken as the elongation was measured.
- Each resin film was irradiated with 5000 mJ / cm 2 of ultraviolet rays (wavelength 365 nm) with an ultraviolet exposure machine (Mikasa Co., Ltd. “ML-320FSAT”) to cure the resin film, thereby forming a flexible resin layer. . Thereafter, a laminated film having a length of 70 mm and a width of 5 mm was cut out, the base film and the protective film were removed, and a measurement sample was obtained. The recovery rate of the measurement sample was measured using a micro force tester (IllinoisTool Works Inc “Instron 5948”).
- the recovery rate is the displacement (strain) added in the first tensile test as X, then the position (displacement) when the load starts to be applied to the measurement sample when returning to the initial position and performing the tensile test again.
- the initial length (distance between chucks) was 50 mm
- X was 25 mm (strain 50%).
- the protective film is removed from the laminated film, and the resin film is placed on a slide glass (Matsunami Glass Industry Co., Ltd. “S1111”) using a vacuum pressure laminator (Nichigo Morton Co., Ltd. “V130”) at a pressure of 0. Lamination was performed under conditions of 5 MPa, a temperature of 60 ° C., and a pressing time of 60 seconds.
- the laminated resin film was irradiated with 5000 mJ / cm 2 of ultraviolet rays (wavelength 365 nm) with the ultraviolet exposure machine to form a flexible resin layer. Thereafter, the base film was peeled off, and the total light transmittance, YI and haze of the flexible resin layer were measured using a spectroscopic haze meter (Nippon Denshoku Industries Co., Ltd. “SH7000”).
- a silicon wafer was processed into a size of 0.1 mm, 10 mm ⁇ 10 mm, and this was a resin film produced in the above examples and comparative examples (thicknesses were 100 ⁇ m in Examples 1 to 5 and Comparative Example 1, comparative example) 2 is 200 ⁇ m).
- a resin film was laminated on a silicon wafer under the conditions of a pressure of 0.8 MPa, a temperature of 90 ° C., and a pressurization time of 60 seconds, and the embedded state at that time was observed.
- a step having a height of 100 ⁇ m was evaluated as A when embedding was possible without voids, and as C when embedding was not possible.
- Table 1 shows the evaluation results of Examples 1 to 5 and Comparative Examples 1 and 2.
- SR-50 Ethylene oxide-modified bisphenol A dimethacrylate (Hitachi Chemical Co., Ltd. “Funkryl FA-321M”) 7) Bis (2,4,6-trimethylbenzoyl) phenylphosphine oxide (BASF Japan Ltd. “Irgacure 819”)
- the flexible resin layers formed of the resin compositions of Examples 1 to 5 containing thermoplastic polyurethane have low elasticity and high flexibility, and are excellent in transparency and step embedding.
- the flexible resin layer formed of the resin composition of Comparative Examples 1 and 2 containing an elastomer other than thermoplastic polyurethane is inferior in flexibility, transparency or step embedding.
- Example 6 [Preparation of resin varnish VA1]
- component (A) 80 parts by mass of a styrene isoprene copolymer (Clayton Polymer Japan Co., Ltd. “Clayton D1117”) and as component (B), butanediol diacrylate (manufactured by Hitachi Chemical Co., Ltd., “Fancryl FA-124AS”). ") 20 parts by mass, bis (2,4,6-trimethylbenzoyl) phenylphosphine oxide (" Irgacure 819 "manufactured by BASF) as a component (C), and 125 parts by mass of toluene as a solvent. While mixing, a resin varnish VA1 was obtained.
- a surface release-treated PET film (“Purex A31” manufactured by Teijin DuPont Films Ltd., thickness 25 ⁇ m) was prepared as a base film.
- Resin varnish VA1 was applied onto the release-treated surface of this PET film using a knife coater (“SNC-350” manufactured by Yasui Seiki Co., Ltd.) and then a dryer (“MSO-80TPS” manufactured by Futaba Kagaku Co., Ltd.).
- a resin film was formed by drying for 20 minutes at 100 ° C. Inside the formed resin film, the same surface release treatment PET film as the base film was protected with the release treatment surface facing the resin film side. The film was pasted to obtain a laminated film FA1.
- the thickness of the resin film can be arbitrarily adjusted by adjusting the gap of the coating machine.In this embodiment, the film thickness of the cured resin film is 100 ⁇ m. It adjusted so that it might become.
- the flexible resin layer formed from the resin compositions of Examples 7 to 13 containing a styrene elastomer has low elasticity and high flexibility, and is excellent in transparency and step embedding. .
- the flexible resin layer formed by the resin composition of Comparative Examples 1 and 2 containing an elastomer other than the styrene-based elastomer is inferior in flexibility, transparency, or step embedding property.
- the flexible resin composition and the resin film of the present invention are excellent in flexibility and transparency, and further in step embedding, and these are preferably used as a sealing layer for protecting a circuit board of a wearable device. it can.
- SYMBOLS 1 Flexible substrate, 2 ... Circuit component, 3 ... Flexible resin layer (flexible member), 100 ... Semiconductor device.
Abstract
Description
図1は、本実施形態に係る半導体装置を模式的に示す断面図である。本実施形態に係る半導体装置100は、可撓性を有する可撓性基板1と、回路部品2と、可撓性を有する可撓性樹脂層(可撓性層、又は可撓性部材ということもある。)3とで構成される回路基板を備える。可撓性基板1は、可視域で透明であってもよい。可撓性基板1は、例えば、可視域で透明であってもよいフレキシブル基板である。回路部品2は、可撓性基板1上に実装されている。可撓性樹脂層3は、可撓性基板1及び回路部品2を封止しており、回路基板の表面を保護している。
本実施形態に係る半導体装置を製造する方法は、例えば、実装工程と、封止工程と、硬化工程と、切断工程とをこの順に備える。
まず、図2に示すように、可撓性基板1の上に回路部品2を実装する。実装される複数の回路部品2は、1種類でも、2種類以上の組み合わせであってもよい。実装される回路部品2は、1個でも複数個でもよい。
次に、可撓性基板1、及び、回路部品2を封止材としての樹脂組成物又は樹脂フィルムで封止する。可撓性基板1及び回路部品2は、例えば、フィルム状の封止材(樹脂フィルム)を可撓性基板1に積層すること、封止材(樹脂組成物)を可撓性基板1に印刷すること、又は、封止材(樹脂組成物)に可撓性基板1を浸漬し、乾燥することにより封止することができる。封止は、加熱プレス、ロールラミネート、真空ラミネート、印刷法又はディッピング法等によって行うことができる。この中でも、Roll to Rollのプロセスで使用できる方法は、製造工程を短縮できる。
封止工程において可撓性基板1及び回路部品2を封止材で封止した後、封止材を硬化させることにより可撓性樹脂層3を形成し、可撓性樹脂層3を有する回路基板を得る。これにより、図1に示される半導体装置100が得られる。加熱による熱硬化、露光による光硬化、又はこれらの組み合わせにより、封止材を硬化させることができる。封止材は、回路部品2の耐熱性の観点から、熱硬化性であれば低温で硬化する材料(樹脂組成物)であってもよい。封止材は、室温で硬化できる観点から、光硬化する材料(樹脂組成物)であってもよい。
半導体装置の製造方法は、必要に応じて、例えば、図3に示すように、回路基板を切断し分離することにより、回路部品を有する複数の半導体装置を得る工程を備えることができる。これにより、複数の半導体装置を一度に大面積で製造することが可能となり、容易に製造工程を減らすことができる。
一実施形態に係る樹脂組成物は、(A)熱可塑性ポリウレタン又はスチレン系エラストマーのうち少なくとも一方を含むエラストマー、(B)重合性化合物及び(C)重合開始剤を含有し、可撓性樹脂層を形成するために用いられる。この樹脂組成物は、活性光線の照射及び/又は加熱によって硬化することができる。
[樹脂ワニスVU1の調合]
(A)成分として、ポリエーテル系熱可塑性ポリウレタン(BASFジャパン(株)「エラストンET385A」)80質量部、(B)成分として、エチレンオキサイド変性ビスフェノールA型ジメタクリレート(日立化成(株)製「ファンクリルFA-321M」)20質量部、(C)成分として、ビス(2,4,6-トリメチルベンゾイル)フェニルホスフィンオキシド(BASF社製「イルガキュア819」)1.5質量部、及び溶剤としてトルエン125質量部を攪拌しながら混合し樹脂ワニスVU1を得た。
基材フィルムとして表面離型処理PETフィルム(帝人デュポンフィルム(株)製「ピューレックスA31」、厚み25μm)を準備した。このPETフィルムの離型処理面上にナイフコータ((株)康井精機製「SNC-350」を用いて樹脂ワニスVU1を塗布した。次いで乾燥機((株)二葉科学製「MSO-80TPS」)中100℃で20分乾燥して、樹脂フィルムを形成させた。形成された樹脂フィルムに、基材フィルムと同じ表面離型処理PETフィルムを、離型処理面が樹脂フィルム側になるよう貼付けて、積層フィルムFU1を得た。このとき樹脂フィルムの厚みは、塗工機のギャップを調節することで任意に調整可能である。本実施例では硬化後の樹脂フィルムの膜厚が100μmとなるように調節した。
実施例1と同様の方法で、表1に示す配合比に従って樹脂ワニスVU2~VU6を調合し、樹脂フィルムFU2~FU6を作製した。比較例2としてシリコーンゴム製のシート状フィルムFS1(厚さ200μm)を準備した。
各樹脂フィルムに、紫外線露光機(ミカサ(株)「ML-320FSAT」)によって紫外線(波長365nm)を5000mJ/cm2照射して樹脂フィルムを硬化させることで、可撓性樹脂層を形成させた。次いで、長さ40mm、幅10mmの積層フィルムを切り出し、基材フィルム及び保護フィルムを除去して、可撓性樹脂層の測定用サンプルを得た。測定用サンプルの応力-ひずみ曲線を、オートグラフ((株)島津製作所「EZ-S」)を用いて測定し、その応力-ひずみ曲線から弾性率及び伸び率を求めた。測定時のチャック間距離は20mm、引っ張り速度は50mm/minとした。なおここでは、弾性率として荷重0.5から1.0Nにおける値を、伸び率としてサンプルが破断した際の値(破断伸び率)を測定した。
各樹脂フィルムに、紫外線露光機(ミカサ(株)「ML-320FSAT」)によって紫外線(波長365nm)を5000mJ/cm2照射して樹脂フィルムを硬化させることで、可撓性樹脂層を形成させた。その後、長さ70mm、幅5mmの積層フィルムを切り出し、基材フィルム及び保護フィルムを除去して、測定用サンプルを得た。測定用サンプルの回復率を、マイクロフォース試験機(IllinoisTool Works Inc「Instron 5948」)を用いて測定した。
積層フィルムから保護フィルムを除去し、樹脂フィルムを、スライドガラス(松浪硝子工業(株)「S1111」)上に真空加圧式ラミネータ(ニチゴー・モートン(株)「V130」)を用いて、圧力0.5MPa、温度60℃及び加圧時間60秒の条件でラミネートした。ラミネートされた樹脂フィルムに、前記紫外線露光機にて紫外線(波長365nm)を5000mJ/cm2照射して、可撓性樹脂層を形成させた。その後、基材フィルムを剥がし、可撓性樹脂層の全光線透過率、YI及びヘイズを分光ヘイズメータ(日本電色工業(株)「SH7000」)を用いて測定した。
シリコンウェハを厚さ0.1mm、10mm×10mmのサイズに加工し、これを上記実施例及び比較例で作製した樹脂フィルム(厚さは、実施例1~5及び比較例1が100μm、比較例2が200μm)によって埋め込み可能か試験した。前記真空加圧式ラミネータを用い、圧力0.8MPa、温度90℃及び加圧時間60秒の条件で樹脂フィルムをシリコンウェハにラミネートし、そのときの埋め込みの状態を観察した。100μmの高さを有する段差を、ボイド等なく埋め込みが可能であった場合はA、埋め込みができなかった場合はCとして評価した。
2)ポリエステル系熱可塑性ポリウレタン、BASFジャパン(株)「エラストンC85A」、重量平均分子量:1.2×105
3)無黄変タイプ熱可塑性ポリウレタン、東ソー(株)「ミラクトランXN-2001」、重量平均分子量:8.1×104
4)ゴム変性ポリアミド、日本化薬(株)「カヤフレックスBPAM-155」、重量平均分子量: 3.1×104
5)シリコーンゴムシート、タイガースポリマー(株)「SR-50」
6)エチレンオキサイド変性ビスフェノールA型ジメタクリレート(日立化成(株)「ファンクリルFA-321M」)
7)ビス(2,4,6-トリメチルベンゾイル)フェニルホスフィンオキシド(BASFジャパン(株)「イルガキュア819」)
[樹脂ワニスVA1の調合]
(A)成分として、スチレンイソプレン共重合ポリマー(クレイトンポリマージャパン(株)「クレイトンD1117」)80質量部、(B)成分として、ブタンジオールジアクリレート(日立化成(株)製「ファンクリルFA-124AS」)20質量部、(C)成分として、ビス(2,4,6-トリメチルベンゾイル)フェニルホスフィンオキシド(BASF社製「イルガキュア819」)1.5質量部、及び溶剤としてトルエン125質量部を攪拌しながら混合し樹脂ワニスVA1を得た。
基材フィルムとして表面離型処理PETフィルム(帝人デュポンフィルム(株)製「ピューレックスA31」、厚み25μm)を準備した。このPETフィルムの離型処理面上にナイフコータ((株)康井精機製「SNC-350」を用いて樹脂ワニスVA1を塗布した。次いで乾燥機((株)二葉科学製「MSO-80TPS」)中100℃で20分乾燥して、樹脂フィルムを形成させた。形成された樹脂フィルムに、基材フィルムと同じ表面離型処理PETフィルムを、離型処理面が樹脂フィルム側になる向きで保護フィルムとして貼付けて、積層フィルムFA1を得た。樹脂フィルムの厚みは、塗工機のギャップを調節することで任意に調整可能である。本実施例では硬化後の樹脂フィルムの膜厚が100μmとなるように調節した。
実施例6と同様の方法で、表2に示す配合比に従って樹脂ワニスVA2~VA8を調合し、積層フィルムFA2~FA8を作製した。比較例2としてシリコーンゴム製のシート状フィルムFS1(厚さ200μm)を準備した。
2)水素添加型スチレンブタジエンラバー、JSR(株)「ダイナロン2324P、重量平均分子量:1.0×105
3)ゴム変性ポリアミド(日本化薬(株)「カヤフレックスBPAM-155」、重量平均分子量: 3.1×104
4)シリコーンゴムシート、タイガースポリマー(株)「SR-50」
5)ブタンジオールジアクリレート(日立化成(株)「ファンクリルFA-124AS6)ヘキサンジオールジアクリレート(日立化成(株)「ファンクリルFA-126AS
7)ノナンジオールジアクリレート(日立化成(株)「ファンクリルFA-129AS8)エチレンオキサイド変性ビスフェノールA型ジメタクリレート(日立化成(株)「ファンクリルFA-321M」)
9)ビス(2,4,6-トリメチルベンゾイル)フェニルホスフィンオキシド(BASFジャパン(株)「イルガキュア819」)
Claims (17)
- 可撓性基板と、前記可撓性基板上に実装された回路部品と、前記回路部品を封止する可撓性樹脂層とを有する回路基板を備える半導体装置を製造する方法であって、
封止材を前記可撓性基板に積層することにより前記回路部品を前記封止材で封止する工程と、
前記封止材を硬化させることにより、前記可撓性樹脂層を形成させる工程と、を備える、方法。 - 可撓性基板と、前記可撓性基板上に実装された回路部品と、前記回路部品を封止する可撓性樹脂層とを有する回路基板を備える半導体装置を製造する方法であって、
封止材を前記可撓性基板に印刷することにより前記回路部品を前記封止材で封止する工程と、
前記封止材を硬化させることにより、前記可撓性樹脂層を形成させる工程と、を備える、方法。 - 可撓性基板と、前記可撓性基板上に実装された回路部品と、前記回路部品を封止する可撓性樹脂層とを有する回路基板を備える半導体装置を製造する方法であって、
封止材に前記可撓性基板を浸漬し、乾燥することにより前記回路部品を前記封止材で封止する工程と、
前記封止材を硬化させることにより、前記可撓性樹脂層を形成させる工程と、を備える、方法。 - 前記回路基板を切断する工程を更に備える、請求項1~3のいずれか一項に記載の方法。
- 前記可撓性樹脂層が、ポリイミド樹脂、アクリル樹脂、シリコーン樹脂、ウレタン樹脂、エポキシ樹脂及びポリエチレングリコール樹脂からなる群より選ばれる少なくとも一種を含む、請求項1~4のいずれか一項に記載の方法。
- 前記可撓性基板及び前記可撓性樹脂層が可視域で透明である、請求項1~5のいずれか一項に記載の方法。
- 前記回路部品が2種類以上である、請求項1~6のいずれか一項に記載の方法。
- 請求項1~7のいずれか一項に記載の方法により得られる、半導体装置。
- (A)熱可塑性ポリウレタン又はスチレン系エラストマーのうち少なくともいずれか一方を含むエラストマー、(B)重合性化合物及び(C)重合開始剤を含有する、
可撓性樹脂層形成用樹脂組成物。 - (A)エラストマーが前記熱可塑性ポリウレタンを含む、請求項9に記載の可撓性樹脂層形成用樹脂組成物。
- (A)エラストマーが前記スチレン系エラストマーを含む、請求項9に記載の可撓性樹脂層形成用樹脂組成物。
- (B)重合性化合物が、エチレン性不飽和基を含む、請求項9~11のいずれか一項に記載の可撓性樹脂層形成用樹脂組成物。
- (C)重合開始剤が、光ラジカル重合開始剤である、請求項9~12のいずれか一項に記載の可撓性樹脂層形成用樹脂組成物。
- (A)エラストマーの含有量が、(A)エラストマー及び(B)重合性化合物の総量に対して50~90質量%であり、
(B)重合性化合物の含有量が、(A)エラストマー及び(B)重合性化合物の総量に対して10~50質量%であり、
(C)重合開始剤の含有量が、(A)エラストマー及び(B)重合性化合物の総量100質量部に対して0.1~10質量部である、
請求項9~13のいずれか一項に記載の可撓性樹脂層形成用樹脂組成物。 - 当該樹脂組成物が封止材である、請求項9~14のいずれか一項に記載の可撓性樹脂層形成用樹脂組成物。
- 請求項9~15のいずれか一項に記載の可撓性樹脂層形成用脂組成物からなる樹脂フィルム。
- 可撓性基板と、該可撓性基板上に実装された回路部品と、該回路部品を封止する可撓性樹脂層と、を有する回路基板を備え、
前記可撓性樹脂層が、請求項9~14のいずれか一項に記載の可撓性樹脂層形成用樹脂組成物を硬化した層である、半導体装置。
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Also Published As
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US20200253059A1 (en) | 2020-08-06 |
US20170325336A1 (en) | 2017-11-09 |
US11330721B2 (en) | 2022-05-10 |
JP6624065B2 (ja) | 2019-12-25 |
TWI674632B (zh) | 2019-10-11 |
JPWO2016080346A1 (ja) | 2017-09-28 |
US20180288882A1 (en) | 2018-10-04 |
TW201626472A (zh) | 2016-07-16 |
KR20170085029A (ko) | 2017-07-21 |
KR102520360B1 (ko) | 2023-04-11 |
US10674612B2 (en) | 2020-06-02 |
CN106663638A (zh) | 2017-05-10 |
US11147166B2 (en) | 2021-10-12 |
CN106663638B (zh) | 2020-04-07 |
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