WO2022202987A1 - フィラー配列フィルム - Google Patents
フィラー配列フィルム Download PDFInfo
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- WO2022202987A1 WO2022202987A1 PCT/JP2022/013939 JP2022013939W WO2022202987A1 WO 2022202987 A1 WO2022202987 A1 WO 2022202987A1 JP 2022013939 W JP2022013939 W JP 2022013939W WO 2022202987 A1 WO2022202987 A1 WO 2022202987A1
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- article
- film
- density
- unevenly distributed
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
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- G—PHYSICS
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- G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
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- G—PHYSICS
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- G09F9/30—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements in which the desired character or characters are formed by combining individual elements
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- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a 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
- H01L21/60—Attaching or detaching leads or other conductive members, to be used for carrying current to or from the device in operation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/62—Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
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- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/01—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the form or arrangement of the conductive interconnection between the connecting locations
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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Definitions
- the present invention provides a filler arrangement film in which fillers are arranged in a resin layer, a method for connecting a first fine article to a second article such as a substrate using the filler arrangement film, and a connected structure obtained by the method.
- minute light-emitting elements such as mini-LEDs and ⁇ LEDs can be cited as the minute first articles.
- a ⁇ LED display in which ⁇ LEDs, which are minute light-emitting elements, are arranged on a substrate can be made thinner by omitting the backlight required for a liquid crystal display. It is expected as a display that can realize power saving, and is also expected as a transparent display application. The same applies when used as a light source. Since it can be made lighter and thinner than before, performance improvements such as portability can be expected. In view of the so-called "telework" that has become active in recent years, various demands for displays are increasing, and it is expected that these demands will be met.
- Patent Document 1 discloses that red, blue, and green ⁇ LED arrays formed on a carrier substrate are picked up by a transfer head, placed on a transfer destination substrate such as a display substrate, and soldered. It describes joining a ⁇ LED array and a destination substrate by welding, and then forming a contact line thereon with ITO or the like.
- Patent Document 2 ⁇ LEDs formed on a wafer are arranged on a substrate, and an anisotropic conductive film in which conductive particles are dispersed in an adhesive component using a hydrogenated epoxy compound or the like is used to form the substrate. and a method for lifting off the wafer is described. According to the method using the anisotropic conductive film described in Patent Document 2, a display using ⁇ LEDs can be easily obtained.
- Patent Document 3 when connecting an IC chip and an FPC using an anisotropic conductive film having a conductive particle arrangement layer in which the area occupancy of conductive particles in a plan view is 35% or less, the capture efficiency of conductive particles is increased.
- a pulse heater type bonder is used, and in the first step, the IC chip and FPC are pressed into the insulating resin layer of the anisotropic conductive film to temporarily fix the electrodes close to the conductive particle arrangement layer.
- a two-stage connection method is described in which main crimping is performed on the eye.
- the size of the ⁇ LED becomes smaller for high-definition displays, and the size of the LED electrode also becomes smaller accordingly, when using an anisotropic conductive film in which conductive particles are simply mixed in an insulating material, individual ⁇ LEDs It becomes difficult to reliably capture the conductive particles on the electrodes.
- an object of the present invention is to provide a connecting structure of a first article and a second article by connecting a minute first article such as a ⁇ LED and a second article such as a substrate for a transparent display using a filler array film. and to provide a connection structure between a first article and a second article obtained by using such a filler arrangement film. Make it an issue.
- the inventor of the present invention uses a filler arrangement film in which fillers such as conductive particles are arranged in an insulating resin layer to connect minute connecting portions of a first article such as an electrode of a ⁇ LED to a second article such as an electrode of a substrate for a transparent display.
- the filler in the filler array film forms a high-density region that is regularly arranged corresponding to the arrangement of the first article, and in the high-density region, the filler connects the first article.
- the filler is less likely to affect the inside, the filler is reliably captured between the connecting portion of the first article and the connecting portion of the second article, and the filler prevents unnecessary short-circuiting between the adjacent connecting portions in the film surface direction. and when the first article is a light-emitting element such as a ⁇ LED, the filler is concentrated in the high-density region, so that the light from the light-emitting element passes through the portion other than the high-density region with high transmittance. Therefore, the inventors have conceived of improving the luminous efficiency of a light-emitting device in which light-emitting elements are mounted, and completed the present invention.
- the present invention provides a filler arrangement film in which a filler is arranged in an insulating adhesive layer, The high-density areas of the filler are regularly arranged at intervals, A plurality of unevenly distributed regions of filler are formed in each high-density region, Provided is a filler-arranged film having an average visible light transmittance of 40% or more.
- connection portion of each first article and the connection portion of the second article are arranged in a filler arrangement in an insulating resin layer.
- a connection method for connecting by heating or pressurizing through a film As a filler arrangement film, High-density filler regions are regularly arranged at intervals in the insulating adhesive layer, A plurality of unevenly distributed regions of filler are formed in each high-density region, Provided is a connection method using a filler-arranged film having an average visible light transmittance of 40% or more.
- the present invention provides a connection structure in which a plurality of first articles are arranged on a second article, and the connection portions of the individual first articles and the connection portions of the second article are connected via fillers.
- the filler forms a high density region corresponding to the arrangement of the first article.
- a connection structure in which fillers are unevenly distributed in a high-density region corresponding to a connection portion of a first article.
- the fine connecting portion of the first article such as the ⁇ LED electrode is heated or pressurized to the connecting portion of the second article such as the electrode of the transparent display substrate through the filler arrayed film.
- At least one filler is reliably captured between the connecting portion of the first article and the connecting portion of the second article, and the connecting portions that are adjacent in the film surface direction, that is, the first article.
- the first article is a light-emitting element such as a ⁇ LED
- the filler since the high-density regions of the filler are arranged in correspondence with the arrangement of the light-emitting elements, the filler hardly hinders the emission of light from the light-emitting element. . Therefore, the luminous efficiency of the light-emitting device mounted with the light-emitting element is improved.
- FIG. 1 is an arrangement diagram of fillers in a filler arrangement film 1A of an example.
- FIG. 2 is a diagram showing the correspondence between the arrangement of fillers in the filler arrayed film 1A of the example and the joints of articles connected by the filler arrayed film 1A.
- FIG. 3 is a cross-sectional view of the filler arrangement film 1A of the example.
- FIG. 4 is an arrangement diagram of fillers in the filler arrangement film 1B of the example.
- FIG. 1 is an arrangement diagram of fillers in a filler arrangement film 1A of one example of the present invention.
- This filler arrangement film is obtained by arranging conductive particles as fillers 2 in an insulating resin layer 10 .
- the filler array film may be used as an anisotropic conductive film or as a conductive film.
- the filler-arranged film of the present invention With the filler-arranged film of the present invention, a plurality of first articles are arranged on the second article, and the first article and the second article are heated or pressurized through the filler-arranged film to obtain individual first articles. and the connection part of the second article, and in this connected state, the filler is sandwiched between the connection part of the first article and the connection part of the second article, and the first article and the second article are adhered to each other by an insulating resin layer. Since this filler array film has an average visible light transmittance of 40% or more, the first article is a ⁇ LED, the electrode is a connection portion of the first article, and the second article is a transparent transparent wiring circuit formed with a wiring circuit for the ⁇ LED.
- the display substrate and its electrodes When used as the connection part of the second article, it can be used as an anisotropic conductive film for anisotropically conductively connecting the first article and the second article. Since the filler arrayed film of the present invention is used for connecting minute parts, it is necessary to be able to sufficiently visually recognize microscopic articles through the filler arrayed film before connection.
- the visible light transmittance of the filler array film is the average transmittance of visible light (wavelength 400 to 700 nm) measured using a visible light transmittance measuring device. Visible light transmittance is measured in the cured state of the film. For this average transmittance, for example, the transmittance of an area of 10 mm ⁇ 10 mm may be measured.
- the visible light transmittance can be measured in the range of 10 x 10 mm.
- a region of 10 ⁇ 10 mm is randomly measured at 5 points, preferably 10 points or more, and the visible light transmittance can be calculated from the average.
- the visible light transmittance was measured by setting the visible light transmittance measurement area so that the number density of the conductive particles in the same area was within a range of about ⁇ 10% with respect to the average number density.
- the range of 10 ⁇ 10 mm can be a range (connection area) in which multiple ⁇ LEDs are arranged, even if it is not on one surface, but it is assumed that the film will be cut into pieces equal to or larger than this size. Even so, it is considered that calculating the visible light transmittance as described above can contribute to productivity and the like.
- each ⁇ LED 20 connected using the filler arrangement film 1A of the present embodiment has two electrodes 21, which are regularly arranged in a grid pattern on the wafer 22.
- FIG. 2 each ⁇ LED 20 connected using the filler arrangement film 1A of the present embodiment has two electrodes 21, which are regularly arranged in a grid pattern on the wafer 22.
- the long side is 200 ⁇ m or less, less than 150 ⁇ m, less than 50 ⁇ m, or less than 20 ⁇ m. More specifically, for example, a rectangle of 10 ⁇ m ⁇ 20 ⁇ m, 7 ⁇ m ⁇ 14 ⁇ m, or 5 ⁇ m ⁇ 5 ⁇ m can be mentioned.
- the outer shape of the ⁇ LED is not limited to a rectangle, and may be, for example, a rhombus.
- the shape and size of the electrode 21 are not particularly limited.
- the interval Ls can be appropriately selected depending on the method of use.
- the lower limit is preferably 3 ⁇ m or more, more preferably 5 ⁇ m or more, from the viewpoint of convenience of the mounting process.
- the thickness may be 1000 ⁇ m or less, 500 ⁇ m or less, 150 ⁇ m or less, or 20 ⁇ m or less.
- the high-density regions 4 of the fillers 2 are formed corresponding to the outer shape of the ⁇ LEDs (first article) 20, and are regularly arranged at intervals corresponding to the ⁇ LEDs array.
- the unevenly distributed regions 3 are formed by the fillers 2 being unevenly distributed at positions corresponding to the individual electrodes (connections) 21 of the ⁇ LED (first article) 20 .
- the unevenly distributed region 3 and the high-density region 4 can be recognized as an aggregate shape of the filler 2 .
- the expression that the unevenly distributed regions 3 are arranged at positions corresponding to the electrodes 21 of the ⁇ LEDs 20 means that when a plurality of ⁇ LEDs in a predetermined array state and the filler array film are aligned, the individual ⁇ LEDs 20 are arranged in plan view. It means that the electrode 21 and the unevenly distributed region 3 overlap, and that the space between the electrodes 21 of each ⁇ LED 20 and the space between the unevenly distributed region 3 overlap, preferably the electrode 21 is located in the unevenly distributed region 3, or It means that one or more of the conductive particles 2 forming 3 overlap with the electrode 21 .
- the high-density regions 4 are arranged corresponding to the arrangement of the ⁇ LEDs 20 means that each ⁇ LED 20 overlaps the high-density region 4 in plan view due to the alignment described above, and the space between the ⁇ LEDs and the high-density region 4
- the total area of the conductive particles 2 outside the outer shape of the ⁇ LED 20 among the conductive particles 2 forming the high-density region 4 is 50 times the area of the outer shape of the ⁇ LED 20. %, more preferably, all the conductive particles 2 forming the high-density region 4 are positioned within the outer shape of each ⁇ LED 20 .
- the area of the high-density region 4, that is, the area of the contour shape of the high-density region circumscribing the conductive particles 2 in the outer peripheral portion of the conductive particles 2 constituting the high-density region 4 is, for example, a rectangle with a side of 10 ⁇ m to 1000 ⁇ m.
- This ratio is preferably 0.1 times or more, more preferably 0.2 times or more, and even more preferably 0.5 times or more so that the electrodes can easily capture the conductive particles.
- the upper limit is increased, it is possible to avoid the concern that the conductive particles captured by the electrode will be insufficient, but there is a risk of impairing the transparency and aesthetic appearance.
- 1.2 times or less is more preferable.
- the high-density regions 4 are arranged corresponding to the arrangement of ⁇ LEDs means that the arrangement direction and arrangement pitch of the high-density regions 4 are equal to the arrangement direction and arrangement pitch of the ⁇ LEDs.
- the uneven distribution region 3 of the conductive particles of the filler array film 1A corresponds to the electrode 21 of the ⁇ LED 20, and the high-density region 4 corresponds to the external shape of the ⁇ LED 20. Therefore, the closest distance between the high-density regions 4 (that is, , the distance between the conductive particles that make up a certain high-density region and the conductive particles that make up the closest high-density region to that high-density region) is L1, and the distance between the unevenly distributed regions 3 in each high-density region is The tangent distance (that is, the distance between the conductive particles that make up a certain unevenly distributed region and the conductive particles that make up the closest unevenly distributed region to the unevenly distributed region in each high-density region 4) is L2, and the unevenly distributed region 3 When the closest distance between the conductive particles 2 in is L3, L1>L2>L3 It is preferable that
- L1 and L2 are appropriately determined according to the outer shape of the ⁇ LED, the arrangement pitch, the distance between the electrodes, and the like.
- the uneven distribution area 3 of the filler array film 1A, the electrode 21 of the ⁇ LED 20, and the electrode of the substrate are allowed to be misaligned by about ⁇ 10%.
- the area of the contour shape circumscribing the filler in the outer peripheral portion of the particles 2 may be 0.5 times or more and 1.8 times or less, or 1.0 times or more 1 .2 times or less is preferable. Within this range, the number of conductive particles is present in just the right amount, so both trapping and short-circuiting can be achieved, and a good trapping state can be easily obtained and confirmation is easy.
- one high-density region 4 can have a number of unevenly distributed regions 3 corresponding to the number of connection portions of one first article, and in particular, three or less can be present. In the embodiment, two unevenly distributed regions 3 are present.
- the lower limit of the ratio L3/D is preferably 0.3 or more, more preferably 0.3. It is 5 or more, and the upper limit is preferably 4 or less, more preferably 3 or less.
- the arrangement of the conductive particles 2 in the unevenly distributed region 3 may be random or regular, but in order to improve the ability to capture the conductive particles in each electrode 21, the conductive particles are arranged at a predetermined pitch in a predetermined direction.
- Planar lattice patterns having one or more alignment axes are preferred, and examples thereof include orthorhombic lattices, hexagonal lattices, square lattices, rectangular lattices, and parallel lattices. Also, there may be regions with different planar grid patterns.
- the density portion of the filler in the unevenly distributed region 3 of the filler array film 1A is designed according to the object to which the filler array film 1A is connected.
- the filler array film is an anisotropic conductive film
- irregular arrangement or agglomeration of conductive particles should be avoided. Less is better.
- the particle size of the conductive particles is less than 3 ⁇ m, it is desirable that the irregular arrangement or agglomeration of the conductive particles in the unevenly distributed region 3 is small.
- the number density of the fillers in the unevenly distributed region 3 is designed depending on the object to which the filler array film 1A is connected. For example, 50,000/mm 2 or more is preferable, and 500,000/mm 2 or more is more preferable.
- the number density of fillers between the high-density regions 4 is preferably 1000/mm 2 or less, and more preferably substantially zero. Therefore, even if the filler number density is increased in the unevenly distributed regions 3, the visible light transmittance between the high density regions 4 can be approximately 40% or more, and the visible light transmittance of the entire filler array film can be improved. It can be 40% or more, preferably 50% or more.
- the high density region 4 is a region sandwiched between the first article and the second article. Therefore, the number density between the unevenly distributed regions 3 in the high density region 4 may not necessarily be zero in order to improve the light transmittance after connecting the first article and the second article.
- the filler 2 may be present between two unevenly distributed regions 3 in the high density region 4 as in the filler array film 1B shown in FIG.
- the number of fillers between the unevenly distributed regions 3 in one high-density region 4 is preferably 50% or less, more preferably 20% or less, of the number of fillers in the unevenly distributed regions 3. .
- the area occupation ratio of the filler in the unevenly distributed region 3 of the filler can be determined so as to maintain the degree of freedom in the layout of the objects connected by the filler arrangement film, and may be 5% or more, preferably 8% or more. % or more and 85% or less is more preferable.
- the area occupancy of the filler means the area occupancy of the conductive particles in this embodiment, and the number density of the conductive particles in the unevenly distributed region 3 of the filler array film in plan view (pieces/mm 2 ) ⁇ the plan view of one conductive particle It is obtained by the average area (mm 2 /piece) ⁇ 100.
- the number density of the conductive particles is obtained by observing using a metallurgical microscope, and image analysis software (for example, WinROOF (Mitani Shoji Co., Ltd.), Azo-kun (registered trademark) (Asahi Kasei Engineering Co., Ltd.), etc.) may be obtained by measuring the observed image. The number observed on the filler arrangement film is counted. When the filler array film is divided into extremely small pieces, the number density is measured in the state before the division into pieces.
- image analysis software for example, WinROOF (Mitani Shoji Co., Ltd.), Azo-kun (registered trademark) (Asahi Kasei Engineering Co., Ltd.), etc.
- the particle size of the conductive particles 2 used as filler in this embodiment is not particularly limited, the lower limit of the particle size is preferably 1 ⁇ m or more.
- the upper limit of the particle size is preferably, for example, 50 ⁇ m or less, more preferably 20 ⁇ m or less, from the viewpoint of capturing efficiency of the conductive particles in the connection structure.
- the particle size of the conductive particles may be required to be less than 3 ⁇ m, preferably less than 2.5 ⁇ m, more preferably 2 ⁇ m or less. If the particle size is less than 1 ⁇ m, it may be treated as an aggregate of 1 ⁇ m or more.
- the average particle diameter can be a value measured by an image-type particle size distribution analyzer (eg, FPIA-3000: manufactured by Malvern).
- the number of particles is preferably 1000 or more, preferably 2000 or more.
- the type of conductive particles can be appropriately selected from conductive particles used in known anisotropic conductive films.
- the conductive particles include metal particles such as nickel, cobalt, silver, copper, gold, and palladium, alloy particles such as solder, metal-coated resin particles, and metal-coated resin particles having insulating fine particles attached to their surfaces. mentioned. Two or more types can also be used together. Among them, the metal-coated resin particles are preferable because the resin particles repel each other after being connected, thereby making it easy to maintain contact with the terminal and stabilizing the conduction performance.
- the surface of the conductive particles may be subjected to an insulating treatment by a known technique so as not to interfere with the conductive properties.
- inorganic fillers metal particles, metal oxide particles, metal nitride particles, etc.
- organic fillers resin particles, rubber particles, etc.
- fillers containing a mixture of organic and inorganic materials e.g., particles whose core is made of a resin material and whose surface is plated with metal (metal-coated resin particles), and insulating fine particles on the surface of conductive particles.
- the material is appropriately selected from the materials attached to the surface, the surface of the conductive particles subjected to insulation treatment, etc.) depending on the performance required for the application, such as hardness and optical performance.
- filler array film when used as a conductive film or an anisotropic conductive film, conductive particles are included as filler. Fillers other than conductive particles may be used depending on the application of the filler arrayed film.
- the filler array film When the filler array film is used for adjusting the color development of micro-optical elements such as ⁇ LEDs, or for applications such as black matrix in color displays, known dyes, pigments, light-scattering particles, etc. may be used as fillers.
- silica filler titanium oxide filler, styrene filler, acrylic filler, melamine filler, various titanates and the like can be used. Titanium oxide, magnesium titanate, zinc titanate, bismuth titanate, lanthanum oxide, calcium titanate, strontium titanate, barium titanate, barium zirconate titanate, lead zirconate titanate and mixtures thereof in capacitor films etc.
- the adhesive film may contain polymer rubber particles, silicone rubber particles, and the like.
- FIG. 3 is a cross-sectional view of the filler array film 1A shown in FIG. 1 taken along the line AA.
- the conductive particles 2 are arranged in the insulating resin layer 10 .
- the insulating resin layer 10 may be composed of a single insulating resin layer, or may be composed of a laminate of a plurality of resin layers. It is preferable that the positions of the ends of the conductive particles 2 are substantially aligned with one surface of the layer. Approximately matching includes, for example, an error of about ⁇ 10% of the particle diameter.
- the insulating resin layer is a laminate of a plurality of resin layers, for example, as shown in FIG. It can be the agent layer 12 .
- the resin constituting the high-viscosity binder resin layer 11 and the adhesive layer 12 can be the same as the binder and adhesive layer constituting the insulating resin layer described in Patent Document 3, for example. Different layers may be laminated with different fillers.
- the insulating resin layer 10 (high viscosity binder resin layer 11, adhesive layer It is preferable to add as little inorganic filler as possible to 12).
- an epoxy resin is used for the insulating resin layer 10, it is preferable to use an epoxy resin having no conjugated double bonds.
- a rubber component can be added to the insulating resin layer 10 as necessary.
- a rubber component may be added to prevent warping and distortion of the connection structure.
- the rubber component is not particularly limited as long as it is an elastomer with high cushioning properties (shock absorption). Specific examples include acrylic rubber, silicone rubber, butadiene rubber, polyurethane resin (polyurethane elastomer), and the like. be able to.
- the thickness of the insulating resin layer 10 is such that when the ⁇ LED and the substrate are connected by heating and pressurizing through the filler array film 1, unnecessary resin flow does not occur in the insulating resin layer.
- the lower limit of the layer thickness is 0.6 times or more, preferably 0.9 times, the average particle diameter of the conductive particles 2. More preferably, it is 1 time or more, and the upper limit is 3 times or less, preferably 2 times or less, further preferably 1.5 times or less. If the layer thickness of the insulating resin layer 10 is less than 0.6 times the average particle diameter of the conductive particles 2, the conductive particles 2 are exposed from the insulating resin layer 10.
- the lower limit of the layer thickness of the insulating resin layer 10 is preferably 2 ⁇ m or more, more preferably 3 ⁇ m or more.
- the upper limit is preferably 32 ⁇ m or less, more preferably 20 ⁇ m or less, and even more preferably 8 ⁇ m or less, because if the layer thickness is too large, misalignment tends to occur during connection.
- the ⁇ LED itself is small, and the size of the ⁇ LED and the size of the conductive particles are closer than before.
- the connection structure avoids this misalignment.
- the thickness of the insulating resin layer 10 is required to fall within the above range.
- the filler array film 1A can be produced in the same manner as known anisotropic conductive films, except that the conductive particles are specifically arranged as described above.
- a mold having recesses corresponding to the arrangement pattern of the conductive particles is prepared, and the mold is filled with the conductive particles 2,
- a high-viscosity binder resin layer 11 formed on a release film is laminated thereon, the conductive particles 2 are pushed into the high-viscosity binder resin layer 11 and transferred, and an adhesive layer 12 is laminated on the transfer surface.
- the method of connecting the electrodes of the ⁇ LEDs 20 and the electrodes of the substrate with the plurality of ⁇ LEDs 20 arranged regularly on the wafer 22 using the filler arrayed film 1A is as follows.
- the filler array film 1A and the ⁇ LEDs 20 arranged on the wafer 22 are aligned and bonded together, and heated and pressed to connect the electrodes of the ⁇ LEDs 20 and the electrodes of the substrate.
- the connection may be performed by heating and pressurizing in a two-step method.
- the conductive particles are solder particles or the like, they may be connected by reflow.
- the insulating resin layer of the filler array film 1 flows, fills the gaps between the opposed surfaces of the ⁇ LEDs 20 and the substrate, and hardens to bond the ⁇ LEDs 20 and the substrate.
- the fluidity is high between the high-density regions 4 where the conductive particles are not arranged, and the fluidity of the resin is low within the high-density regions 4 compared to between the high-density regions 4 . Therefore, the conductive particles 2 in the unevenly distributed region 3 arranged corresponding to the electrodes of the ⁇ LEDs in the high-density region 4 are less likely to be affected by the resin flow between the high-density regions 4, and the electrodes 21 of the ⁇ LEDs 20 are less likely to be affected. It becomes possible to reliably capture the conductive particles 2 .
- the unevenly distributed regions 3 are arranged with a distance L2 corresponding to the arrangement of the electrodes 21, so short-circuiting between the electrodes 21 in one ⁇ LED is suppressed.
- the conductive particles 2 do not substantially exist between the high-density regions 4, the light emitted from the ⁇ LEDs 20 after the ⁇ LEDs are connected to the substrate is blocked by the conductive particles 2 between them. do not have. Therefore, the luminous efficiency of the light-emitting device mounted with ⁇ LEDs is improved as compared with the case of using a filler-arranged film in which conductive particles are uniformly distributed over the entire surface of the film.
- the filler array film may be in the form of individual pieces.
- the size of the individual piece shape can be designed according to the object, and for example, one side can be 5 ⁇ m or more and 150 m or less. By doing so, it can be expected that the device can also be used for adjusting colors and light, which will be described later. That is, the first article and the second article may be connected by a piece-shaped film, or the piece-shaped film may be arranged only on the electrodes.
- the singulation can be formed by providing incisions using a mechanical method, a chemical method, a laser, or the like. Note that the cut does not have to be deep enough to reach the base material, and may be a half cut.
- Temporary attachment of the filler array film, film transfer, and mounting of the ⁇ LED on the substrate can be performed by known methods such as a method using a stamp material or a laser (laser lift-off method) or a method to which it is applied (for example, Japanese Patent Laid-Open No. 9-124020, Japanese Patent Laid-Open No. 2011-76808, Japanese Patent No. 6636017, Japanese Patent No. 6187665, etc.) are not particularly limited as long as they are methods capable of exhibiting the effects of the invention.
- connection structure In the connection structure between the ⁇ LED 20 and the substrate connected by the above-described method using the filler array film 1A of the example, the filler 2 in the unevenly distributed region 3 constitutes the connection point between the electrode 21 of the ⁇ LED 20 and the electrode of the substrate. ing.
- a ⁇ LED is used as an example, but the connection structure may be a mini-LED in the present invention.
- the effect of resin flow at the time of connection does not easily affect the arrangement of the conductive particles 2 in the high-density region 4. Therefore, the high-density region in which a plurality of unevenly distributed regions are gathered after connection is the same as before connection. , and the high-density regions are arranged corresponding to the arrangement of ⁇ LEDs.
- the visible light transmittance of the portion of the connection structure where the ⁇ LED and the substrate are not connected to the filler array film is higher than the average visible light transmittance of the filler array film of 40%, preferably 50% or more. Therefore, the luminous efficiency of this connection structure is obtained when a filler array film in which the conductive particles are uniformly present on the entire surface of the film at the number density of the conductive particles 2 in the unevenly distributed region 3 of this connection structure is used. significantly improved compared to In addition, the captivity of the conductive particles in each electrode is high, and the rate of occurrence of short circuits is also reduced.
- the connecting method using the filler arrayed film of the present invention and the connected structure obtained by the method are configured such that the first article is the ⁇ LED, the second article is the substrate on which the wiring circuit for the ⁇ LED is formed, and the filler arrayed film is used.
- the filler is the conductive particles, the present invention is not limited to this.
- the first article is a light scattering film, a black matrix layer, or the like
- the second article is a transparent substrate (a substrate on which ⁇ LED is mounted), or the like
- the filler is silica or black-colored particles.
- the color of the connection structure of the second article may be adjusted.
- the number of conductive particles captured by the bumps was measured. The lowest number in 100 bumps of this measured number was evaluated according to the following criteria.
- Conduction resistance The conduction resistance of 100 mounting bodies described above was measured and evaluated according to the following criteria. A: Less than 30 ⁇ B: 30 ⁇ or more and less than 100 ⁇ C: 100 ⁇ or more and less than 300 ⁇ D: 300 ⁇ or more
- Comparative Example 1 in which the conductive particles are uniformly present throughout the film at a number density equal to the number density of the conductive particles in the unevenly distributed regions of Example 1, is inferior in visible light transmittance.
- Comparative Example 2 in which the number density of the entire film is low, the visible light transmittance is evaluated as B, but the particle trapping property and conduction resistance are inferior.
- Comparative Example 4 the number density of the entire film is equal to the number density of the conductive particles in the unevenly distributed region of Example 1, but since the conductive particles are randomly arranged, the evaluation of insulation and visible light transmittance is significantly inferior.
- Comparative Example 3 in which the number density in the entire film is lower than that in Comparative Example 4, the conductive particles are randomly arranged, so the evaluation of the particle trapping property and the conduction resistance is significantly inferior.
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Abstract
Description
フィラーの高密度領域が間隔をあけて規則的に配列しており、
各高密度領域にフィラーの偏在領域が複数個形成されており、
フィラー配列フィルムの平均の可視光透過率が40%以上であるフィラー配列フィルムを提供する。
フィラー配列フィルムとして、
絶縁接着層にフィラーの高密度領域が間隔をあけて規則的に配列しており、
各高密度領域にフィラーの偏在領域が複数個形成されており、
フィラー配列フィルムの平均の可視光透過率が40%以上であるフィラー配列フィルムを使用する接続方法を提供する。
フィラーが第1物品の配列に対応して高密度領域を形成しており、
高密度領域内でフィラーが第1物品の接続部に対応して偏在している接続構造体を提供する。
図1は、本発明の一実施例のフィラー配列フィルム1Aにおけるフィラーの配置図である。このフィラー配列フィルムは、フィラー2として導電粒子を絶縁性樹脂層10に配列させたものである。フィラー配列フィルムは異方性導電フィルムとして用いても良く、導電フィルムとして用いても良い。
L1>L2>L3
となることが好ましい。
フィラー配列フィルム1Aの偏在領域3におけるフィラーの密度部分は、フィラー配列フィルム1Aを接続する対象物によって応じて設計される。フィラー配列フィルムが異方性導電フィルムの場合、異方性導電フィルムによって微小な部品を安定して接続できるようにするため、またショートリスクを回避するため、導電粒子のイレギュラーな配置または凝集は少ないことが望ましい。特に、導電粒子の粒子径が3μm未満では偏在領域3における導電粒子のイレギュラーな配置または凝集が少ないことが望ましい。
本実施例においてフィラーとする導電粒子2の粒子径は特に制限されないが、粒子径の下限は1μm以上であることが好ましい。粒子径の上限は、例えば、接続構造体における導電粒子の捕捉効率の観点から、例えば50μm以下であることが好ましく、20μm以下であることがさらに好ましい。電極のサイズによっては、導電粒子の粒子径は3μm未満、好ましくは2.5μm未満、より好ましくは2μm以下が求められる場合がある。粒子径が1μm未満の場合、1μm以上の集合体として扱ってもよい。
図3は、図1に示したフィラー配列フィルム1AのA-A断面図である。本実施例のフィラー配列フィルム1の偏在領域3では、導電粒子2が絶縁性樹脂層10に配列している。
フィラー配列フィルム1Aは、導電粒子を前述のように特定の配置とする以外は公知の異方性導電フィルムと同様に製造することができる。例えば、特許文献3に記載の異方性導電フィルムの製造方法と同様に、まず、導電粒子の配列パターンに応じた凹部が形成された型を用意し、その型に導電粒子2を充填し、その上に剥離フィルム上に形成した高粘度バインダー樹脂層11を貼り合わせて、導電粒子2を高粘度バインダー樹脂層11に押し込んで転着し、その転着面に接着剤層12を積層する。
フィラー配列フィルム1Aを用いて、複数のμLED20がウエハ22上で規則的に配列した状態でμLED20の電極と、基板の電極とを接続する方法は、まず、基板の電極上にフィラー配列フィルム1Aを位置合わせして貼着し、そのフィラー配列フィルム1Aと、ウエハ22上に配列したμLED20とを位置合わせして貼り合わせ、加熱加圧してμLED20の電極と基板の電極とを接続する。この場合、特許文献3に記載のように2段階方式で加熱加圧することにより接続してもよい。また、導電粒子が半田粒子等である場合に、リフローにより接続してもよい。
実施例のフィラー配列フィルム1Aを用いて上述の方法で接続されたμLED20と基板との接続構造体は、偏在領域3内のフィラー2がμLED20の電極21と基板の電極との接続箇所を構成している。実施例はμLEDを例に説明しているが、本発明において接続構造体はミニLEDであってもよい。
実施例1~4、比較例1~4
(異方性導電フィルムの作製)
表1の樹脂組成で樹脂を混合し、剥離フィルム上に塗布し、乾燥(60℃、3分)することにより接着フィルムを得た。
実施例1~4及び比較例1~4の異方性導電フィルムを用いて粒子捕捉性、導通抵抗、絶縁性、可視光透過率を次のように評価した。結果を表2に示す。
実施例1~4及び比較例1~4の異方性導電フィルムをITO/NdMoパターンガラスに貼り、その上に、μLEDに模した評価用ICチップを加熱圧着(到達温度150℃、加圧30Mpa、10秒)し、実装体を得た。この評価用ICチップは、バンプ10μm×10μmが2つ(バンプ間スペース7μm)で一組となったものが、1.5cm×1.5cmの範囲に略一面に30μmピッチで並べられた電極レイアウトを有する。
B:3~4個
C:1~2個
D:0個
上述の実装体の100個の導通抵抗を測定し、以下の基準で評価した。
A:30Ω未満
B:30Ω以上100Ω未満
C:100Ω以上300Ω未満
D:300Ω以上
上述の実装体の100個のバンプ間スペースについて導通抵抗を測定し、107Ω以下をショートと判定した。このショート数により、以下の基準で評価した。
B:ショート1個
C:ショート2個
D:ショート3個以上
実施例1~4及び比較例1~4の異方性導電フィルムの可視光透過率(400~700nm)を測定し、その平均の透過率(計測面積10mm×10mm)により、以下の基準で評価した。なお、透過率測定にはUV-2450((株)島津製作所製/JIS Z 8729)を使用した。この場合、可視光透過率の測定試料は、異方性導電フィルムを基板に貼り付けた状態で、200℃環境下で1分間放置し、硬化した状態のものとした。可視光透過率により接続構造体においてはみだした樹脂がどのように影響するかをみることができる。また、接続に使用する箇所に適した導電粒子の配置になっているかの判定や、接続構造体に使用する際に十分な透明性を確保されているかを確認することができる。
B:35%以上
C:20%以上
D:20%未満
2 フィラー、導電粒子
3 偏在領域
4 高密度領域
10 絶縁性樹脂層
11 高粘度バインダー樹脂層
12 接着剤層
20 第1物品、μLED
21 電極
22 ウエハ
L1 高密度領域間の最近接距離
L2 偏在領域間の最近接距離
L3 偏在領域内のフィラー間の最近接距離
Ls μLEDの電極間距離
Claims (17)
- 絶縁接着層にフィラーが配置されているフィラー配列フィルムであって、
フィラーの高密度領域が間隔をあけて規則的に配列しており、
各高密度領域にフィラーの偏在領域が複数個形成されており、
フィラー配列フィルムの平均の可視光透過率が40%以上であるフィラー配列フィルム。 - 高密度領域が1辺10μm~1000μmの矩形である請求項1記載のフィラー配列フィルム。
- 高密度領域内のフィラーの偏在領域におけるフィラーの個数密度が50000個/mm2以上である請求項1又は2記載のフィラー配列フィルム。
- 高密度領域内のフィラーの偏在領域におけるフィラーの個数密度が500000個/mm2以上である請求項3記載のフィラー配列フィルム。
- 高密度領域間のフィラーの個数密度が1000個/mm2以下である請求項1~4のいずれかに記載のフィラー配列フィルム。
- 高密度領域内の偏在領域間のフィラーの個数が偏在領域のフィラーの個数の50%以下である請求項1~5のいずれかに記載のフィラー配列フィルム。
- フィラーの偏在領域におけるフィラーの面積占有率が5%以上である請求項1~6のいずれかに記載のフィラー配列フィルム。
- 偏在領域においてフィラーが、正方格子、長方格子又は六方格子に配列している請求項1~7のいずれかに記載のフィラー配列フィルム。
- 高密度領域間の可視光透過率が50%以上である請求項1~8のいずれかに記載のフィラー配列フィルム。
- 複数の第1物品が第2物品上で配列した状態で、個々の第1物品の接続部と第2物品の接続部とを、絶縁性樹脂層にフィラーが配列したフィラー配列フィルムを介して加熱又は加圧することにより接続する接続方法であって、
フィラー配列フィルムとして、
絶縁接着層にフィラーの高密度領域が間隔をあけて規則的に配列しており、
各高密度領域にフィラーの偏在領域が複数個形成されており、
フィラー配列フィルムの平均の可視光透過率が40%以上であるフィラー配列フィルムを使用する接続方法。 - 個々の高密度領域の輪郭形状の面積が、第1物品の平面視面積の0.1倍以上1.5倍以下である請求項10記載の接続方法。
- 個々の偏在領域の面積が、第1物品の接続部の平面視面積の0.5倍以上1.8倍以下である請求項10記載の接続方法。
- 絶縁性樹脂層の厚みがフィラーの平均粒子径の3倍以下である請求項10~12のいずれかに記載の接続方法。
- 第1物品がμLEDであり、第2物品が透明ディスプレイ用基板である請求項10~13のいずれかに記載の接続方法。
- 複数の第1物品が第2物品上で配列した状態で、個々の第1物品の接続部と第2物品の接続部とがフィラーを介して接続されている接続構造体であって、
フィラーが第1物品の配列に対応して高密度領域を形成しており、
高密度領域内でフィラーが第1物品の接続部に対応して偏在している接続構造体。 - 接続構造体において第1物品及び第2物品が接続されていない部分の可視光透過率が50%以上である請求項15記載の接続構造体。
- 第1物品がμLEDであり、第2物品が透明ディスプレイ用基板である請求項15又は16記載の接続構造体。
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JP2017004715A (ja) * | 2015-06-09 | 2017-01-05 | デクセリアルズ株式会社 | 異方性導電接続構造体、異方性導電材料、および異方性導電接続方法 |
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JPS62188184A (ja) * | 1986-02-14 | 1987-08-17 | 日立化成工業株式会社 | 異方導電性を有する回路接続用接着剤組成物および接着フイルム並びにこれらを用いた回路の接続方法 |
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