WO2022138105A1 - 積層体、電子部品及びコンデンサ - Google Patents
積層体、電子部品及びコンデンサ Download PDFInfo
- Publication number
- WO2022138105A1 WO2022138105A1 PCT/JP2021/044688 JP2021044688W WO2022138105A1 WO 2022138105 A1 WO2022138105 A1 WO 2022138105A1 JP 2021044688 W JP2021044688 W JP 2021044688W WO 2022138105 A1 WO2022138105 A1 WO 2022138105A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- clay
- resin
- base material
- electronic component
- Prior art date
Links
- 239000003990 capacitor Substances 0.000 title claims description 123
- 239000004927 clay Substances 0.000 claims abstract description 146
- 239000000463 material Substances 0.000 claims abstract description 94
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- 229920001155 polypropylene Polymers 0.000 claims description 30
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- AYKYXWQEBUNJCN-UHFFFAOYSA-N 3-methylfuran-2,5-dione Chemical compound CC1=CC(=O)OC1=O AYKYXWQEBUNJCN-UHFFFAOYSA-N 0.000 description 1
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- 239000005977 Ethylene Substances 0.000 description 1
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- HNEGQIOMVPPMNR-IHWYPQMZSA-N citraconic acid Chemical compound OC(=O)C(/C)=C\C(O)=O HNEGQIOMVPPMNR-IHWYPQMZSA-N 0.000 description 1
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- KWLMIXQRALPRBC-UHFFFAOYSA-L hectorite Chemical compound [Li+].[OH-].[OH-].[Na+].[Mg+2].O1[Si]2([O-])O[Si]1([O-])O[Si]([O-])(O1)O[Si]1([O-])O2 KWLMIXQRALPRBC-UHFFFAOYSA-L 0.000 description 1
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- 229910000273 nontronite Inorganic materials 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G2/00—Details of capacitors not covered by a single one of groups H01G4/00-H01G11/00
- H01G2/10—Housing; Encapsulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/002—Details
- H01G4/224—Housing; Encapsulation
-
- 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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal 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
-
- 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
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B33/00—Silicon; Compounds thereof
- C01B33/20—Silicates
- C01B33/36—Silicates having base-exchange properties but not having molecular sieve properties
- C01B33/38—Layered base-exchange silicates, e.g. clays, micas or alkali metal silicates of kenyaite or magadiite type
- C01B33/40—Clays
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/32—Wound capacitors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/33—Thin- or thick-film capacitors
Definitions
- the present disclosure relates to a laminate, an electronic component and a capacitor, and more particularly to a laminate having a clay layer, an electronic component and a capacitor provided with the laminate.
- Patent Document 1 describes a method for producing a clay film.
- Patent Document 2 describes a clay membrane complex.
- a water vapor barrier layer having a water vapor permeability of 1.0 g / m 2 ⁇ day or less is provided on at least one surface of a clay film composed of clay alone or clay and additives, and the water vapor barrier layer is combined with the clay film complex.
- the clay film is melt-bonded.
- present disclosure is intended to provide electronic components and capacitors using the above laminated body.
- the laminate according to one aspect of the present disclosure has a base material layer, an adhesive layer, and a clay layer.
- the base material layer contains a crystalline resin.
- the adhesive layer contains a resin different from the crystalline resin and is provided on one surface of the base material layer.
- the clay layer is provided on one surface of the base material layer via the adhesive layer.
- the adhesive development temperature of the adhesive layer is 130 ° C. or lower.
- the electronic component includes an electronic component element and a barrier film that covers at least a part of the periphery of the electronic component element.
- the barrier film includes the laminate.
- the electronic component element of the electronic component includes a capacitor element.
- FIG. 1A is a cross-sectional view showing an embodiment of the laminated body according to the present embodiment.
- FIG. 1B is a schematic perspective view showing an example of mineral particles.
- FIG. 1C is a schematic cross-sectional view showing an example of a clay layer.
- 2A to 2D are cross-sectional views showing an embodiment of an electronic component according to the present embodiment.
- 3A and 3B are cross-sectional views showing another embodiment of the electronic component according to the present embodiment.
- FIG. 4A is a process diagram (perspective view) of a method for manufacturing a wound capacitor element.
- FIG. 4B is a perspective view of the winding type capacitor element.
- FIG. 5A is a process diagram (perspective view) of a method for manufacturing a laminated capacitor element.
- FIG. 5B is a process diagram (cross-sectional view) of a method for manufacturing a laminated capacitor element.
- FIG. 5C is a partially cutaway perspective view of the laminated capacitor element shown in FIG. 5B.
- FIG. 5D is a perspective view of the laminated capacitor element.
- FIG. 6 is a cross-sectional view showing a method for measuring the adhesiveness development temperature.
- Clay typified by smectite becomes a clay film in which mineral particles are layered and dried by allowing it to stand and dry, and exhibits high gas barrier properties. Therefore, a clay film having a clay layer and a clay film composite as described in Patent Documents 1 and 2 have been proposed.
- Patent Document 1 it is necessary to take about 350 to 500 ° C. for several hours as the heat treatment, and there is a big limitation when the film is used as the base material.
- polypropylene or the like having a melting point near 160 ° C. may not be used as a base material.
- an aqueous binder was used as an additive, the characteristics may deteriorate due to the swelling of the binder under high temperature and high humidity.
- the steam barrier layer which is a base film
- the clay film are thermocompression bonded and melt-bonded, but the thermocompression bonding that exceeds the melting point of the base film is required, which lacks the simplicity of the process. ing.
- a base film having a water vapor transmission rate of 1 g / mm 2 ⁇ day or less is used for improving the characteristics, it may not be possible to use an inexpensive and versatile film.
- the laminate uses a base material layer containing a crystalline resin having a good water vapor barrier property to reduce the amount of water vapor reaching the clay layer.
- a laminated body having a good water vapor barrier property can be obtained.
- the laminate according to the present embodiment has an adhesive layer between the base material layer and the clay layer, the base material layer and the clay layer can be bonded by a low temperature process without being melt-bonded. can. As a result, the adhesion between the base material layer and the clay layer is improved, and it is possible to reduce the occurrence of abnormalities such as cracks in the clay layer.
- the laminated body 30 has a base material layer 33, an adhesive layer 32, and a clay layer 31.
- the base material layer 33 contains a crystalline resin.
- the adhesive layer 32 contains a resin different from the crystalline resin contained in the base material layer 33. Further, the adhesive layer 32 is provided on one surface (surface) of the base material layer 33.
- the clay layer 31 is provided on one surface of the base material layer 33 via the adhesive layer 32.
- the laminate 30 has a form such as a film, a sheet, and a plate.
- the base material layer 33 contains a crystalline resin.
- the resin used as the base material layer 33 includes polyethylene, polypropylene, polyethylene terephthalate, polyamide, fluororesin, acrylic resin, polyimide, polyethylene naphthalate, polymethylpentene, cycloolefin, polyallylate, polyether ether ketone, and polyphenylensul. Examples include fids, syndiotactic polystyrenes, and epoxy resins.
- the base material layer 33 contains one or more of the above-exemplified crystalline resins. Among the plurality of types of crystalline resins exemplified above, the base material layer 33 preferably contains polypropylene having a good water vapor barrier property.
- the water vapor barrier property refers to the property that water vapor does not easily pass through.
- a polypropylene film has a water vapor permeability of about 4 to 5 g / (m 2 ⁇ d) and has a good water vapor barrier property.
- the base material layer 33 has the form of, for example, a film, a sheet, a plate, or the like.
- the thickness of the base material layer 33 is appropriately set in consideration of electrical insulation and flexibility, but is preferably several tens of ⁇ m, more preferably 10 ⁇ m or more and 30 ⁇ m or less.
- the base material layer 33 is preferably a biaxially stretched polypropylene film. As a result, the water vapor barrier property can be improved as compared with the base material layer 33 made of a normal polypropylene film which is not biaxially stretched.
- the adhesive layer 32 is a layer for adhering the base material layer 33 and the clay layer 31.
- the base material layer 33 and the clay layer 31 are adhered to each other by the adhesive layer 32, and have excellent adhesion.
- excellent in adhesion means that the clay layer 31 does not peel off from the adhesive layer 32 and the base material layer 33 by an evaluation method (cross-cut method) based on JIS K 5600-5-6.
- the adhesive layer 32 contains a resin different from the crystalline resin contained in the base material layer 33.
- the adhesive layer 32 contains a resin other than the crystalline polypropylene.
- the adhesive layer 32 has an adhesive development temperature of 130 ° C. or lower.
- the adhesiveness development temperature refers to the temperature at which the adhesive layer 32 develops adhesiveness. That is, the adhesive layer 32 develops adhesiveness by thermal melting, but when the adhesiveness is improved as compared with that before thermal melting, the temperature at which the adhesive layer 32 is thermally melted becomes the adhesive development temperature.
- a pair of test pieces having a base material layer 33 and an adhesive layer 32 are sandwiched between a pair of hot plates H and heated at a predetermined temperature to heat the adhesive layers 32 to each other. Thermocompression bonding.
- the crimping force can be 0.3 MPa and the crimping time can be 10 minutes.
- the heating temperature on the hot plate H is the tackiness development temperature.
- a 180 ° peeling test based on JIS Z 0237: 2009 can be adopted.
- the adhesive layer development temperature of the adhesive layer 32 is preferably lower than the heat melting temperature of the base material layer 33.
- the lower limit of the adhesiveness development temperature of the adhesive layer 32 is not particularly set, but can be, for example, 80 ° C. or higher.
- the clay layer 31 is coated and mounted in the roll-to-roll process, there is a problem that the handleability is impaired if the adhesive layer 32 develops adhesiveness at the temperature in the process.
- the adhesive layer 32 contains a resin different from the crystalline resin contained in the base material layer 33.
- a hot melt resin can be used as a resin different from the crystalline resin contained in the base material layer 33.
- a hot melt resin is a resin that melts due to heat and reversibly solidifies when the heat disappears.
- the hot melt resin a hot melt resin having a low melting point is preferable.
- the hot melt resin include EVA (ethylene vinyl acetate) -based resin, olefin-based resin, rubber-based resin, polyamide-based resin, nylon-based resin, polyurethane-based resin, and acrylic-based resin.
- the adhesive layer 32 is preferably formed of an olefin resin having a high affinity with crystalline polypropylene. As an olefin resin having a high affinity with crystalline polypropylene, it is preferable that the adhesive layer 32 contains an amorphous resin. When the base material layer 33 is formed of crystalline polypropylene, it is preferable to form the adhesive layer 32 with amorphous polypropylene having a smaller crystallinity than crystalline polypropylene.
- Amorphous polypropylene is polypropylene that does not have a polar group and has many branches, or polypropylene obtained by copolymerizing ethylene and butene. Amorphous polypropylene generally has a density of 0.855 g / cm 3 or less.
- the stability is low, so polar groups (hydroxyl groups and carbonyl groups) are likely to be generated on the surface of the adhesive layer 32 during corona treatment. Therefore, in forming the clay layer 31, the wettability at the time of applying the treatment liquid containing clay is improved, and the adhesion between the clay layer 31 and the adhesive layer 32 is improved.
- the adhesive layer 32 preferably contains a resin having a polar group.
- a modified polyolefin can be used.
- the modified polyolefin may be a modified polyolefin containing modified polypropylene as the maximum content component.
- an acid-modified polyolefin can be used.
- the acid-modified polyolefin is a polyolefin modified with an acid and its anhydride, and examples of the acid include maleic acid, maleic anhydride, fumaric acid, citraconic acid, citraconic anhydride, mesaconic acid, crotonic acid, itaconic acid, and itacone anhydride.
- Acids, aconitic acids, anhydrous aconitic acids and the like can be mentioned.
- a carboxylic acid anhydride-modified polyolefin can be used, and examples thereof include maleic anhydride-modified polyolefin, acrylic acid-modified polyolefin, and imine-modified polyolefin.
- the modified polyolefin even if the crystallinity is high, the polar group will be present due to the modification. Therefore, in forming the clay layer 31, the wettability at the time of applying the treatment liquid containing clay is improved, and the adhesion between the clay layer 31 and the adhesive layer 32 is improved.
- the laminated body 30 according to the present embodiment has the adhesive layer 32 as described above, the clay layer 31 and the adhesive layer do not need to be heat-welded to the clay layer 31 and the base material layer 33. High adhesion to 32 and the base material layer 33.
- the adhesive layer 32 is heated at a temperature at which the adhesive layer 32 is developed when the clay layer 31 is formed, the adhesion between the clay layer 31 and the adhesive layer 32 is further improved, and the clay layer 31 is damaged or dropped off. Hard to occur.
- the thickness of the adhesive layer 32 is not particularly limited, but is preferably 5 ⁇ m or less, more preferably 1 ⁇ m or less in consideration of performance such as adhesive strength, adhesiveness, and ease of formation.
- the clay layer 31 contains clay and is formed in a layered manner.
- clay is an aggregate of a plurality of mineral particles 311.
- Clay may also contain a small amount of water in an aggregate of a plurality of mineral particles 311.
- Mineral particles 311 include one or more selected from the herd of mica, vermiculite, montmorillonite, iron montmorillonite, byderite, saponite, hectorite, stepvensite, nontronite.
- the mineral particles 311 preferably contain montmorillonite, which is a highly moisture-resistant clay material.
- the crystal structure of montmorillonite is a single-layer structure in which an octahedral structure centered on Al (aluminum atom) is sandwiched between a tetrahedral structure centered on Si (silicon atom). Specifically, a part of trivalent Al is replaced with divalent Mg or Fe, and the monolayer is negatively charged. Therefore, cation hydrates such as Na + and Ca 2+ are present in the crystal structure for charge compensation.
- montmorillonite is dispersed in water, the cation portion is hydrated and easily separated in a single layer unit. Therefore, montmorillonite can be easily separated into a single layer by dispersing it in water. Therefore, montmorillonite is easily contained in the clay layer 31 in a state of being separated into a single layer, and a maze structure composed of mineral particles 311 is easily formed in the clay layer 31.
- the commutative cations between layers can be easily exchanged with other inorganic and organic cations. Therefore, it is possible to impart affinity with an organic solvent and intercalate various compounds between layers. Further, since the hydroxyl group is present on the crystal end face, it can be decorated with various silylating agents. Then, in order to obtain high moisture resistance of the clay layer 31, it is preferable to make the clay layer 31 hydrophobic. For example, if commutative cations (Na + , etc.) have a high affinity for water and exist between layers, they tend to be disadvantageous for the hydrophobicity of the clay layer 31. Therefore, it is conceivable to replace the commutative cations with Li and protons. For example, when montmorillonite is heat-treated, ions move to the inside and the surface of the crystal, and the clay layer 31 is easily made hydrophobic.
- FIG. 1B shows a schematic perspective view of one mineral particle 311.
- the mineral particles 311 are plate-shaped or flaky particles. That is, the mineral particles 311 are particles having a thickness a smaller than the width b.
- the width b is the dimension of the longest portion of the mineral particles 311 when the mineral particles 311 are viewed from the front (viewed from directly in the thickness direction). If the mineral particle 311 is, for example, a disk, the diameter is b.
- the thickness a is a dimension in a direction orthogonal to the width b, and is a dimension between two facing surfaces of the mineral particles 311.
- the mineral particles 311 have a high aspect ratio. That is, the aspect ratio defined by the width b / thickness a is high.
- the aspect ratio is obtained by measuring the thickness a and the width b of the mineral particles 311.
- the thickness a is measured by, for example, a transmission electron microscope (TEM), but since the thickness of the single layer of the mineral particles 311 is almost uniform for each type, it is not necessary to measure the thickness a for a large amount of mineral particles 311. ..
- the thickness a is about 1 nm.
- the width b is measured, for example, with an atomic force microscope (AFM). Observing the flat portion of the mineral particles 311, the longest dimension is estimated as the width b.
- AFM atomic force microscope
- FIG. 1C shows a schematic cross-sectional view of the clay layer 31.
- the clay layer 31 contains mineral particles 311 and a binder 312. That is, the clay layer 31 may be composed of the mineral particles 311 and the binder 312, or may contain the mineral particles 311 and the binder 312 and other additives.
- the binder 312 is one or more selected from a group of polyethylene, polypropylene, polyethylene sulfide, polyimide, polyamide, polyethylene terephthalate, epoxy resin, fluororesin, polyester resin, polyurethane resin, acrylic resin, phenoxy resin, polyacetal, and polyvinyl alcohol. include. Further, the binder 312 may be a binder resin that can be used as a varnish for paints and slurries.
- the binder 312 is preferably a polyamide, polyimide, polyurethane resin, epoxy resin, or phenoxy resin in consideration of the ease of forming the clay layer 31 and the adhesion to the mineral particles 311. Further, a suitable curing agent (crosslinking agent) may be used for the above resin. In this case, the binder 312 is formed of the crosslinked resin, and the moisture resistance of the clay layer 31 may be improved.
- the clay layer 31 is formed by dispersing a plurality of mineral particles 311 in the binder 312.
- the mineral particles 311 are dispersed in a state in which the thickness direction thereof substantially coincides with the thickness direction of the clay layer 31.
- the clay layer 31 has a maze-like structure (maze structure) in which a plurality of mineral particles 311 are formed as a passage.
- the plurality of mineral particles 311 are dispersed in a state of being substantially randomly located in the width direction while the thickness direction coincides with the thickness direction of the clay layer 31, and therefore the adjacent mineral particles 311.
- the space is formed like a zigzag passage. Therefore, when the water W passes through the clay layer 31 in the thickness direction, it cannot move linearly and must move in a zigzag manner through between adjacent mineral particles 311 (FIG. 1C). See dotted line). Therefore, the clay layer 31 is less likely to allow moisture W to pass through than a resin layer containing no mineral particles (a layer containing only a binder), and even if the thickness of the laminate 30 is reduced, the moisture resistance of the capacitor 10 is ensured. Can be done.
- the capacitor 10 of the present embodiment may have a moisture resistance of 1000 times or more that of the laminated body of the resin alone.
- P / P0 (1- ⁇ ) / (1 + 0.5A ⁇ ) ... (1)
- P / P0 indicates the specific transmittance.
- ⁇ indicates the volume fraction of the mineral particles 311 in the clay layer 31.
- A indicates the aspect ratio of the mineral particles 311.
- the laminated body 30 in order to obtain the laminated body 30 through which moisture does not easily pass in order to improve the moisture resistance performance of the capacitor 10, it is preferable to increase the volume fraction of the mineral particles 311 in the clay layer 31, and the mineral having a high aspect ratio. It is preferable to increase the content of the particles 311.
- the aspect ratio of the mineral particles 311 is preferably 20 or more. In order to obtain the clay layer 31 through which moisture does not easily pass, it is preferable to use mineral particles 311 having a higher aspect ratio, but other performances of the clay layer 31, for example, strength, adhesion and formation of the clay layer 31. The above range is preferable in consideration of ease of use and the like.
- the aspect ratio of the mineral particles 311 is more preferably 100 or more, and further preferably 150 or more.
- the upper limit of the aspect ratio of the mineral particles 311 is not particularly set, and is appropriately set in consideration of the dispersibility of the mineral particles 311 in the clay layer 31 and the like.
- the mineral particles 311 may be used in combination with a material having a high aspect ratio and a material having a low aspect ratio.
- the material having a low aspect ratio (mineral particles having a small diameter) can easily enter between the materials having a high aspect ratio, and the filling rate of the mineral particles 311 in the clay layer 31 can be improved.
- the material having a high aspect ratio occupies at least half of the total amount of the mineral particles 311 contained in the clay layer 31.
- the content of the mineral particles 311 in the clay layer 31 is 50% by mass or more with respect to the total amount.
- the content of the mineral particles 311 is 50% by mass or more and 95% by mass or less with respect to the total amount of the clay layer 31, and the binder 312 is contained.
- the ratio is preferably 5% by mass or more and 50% by mass or less with respect to the total amount of the clay layer 31. This makes it easier to obtain the clay layer 31 through which moisture does not easily pass, while ensuring the strength, adhesion, and ease of formation of the clay layer 31.
- the thickness of the clay layer 31 is preferably 0.5 ⁇ m or more and 5 ⁇ m or less.
- the thickness of the clay layer 31 is more preferably 1.0 ⁇ m or more and 3 ⁇ m or less.
- the clay layer 31 not only has low moisture permeability, but also has low gas permeability, which makes it easy to ensure the gas barrier property of the laminated body 30.
- the laminate 30 is created by forming an adhesive layer 32 on the surface of the base material layer 33 and forming a clay layer 31 on the surface of the adhesive layer 32.
- the adhesive layer 32 is obtained by supplying a treatment liquid containing a resin constituting the adhesive layer 32 onto the surface of the base material layer 33 and drying the treatment liquid on the surface of the base material layer 33.
- the resin constituting the adhesive layer 32 is dispersed or dissolved in the solvent.
- the solvent water, an organic solvent and a mixed solvent thereof can be used, but the solvent is preferably water from the viewpoint of ease of handling such as waste liquid treatment.
- a coating method such as gravure coating, roll coater, die coater, brush coating, spraying, dipping, etc. and a dipping method can be adopted.
- a coating method such as gravure coating, roll coater, die coater, brush coating, spraying, dipping, etc. and a dipping method.
- the treatment liquid is dried, natural drying, heat drying, or the like can be adopted.
- the clay layer 31 is obtained by supplying a treatment liquid containing mineral particles 311 and a binder 312 onto the surface of the adhesive layer 32 and drying the treatment liquid on the surface of the adhesive layer 32.
- mineral particles 311 and binder 312 are dispersed in a solvent.
- the solvent water, an organic solvent and a mixed solvent thereof can be used, but the solvent is preferably water from the viewpoint of ease of handling such as waste liquid treatment.
- a coating method such as brush coating or spray coating or a dipping method such as dipping can be adopted.
- a coating method such as brush coating or spray coating or a dipping method such as dipping
- the treatment liquid is dried, natural drying, heat drying, or the like can be adopted.
- the clay layer (clay layer) 31 capable of exhibiting high moisture resistance can be mounted even with a thin film (several to several tens of ⁇ m), and the moisture resistance of the laminated body 30 can be improved. Can be secured.
- the adhesive layer 32 on the base material layer 33 it is preferable to perform corona treatment on the adhesive layer 32 before forming the clay layer 31.
- a polar group hydrophilic functional group
- the corona treatment is performed by causing a corona discharge in the air. Oxygen molecules dissociate into oxygen ions and oxygen radicals due to the corona discharge. The oxygen ions and oxygen radicals chemically react on the surface of the adhesive layer 32, and as a result, hydrophilic functional groups are generated on the surface of the adhesive layer 32.
- the hydrophilic functional group include a carbonyl group and a hydroxyl group.
- the laminate 30 preferably has an aluminum layer or a polyvinyl alcohol layer on the other surface.
- the other surface is the surface of the two surfaces of the base material layer 33 arranged in the thickness direction, which is not provided with the adhesive layer 32 and the clay layer 31.
- the laminate 30 preferably has an aluminum layer or a polyvinyl alcohol layer on the surface of the base material layer 33 opposite to the surface on which the adhesive layer 32 and the clay layer 31 are provided. As a result, the moisture permeability of the laminated body 30 is further reduced.
- the electronic component 1 includes an electronic component element 2 and a barrier film.
- the barrier film contains the laminate 30. That is, the laminate 30 having the base material layer 33, the adhesive layer 32, and the clay layer 31 is used as the barrier film.
- the electronic component element 2 is a component or part for exhibiting the desired function of the electronic component 1.
- the electronic component element 2 has external electrodes 24 at both ends.
- the laminated body 30 has a function of protecting the electronic component element 2.
- the laminate 30 has a function of protecting the electronic component element 2 from moisture. Further, the laminated body 30 may have a function of protecting the electronic component element 2 from heat, light, electromagnetic waves, shocks, chemicals and the like.
- the laminate 30 covers at least a part of the periphery of the electronic component element 2.
- the laminate 30 is formed so as to cover the entire electronic component element 2 except for the portion of the external electrode 24, for example.
- the laminate 30 can be provided in contact with the surface of the electronic component element 2.
- the clay layer 31 is arranged so as to face the electronic component element 2. That is, it is preferable that the laminated body 30 covers the periphery of the electronic component element 2 so that the clay layer 31 is located inside (toward the electronic component element 2) when viewed from the position of the base material layer 33.
- the clay layer 31 has higher adhesion to the electronic component element 2 than the base material layer 33. Therefore, by arranging the laminated body 30 with the clay layer 31 facing toward the electronic component element 2, the clay layer 31 and the electronic component element 2 can be easily brought into close contact with each other, and moisture can penetrate into the electronic component element 2. It becomes easy to reduce.
- the electronic component 1 may further include an exterior resin layer 4 that covers the electronic component element 2 and the laminate 30.
- the exterior resin layer 4 has a function of protecting the electronic component element 2 and the laminate 30 from moisture. Further, the exterior resin layer 4 may have a function of protecting the electronic component element 2 and the laminate 30 from heat, light, electromagnetic waves, impacts, chemicals and the like.
- the exterior resin layer 4 is formed of one or both of the case (container) and the mold resin.
- the electronic component 1 may further include a bus bar 6.
- the bus bar 6 is a terminal for electrically connecting the electronic component 1 to a circuit board or the like.
- One end (base end) of the bus bar 6 is electrically and mechanically connected to the external electrode 24 of the electronic component element 2.
- the other end (tip) of the bus bar 6 is located outside the exterior resin layer 4.
- the bus bar 6 is made of, for example, copper or a copper alloy and is formed in a plate shape.
- the electronic component 1 of the present embodiment includes a pair of bus bars 6, and the tip of each bus bar 6 projects outward (for example, upward) from the same surface (for example, the upper surface) of the exterior resin layer 4.
- the shape and structure are not limited.
- the electronic component 1 according to the present embodiment has the clay layer 31 containing clay in the laminated body 30 covering the electronic component element 2, the laminated body is compared with the resin layer having the same thickness formed by the resin alone.
- the amount of water passing through 30 is likely to be reduced. Therefore, the amount of water reaching the electronic component element 2 from the outside of the electronic component 1 is reduced, the moisture is less likely to act on the electronic component element 2, and the electronic component 1 having excellent moisture resistance can be easily obtained.
- the clay layer 31 can be formed on the surface of the base material layer 33 by a simple means such as coating, the manufacturing process of the electronic component 1 is less complicated, and the cost can be easily reduced.
- the electronic component 1 which is the capacitor 10 includes the capacitor element 20 as the electronic component element 2. That is, the electronic component element 2 in the capacitor 10 is the capacitor element 20.
- the capacitor element 20 various capacitor elements are used depending on the type of the capacitor 10.
- the capacitor 10 include a film capacitor, a ceramic capacitor, an electrolytic capacitor, and the like.
- the capacitor 10 is preferably a film capacitor, and further, among the film capacitors, it is preferable that the winding type capacitor element 20 is used.
- the laminated body 30 can be wound around the capacitor element 20 by the same device and procedure as that for manufacturing the winding type capacitor element 20, and the capacitor element 20 around which the laminated body 30 is wound can be easily manufactured. can do.
- the capacitor element 20 may be a laminated film capacitor.
- the capacitor element 20 has external electrodes 24 at both ends in the axial direction.
- the external electrode 24 is preferably formed by thermal spraying of a metal material. Further, the external electrode 24 preferably contains 50% by weight or more of tin. This type of external electrode 24 is usually formed by spraying zinc, but the external electrode 24 made of zinc tends to be porous, and moisture may infiltrate from the external electrode 24. Therefore, in the present embodiment, the tin content of the external electrode 24 is increased, which makes the metal structure constituting the external electrode 24 dense and makes it difficult for water to pass through the external electrode 24, so that the capacitor element 20 The infiltration of water into the water is reduced.
- the metal structure constituting the external electrode 24 becomes dense, so that the adhesion between the laminated body 30 and the external electrode 24 can be improved, and the adhesion to the capacitor element 20 can be improved.
- the infiltration of water can be further reduced.
- the tin content of the external electrode 24 may be in the range of 50% by weight or more and 100% by weight.
- the laminated body 30 is a barrier film. That is, the laminated body 30 has a function of protecting the capacitor element 20 from moisture. Further, the laminated body 30 may have a function of protecting the capacitor element 20 from heat, light, electromagnetic waves, shocks, chemicals and the like.
- the laminated body 30 covers at least a part around the capacitor element 20.
- the periphery of the capacitor element 20 means the axis of the capacitor element 20 when the opposite direction of the pair of external electrodes 24 is the axis.
- the laminated body 30 is arranged so as to face the peripheral surface of the capacitor element 20. Therefore, the laminated body 30 is formed so as to cover the entire capacitor element 20 except for the portion of the external electrode 24. That is, the capacitor element 20 is protected by being almost entirely covered with the laminated body 30 except for the portion of the external electrode 24. As a result, it becomes difficult for moisture to enter the capacitor element 20 from all around, and the moisture resistance of the capacitor 10 is improved.
- the laminated body 30 is provided so as to surround at least the peripheral surface of the capacitor element 20. Is preferable. As described above, the laminate 30 is provided so as to cover at least a part of the periphery of the capacitor element 20, but the “at least a part” here means, for example, the outer surface of the capacitor element 20 excluding the external electrode 24. It is preferably 80% or more of the surface area.
- the laminate 30 is preferably arranged so as to form a plurality of layers around the capacitor element 20. That is, it is preferable that the plurality of laminated bodies 30 are provided around the capacitor element 20 in a state of being overlapped in the thickness direction. In this case, a plurality of clay layers 31 are laminated, and the moisture resistance of the capacitor 10 is improved as compared with the single clay layer 31. Further, even if a defect such as a pinhole is present in the clay layer 31, the defect can be covered by overlapping the other clay layers 31, and the moisture resistance performance of the capacitor 10 is not easily impaired.
- the exterior resin layer 4 covers at least a part of the capacitor element 20 and the laminate 30.
- the exterior resin layer 4 preferably covers the entire capacitor element 20 and the laminate 30, and in this case, the entire capacitor element 20 and the laminate 30 are sealed with the exterior resin layer 4.
- the clay layer 31 and the exterior resin layer 4 are laminated. That is, the clay layer 31 and the exterior resin layer 4 are arranged so as to face each other in the thickness direction of the laminated body 30.
- the thickness of the exterior resin layer 4 is preferably larger than the thickness of the clay layer 31. As a result, the clay layer 31 having a thin thickness and being easily cracked can be easily protected by the exterior resin layer 4.
- the thickness of the exterior resin layer 4 is preferably 1 mm or more and 6 mm or less.
- the thickness of the exterior resin layer 4 is more preferably 1 mm or more and 4.5 mm or less, and further preferably 1 mm or more and 3 mm or less.
- the resin contained in the exterior resin layer 4 examples include an epoxy resin, an unsaturated polyester resin, and a polyimide resin. However, considering the moldability when coating the condenser element 20, the epoxy resin is used. preferable. Further, the exterior resin layer 4 may be formed of only the resin, but the exterior resin layer 4 may be formed of a composite material containing the resin and the filler. In this case, for example, silica or the like can be used as the filler, and the content of the filler with respect to the total amount of the exterior resin layer 4 can be 1% by mass or more and 99% or less.
- FIG. 3A shows a capacitor 10 in which the position of the laminated body 30 is different from that of FIG. 2A.
- the capacitor 10 includes a laminate 30 and an exterior resin layer 4, but the laminate 30 is provided so as not to contact the surface of the capacitor element 20 and to cover the periphery of the exterior resin layer 4. ..
- the exterior resin layer 4 is located between the capacitor element 20 and the laminated body 30. Therefore, the exterior resin layer 4 is located closer to the electronic component element 2 (capacitor element 20) than the laminate 30.
- the laminate 30 is in contact with the surface of the exterior resin layer 4.
- the capacitor element 20 is also covered with the laminated body 30 via the exterior resin layer 4, and the laminated body 30 makes it difficult for moisture to reach the capacitor element 20, reducing the moisture absorption of the capacitor element 20 and reducing the moisture absorption of the capacitor 10. Moisture resistance is improved.
- FIG. 3B shows a capacitor 10 in which the position of the laminated body 30 is different from that of FIGS. 2A and 3A.
- the capacitor 10 includes a laminate 30 both on the surface of the capacitor element 20 and on the surface of the exterior resin layer 4. That is, the laminated body 30 includes a first laminated body 30a arranged in contact with the surface of the capacitor element 20, and a second laminated body 30b arranged in contact with the surface of the exterior resin layer 4. .. Therefore, the exterior resin layer 4 is provided between the first laminated body 30a and the second laminated body 30b.
- the capacitor element 20 is covered with the first laminated body 30a, the second laminated body 30b, and the exterior resin layer 4, and the two laminated bodies 30 make it difficult for moisture to reach the capacitor element 20, and the capacitor element 20.
- the moisture absorption of 20 is further reduced, and the moisture resistance of the capacitor 10 is improved.
- the manufacturing method of the electronic component 1 is a step of forming the electronic component element 2 and a step of winding the laminate 30 around at least a part of the periphery of the electronic component element 2. And.
- the electronic component 1 is a capacitor 10
- it is a method for manufacturing a capacitor 10 including a step of forming a capacitor element 20 and a step of winding a laminate 30 around at least a part of the periphery of the capacitor element 20.
- the method for manufacturing the electronic component 1 or the capacitor 10 according to the present embodiment may further include a step of covering the capacitor element 20 with the exterior resin layer 4.
- the winding type capacitor element 7, which is the capacitor element 20, is manufactured by winding the metallized films 71 and 72 to form the winding body 73 and forming the laminated body 30 on at least a part around the winding body 73. It includes a step of winding and a step of spraying a metal material on both ends of the winding body 73 around which the laminated body 30 is wound to form an external electrode 24.
- the winding type capacitor element 7 can be manufactured as follows.
- the first metallized film 71 and the second metallized film 72 are prepared (see FIG. 4A).
- the first metallized film 71 has a first dielectric film 701 and a first conductive layer 711.
- the first dielectric film 701 is a long object.
- a first conductive layer 711 is formed on one side of the first dielectric film 701 except for the first margin portion 721.
- the first margin portion 721 is a portion where the first dielectric film 701 is exposed, and is formed along one long side of the first dielectric film 701 in a strip shape thinner than the first conductive layer 711. There is.
- the second metallized film 72 is formed in the same manner as the first metallized film 71. That is, the second metallized film 72 has a second dielectric film 702 and a second conductive layer 712.
- the second dielectric film 702 is a long object having the same width as the first dielectric film 701.
- a second conductive layer 712 is formed on one side of the second dielectric film 702 except for the second margin portion 722.
- the second margin portion 722 is a portion where the second dielectric film 702 is exposed, and is formed along one long side of the second dielectric film 702 in a strip shape thinner than the second conductive layer 712. There is.
- the first dielectric film 701 and the second dielectric film 702 are made of the same type of resin as the base material layer 33 of the laminate 30.
- the first dielectric film 701 and the second dielectric film 702 are made of polypropylene, polyethylene terephthalate, polyethylene naphthalate, polyphenyl sulfide, polystyrene, or the like.
- the first conductive layer 711 and the second conductive layer 712 are formed by a method such as a thin film deposition method or a sputtering method.
- the first conductive layer 711 and the second conductive layer 712 are made of, for example, aluminum, zinc, magnesium, or the like.
- the two long sides of each of the first metallized film 71 and the second metallized film 72 are aligned and overlapped.
- the first dielectric film 701 or the second dielectric film 702 is interposed between the first conductive layer 711 and the second conductive layer 712. Further, the long side on which the first margin portion 721 is formed and the long side on which the second margin portion 722 is formed are reversed.
- the wound body 73 is covered with the laminated body 30 by winding the laminated body 30 around the outer periphery of the wound body 73.
- the laminated body 30 may be wound only once (one roll) or may be wound a plurality of times.
- the side surface of the winding body 73 is pressed from both sides to process the winding body 73 having an elongated cross section (see FIG. 4B). By flattening in this way, space can be saved. In this way, the element main body 2a made of the winding body 73 can be covered with the laminated body 30.
- the wound capacitor element 7 can be obtained by forming the first external electrode 21 and the second external electrode 22 as the external electrodes 24 at both ends of the winding body 73 by a metallikon (metal spraying method). ..
- the first external electrode 21 is electrically connected to the first conductive layer 711 (first internal electrode).
- the second external electrode 22 is electrically connected to the second conductive layer 712 (second internal electrode).
- the first conductive layer 711 and the second conductive layer 712 form a pair of internal electrodes.
- the first external electrode 21 and the second external electrode 22 are formed of, for example, tin, zinc, or a metal material containing them as a main component.
- the first bus bar 61 is electrically connected to the first external electrode 21, and the second bus bar 62 is electrically connected to the second external electrode 22.
- this connection method include solder welding, resistance welding, and ultrasonic welding.
- the first bus bar 61 and the second bus bar 62 are formed of, for example, copper or a copper alloy in a plate shape.
- the process is rational and can be simplified. Further, when it is necessary to remove metal debris adhering to a portion other than the formed portion of the external electrode 24 (for example, around the capacitor element 20) after the step of spraying the metal material, a laminate is formed around the capacitor element 20.
- the base material layer 33 of 30 is wound so as to be located at the outermost position, and the metal debris adhering to the base material layer 33 can be easily removed. The work of removing such metal debris is performed by scrub polishing or the like.
- the laminated capacitor element 8 which is the capacitor element 20 can be manufactured, for example, as follows. First, the first metallized film 81 and the second metallized film 82 are prepared (see FIG. 5A).
- the first metallized film 81 has a first dielectric film 801 and a first conductive layer 811.
- the first dielectric film 801 has a rectangular shape.
- a first conductive layer 811 is formed on one side of the first dielectric film 801 except for the first margin portion 821.
- the first margin portion 821 is formed in a strip shape thinner than the first conductive layer 811 along one side of the first dielectric film 801.
- the second metallized film 82 is formed in the same manner as the first metallized film 81. That is, the second metallized film 82 has a second dielectric film 802 and a second conductive layer 812.
- the second dielectric film 802 has a rectangular shape having the same size as the first dielectric film 801.
- a second conductive layer 812 is formed on one side of the second dielectric film 802 except for the second margin portion 822.
- the second margin portion 822 is formed in a strip shape thinner than the second conductive layer 812 along one side of the second dielectric film 802.
- the first dielectric film 801 and the second dielectric film 802 are made of the same type of resin as the base material layer 33 of the laminate 30.
- the first dielectric film 801 and the second dielectric film 802 are made of polypropylene, polyethylene terephthalate, polyethylene naphthalate, polyphenyl sulfide, polystyrene, or the like.
- the first conductive layer 811 and the second conductive layer 812 are formed by a method such as a thin film deposition method or a sputtering method.
- the first conductive layer 811 and the second conductive layer 812 are made of, for example, aluminum, zinc, magnesium, or the like.
- the four sides of the first metallized film 81 and the second metallized film 82 are aligned and stacked alternately.
- the first dielectric film 801 or the second dielectric film 802 is interposed between the first conductive layer 811 and the second conductive layer 812. Further, one side on which the first margin portion 821 is formed and one side on which the second margin portion 822 is formed are opposed to each other.
- the first margin portion 821 is arranged at the rear and the second margin portion 822 is arranged at the front.
- the laminate 83 is covered with a protective film 84 except for the front surface and the rear surface.
- the protective film 84 is a film having an electrical insulating property.
- the protective film 84 may be formed of the laminated body 30.
- the laminated capacitor element 8 can be obtained by forming the first external electrode 21 and the second external electrode 22 on the front surface and the rear surface of the laminated body 83 by metallikon (metal spraying method), respectively (see FIG. 5D). ).
- the first external electrode 21 is electrically connected to the first conductive layer 811 (first internal electrode).
- the second external electrode 22 is electrically connected to the second conductive layer 812 (second internal electrode).
- the first conductive layer 811 and the second conductive layer 812 serve as a pair of internal electrodes.
- the first external electrode 21 and the second external electrode 22 are made of, for example, zinc.
- the first bus bar 61 is electrically connected to the first external electrode 21, and the second bus bar 62 is electrically connected to the second external electrode 22.
- this connection method include solder welding, resistance welding, and ultrasonic welding.
- the first bus bar 61 and the second bus bar 62 are formed of, for example, copper or a copper alloy in a plate shape.
- the step of forming the exterior resin layer 4 is performed.
- the capacitor element 20 to which the bus bar 6 is connected is sealed with a resin to form the exterior resin layer 4.
- the resin include an epoxy resin, an unsaturated polyester resin, a polyimide resin, a urethane resin, and a silicone resin.
- the molding method for covering the capacitor element 20 include transfer molding, compression molding, and laminating molding.
- the capacitor element 20 may be housed and sealed in the case having the exterior resin layer 4.
- the exterior resin layer 4 is formed so as to cover the entire capacitor element 20 except for the connection portion of the capacitor element 20 with the bus bar 6.
- the tip of the bus bar 6 is located on the outside of the exterior resin layer 4 (on the opposite side of the capacitor element 20).
- the laminate 30 is provided on the surface of the exterior resin layer 4, if necessary.
- the winding body 73 may be covered with the laminated body 30.
- the winding body 73 and the second external electrode 22 are formed after the first external electrode 21 and the second external electrode 22 are formed on the winding body 73. 1
- the external electrode 21 and the second external electrode 22 may be covered with the laminated body 30.
- the laminated body 30 is a wound body before forming the first external electrode 21 and the second external electrode 22. 73 may be covered.
- the width of the laminated body 30 is made 1 to 2 mm larger than the width of the metallized films 71 and 72 forming the wound body 73, and the end portion of the laminated body 30 is larger than the axial end surface of the wound body 73. Make it stick out. Then, the formation of the first external electrode 21 and the second external electrode 22 by metal spraying is performed on the axial end face of the wound body 73 in the space surrounded by the end portions of the laminated body 30.
- the laminated body (30) has a base material layer (33), an adhesive layer (32), and a clay layer (31).
- the base material layer (33) contains a crystalline resin.
- the adhesive layer (32) contains a resin different from the crystalline resin, and is provided on one of the surfaces of the base material layer (33).
- the clay layer (31) is provided on one surface of the base material layer (33) via the adhesive layer (32).
- the adhesive development temperature of the adhesive layer (32) is 130 ° C. or lower.
- the laminated body (30) has a good water vapor barrier property due to the base material layer (33) containing the crystalline resin, and the base material layer (33) and the clay layer (31) due to the adhesive layer (32). It has the advantage of excellent adhesion to.
- the second aspect is the laminate (30) according to the first aspect, in which the adhesive layer (32) contains an amorphous resin.
- the third aspect is the laminate (30) according to the first aspect, wherein the adhesive layer (32) contains a resin having a polar group.
- the fourth aspect is the laminate (30) according to any one of the first to third aspects, and the crystalline resin is polypropylene.
- the fifth aspect is the laminate (30) according to any one of the first to fourth aspects, and the base material layer (33) is a biaxially stretched polypropylene film.
- the sixth aspect is the laminate (30) according to any one of the first to fifth aspects, and has an aluminum layer or a polyvinyl alcohol layer on the other surface of the base material layer (33).
- the electronic component (1) according to the seventh aspect includes an electronic component element (2) and a barrier film that covers at least a part of the periphery of the electronic component element (2).
- the barrier film includes the laminate (30).
- the electronic component element (2) of the electronic component (1) according to the seventh aspect includes the capacitor element (20).
- a ninth aspect is the capacitor (10) according to the eighth aspect, wherein the capacitor element (20) has a conductive layer (711, 712, 811,) on a dielectric film (701, 702, 801, 802). It has a pair of metallized films (71, 72, 81, 82) forming 812), and the pair of metallized films (71, 72, 81, 82) has a conductive layer (711, 712, 811, 812). Is wound so as to face each other via a dielectric film (701, 702, 801, 802), and the dielectric film (71, 72, 81, 82) is formed with a resin constituting the base material layer (33). It is composed of the same type of resin.
- Example 1 As the clay material, Kunipia F (manufactured by Kunimine Kogyo) was used.
- As the binder water-soluble nylon A-90 (manufactured by Toray Industries, Inc.) was used.
- a treatment liquid (clay coating liquid) was prepared by mixing a clay material, a binder, and a solvent. The contents of the treatment liquid were 6 wt% for clay material and binder, 81 wt% for water, and 13 wt% for ethanol. The mixing ratio (weight ratio) of the clay material and the binder is shown in Table 1.
- a polypropylene film (thickness 24 ⁇ m) having a base material layer and an adhesive layer was subjected to corona treatment, and then a treatment liquid was applied to the surface of the adhesive layer with an applicator, and then dried.
- the film thickness of the clay layer after drying was 1 ⁇ m.
- the adhesive layer is low melting point polypropylene, has a melting point of 130 ° C., and has an adhesive development temperature of 90 ° C.
- the drying conditions were changed in each example as shown in Table 1.
- the film adhesion evaluation of the clay layer (JIS K 5600-5-6 compliant) was performed. That is, cuts were made in the clay layer at intervals of 2 mm, and the clay layer was peeled off with tape.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Dispersion Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Fixed Capacitors And Capacitor Manufacturing Machines (AREA)
- Laminated Bodies (AREA)
Abstract
Description
まず、本実施形態に係る積層体に至った経緯について説明する。
(2-1)積層体
本実施形態に係る積層体30は、図1Aに示すように、基材層33と接着層32と粘土層31とを有している。基材層33は、結晶性樹脂を含んでいる。接着層32は、基材層33に含まれている結晶性樹脂とは異なる樹脂を含んでいる。また接着層32は、基材層33の一方の面(表面)に設けられている。粘土層31は接着層32を介して基材層33の一方の面に設けられている。積層体30は、例えば、フィルム、シート及び板などの形態を有している。
基材層33は、結晶性樹脂を含んでいる。基材層33として使用される樹脂としては、ポリエチレン、ポリプロピレン、ポリエチレンテレフタレート、ポリアミド、フッ素樹脂、アクリル樹脂、ポリイミド、ポリエチレンナフタレート、ポリメチルペンテン、シクロオレフィン、ポリアリレート、ポリエーテルエーテルケトン、ポリフェニレンスルフィッド、シンジオタクティックポリスチレン系、エポキシ樹脂などが例示される。基材層33は、上記例示された一種又は複数種の結晶性樹脂を含んでいる。基材層33は、上記例示された複数種の結晶性樹脂の中でも、水蒸気バリア性の良好なポリプロピレンを含んでいることが好ましい。水蒸気バリア性とは、水蒸気が通過しにくい性質を言う。例えば、ポリプロピレン製のフィルムは、水蒸気通過度が4~5g/(m2・d)程度であり、良好な水蒸気バリア性を有している。
接着層32は基材層33と粘土層31とを接着するための層である。基材層33と粘土層31は、接着層32により接着され、密着性が優れる。ここで、「密着性が優れる」とは、JIS K 5600-5-6に準拠した評価法(クロスカット法)で、粘土層31が接着層32及び基材層33から剥がれないことを言う。
粘土層31は粘土を含んで層状に形成されている。本開示において、粘土とは、複数の鉱物粒子311の集合体である。また粘土は、複数の鉱物粒子311の集合体に少量の水を含んでいてもよい。鉱物粒子311は、雲母、バーミキュライト、モンモリロナイト、鉄モンモリロナイト、バイデライト、サポナイト、ヘクトライト、スチーブンサイト、ノントロナイトの群れから選択される1種以上を含む。この中でも、鉱物粒子311は、高耐湿粘土材料であるモンモリロナイトを含むことが好ましい。
上記式(1)において、「P/P0」は比透過度を示す。「Φ」は粘土層31における鉱物粒子311の体積分率を示す。Aは鉱物粒子311のアスペクト比を示す。
積層体30は、基材層33の表面上に接着層32を形成し、接着層32の表面上に粘土層31を形成することにより作成される。
図2A~図2Dに示すように、本実施形態に係る電子部品1は、電子部品素子2と、バリアフィルムとを備える。前記バリアフィルムは、上記積層体30を含んでいる。すなわち、上記基材層33と接着層32と粘土層31とを有する積層体30がバリアフィルムとして使用される。
以下、電子部品1がコンデンサ10の場合について説明する。コンデンサ10である電子部品1は、電子部品素子2としてコンデンサ素子20を含む。すなわち、コンデンサ10における電子部品素子2はコンデンサ素子20である。
電子部品1の製造方法は、電子部品素子2を形成する工程と、電子部品素子2の周囲の少なくとも一部に積層体30を巻回する工程と、を備える。電子部品1がコンデンサ10である場合は、コンデンサ素子20を形成する工程と、コンデンサ素子20の周囲の少なくとも一部に積層体30を巻回する工程と、を備えるコンデンサ10の製造方法である。本実施形態に係る電子部品1又はコンデンサ10の製造方法は、さらに、コンデンサ素子20を外装樹脂層4で被覆する工程を備えていてもよい。
上記では、電子部品がコンデンサである場合について説明されているが、これに限られない。本開示は、電子部品がコンデンサ以外の受動部品又は能動部品であっても適用可能である。コンデンサ以外の受動部品又は能動部品は、それぞれ、電子部品の種類に応じた受動素子又は能動素子をコンデンサ素子の代わりに備えている。
第1の態様に係る積層体(30)は、基材層(33)と接着層(32)と粘土層(31)とを有する。基材層(33)は、結晶性樹脂を含む。接着層(32)は、結晶性樹脂とは異なる樹脂を含み、基材層(33)の前記一方の面に設けられている。粘土層(31)は、接着層(32)を介して基材層(33)の前記一方の面に設けられている。接着層(32)の粘着性発現温度が130℃以下である。
粘土材料としては、クニピアF(クニミネ工業製)を使用した。バインダとしては、水溶性ナイロンA-90(東レ製)を使用した。粘土材料とバインダと溶媒とを混合することにより処理液(粘土塗工液)を調製した。処理液の内容は、粘土材料とバインダが合計で6wt%、水が81wt%、エタノールが13wt%とした。粘土材料とバインダとの混合比率(重量比)は表1に示す。
接着層を有さないポリプロピレンフィルム(基材層のみ)を使用した以外は、実施例1,2と同様にして膜密着性評価を行った。
10 コンデンサ
2 電子部品素子
20 コンデンサ素子
30 積層体
31 粘土層
32 接着層
33 基材層
71、72、81、82 金属化フィルム
701、702、801、802 誘電体フィルム
711、712、811、812 導電層
Claims (9)
- 結晶性樹脂を含む基材層と、
前記結晶性樹脂とは異なる樹脂を含み、前記基材層の一方の面に設けられている接着層と、
前記接着層を介して前記基材層の前記一方の面に設けられている粘土層と、を有し、
前記接着層の粘着性発現温度が130℃以下である、
積層体。 - 前記接着層が、非晶質の樹脂を含む、
請求項1に記載の積層体。 - 前記接着層が、極性基を有する樹脂を含む、
請求項1に記載の積層体。 - 前記結晶性樹脂が、ポリプロピレンである、
請求項1~3のいずれか1項に記載の積層体。 - 前記基材層が、二軸延伸ポリプロピレンフィルムである、
請求項1~4のいずれか1項に記載の積層体。 - 前記基材層の他方の面にアルミニウム層又はポリビニルアルコール層を有する、
請求項1~5のいずれか1項に記載の積層体。 - 電子部品素子と、
前記電子部品素子の周囲の少なくとも一部を被覆するバリアフィルムと、を備え、
前記バリアフィルムが、請求項1~6のいずれか1項に記載の積層体を含む、
電子部品。 - 請求項7に記載の電子部品の前記電子部品素子が、コンデンサ素子を含む、
コンデンサ。 - 前記コンデンサ素子が、誘電体フィルム上に導電層を形成した一対の金属化フィルムを有し、
前記一対の金属化フィルムは、前記導電層が前記誘電体フィルムを介して対向するように巻回されており、
前記誘電体フィルムが前記基材層を構成する樹脂と同種の樹脂で構成されている、
請求項8に記載のコンデンサ。
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JP2005035167A (ja) * | 2003-07-15 | 2005-02-10 | Daicel Chem Ind Ltd | ガスバリア性フィルム |
WO2010024378A1 (ja) * | 2008-08-29 | 2010-03-04 | 独立行政法人産業技術総合研究所 | 酸化ケイ素薄膜または酸窒化ケイ素化合物薄膜の製造方法およびこの方法で得られる薄膜 |
JP2013133236A (ja) * | 2011-12-26 | 2013-07-08 | Sumitomo Chemical Co Ltd | 無機膜および多層構造体 |
JP2019014609A (ja) * | 2017-07-03 | 2019-01-31 | 日本ケミコン株式会社 | 無機化合物の製造方法および封止材の製造方法 |
JP2019156972A (ja) * | 2018-03-13 | 2019-09-19 | 三井化学株式会社 | ポリウレタンディスパージョンおよびポリウレタン積層体 |
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Patent Citations (5)
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JP2005035167A (ja) * | 2003-07-15 | 2005-02-10 | Daicel Chem Ind Ltd | ガスバリア性フィルム |
WO2010024378A1 (ja) * | 2008-08-29 | 2010-03-04 | 独立行政法人産業技術総合研究所 | 酸化ケイ素薄膜または酸窒化ケイ素化合物薄膜の製造方法およびこの方法で得られる薄膜 |
JP2013133236A (ja) * | 2011-12-26 | 2013-07-08 | Sumitomo Chemical Co Ltd | 無機膜および多層構造体 |
JP2019014609A (ja) * | 2017-07-03 | 2019-01-31 | 日本ケミコン株式会社 | 無機化合物の製造方法および封止材の製造方法 |
JP2019156972A (ja) * | 2018-03-13 | 2019-09-19 | 三井化学株式会社 | ポリウレタンディスパージョンおよびポリウレタン積層体 |
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