Patent Application
20120059124
1. Field of the Invention
The present invention relates to a temporary fixing sheet for a manufacturing process of electronic parts, which makes electronic parts workable with high accuracy and can be efficiently and easily peeled off.
2. Description of the Related Art
As a pressure-sensitive adhesive tape which is used in working on electronic parts, an arbitrary one has been selected from pressure-sensitive adhesive tapes and used, in which a tackiness agent such as an acrylic base, a urethane base, a rubber base and a silicon base is laminated on a substrate such as a polyester base, a polyolefin base, a vinyl-chloride base, an acrylic base, a polyurethane base, a rubber base and a fluorine base. On this occasion, the pressure-sensitive adhesive tape has sufficient tackiness at a certain point in time, and has been subjected to treatment such as a heating treatment, cooling treatment and light irradiation so as not to have tackiness at another point in time.
In the field of recent electronic parts, the miniaturization and refinement of the parts themselves have been required, and, for instance, in a ceramic capacitor, a ceramic resistor and a ceramic inductor, which are electronic parts made from ceramics, the achievements in miniaturization and higher capacitance due to stacking layers so as to greatly exceed several hundreds of layers as represented by parts such as “0603” and “0402”, have been remarkable.
Particularly, in the process of manufacturing the ceramic capacitor, high working accuracy has been required in order to attain the miniaturization and refinement.
Taking the process of manufacturing a ceramic capacitor as one example, there are the following steps:
(1) a step of printing an electrode onto a green sheet
(2) a stacking step
(3) a pressing step
(4) a cutting step
(5) a heat-peeling step
(6) a step of applying and drying an external electrode, and the like.
However, various accuracies are required such as accuracy in the electrode printing in step (1), accuracy in the electrode position in step (2), accuracy in preventing the displacement of the electrode position from occurring due to a deformation of the green sheet by pressurization and a consequent displacement of the electrode position in step (3), and accuracy in cutting in step (4). If the accuracy in even one of these steps is poor, the product becomes faulty and the productivity will be degraded.
Particularly, the above described steps (1) to (4) are conducted generally on a PET film or pressure-sensitive adhesive sheet, and a manufacturing method which uses particularly the pressure-sensitive adhesive sheet is often used from the viewpoint of holding (fixing) the green sheet in the cutting step. As for the pressure-sensitive adhesive sheet which is used for such application, various heat peelable type pressure-sensitive adhesive sheets have been proposed.
In the above described cutting step (4), a dicing technique using a rotary blade has been employed conventionally, but along with the miniaturization of the size, a press-cutting technique is being used which shows a higher yield than that of the dicing technique. However, the press-cutting technique has such a problem that chips adhere to each other again in the case of some ceramic sheets. This occurs due to a factor that in the press-cutting technique, there is almost no gap between the chips which have been cut, and accordingly the chips adhere to each other again, particularly because the chips are softened by heat in the heat-peeling step and exhibit tackiness, which is different from that of the dicing technique.
In response to this, in order to prevent the chips from adhering to each other again in the heat-peeling step, the temporary fixing sheet containing a side-chain crystallizable polymer has been proposed in recent years, which firmly holds the ceramic sheet when the ceramic sheet is cut at approximately 40° C. to 100° C. and then decreases the tackiness of the pressure-sensitive adhesive layer of the pressure-sensitive adhesive sheet by being cooled to room temperature without undergoing a heating treatment step, and therefore the chips can be peeled off, (Japanese Patent No. 3387497 and Japanese Patent No. 3485412, for instance). By using this sheet, the heating treatment step after the ceramic sheet has been cut can be omitted, and accordingly the readherence of the chip originating in the step can be reduced.
Furthermore, as is described in Japanese Patent Laid-Open No. 2002-208537, the method is known which includes press-cutting the ceramic stacked body, by sticking the ceramic stacked body made of stacked ceramic green sheets onto a pressure-sensitive adhesive sheet having a tackiness agent applied onto a substrate made from a plant fiber having a large number of air bubbles therein, and adsorbing and retaining the resultant pressure-sensitive adhesive sheet.
The method for manufacturing the ceramic capacitor with the use of the above described heat-peelable tape tends to make the chips adhere to each other again in the heat-peeling step, as was described above. In addition, there is a case in which the electronic parts are overloaded due to the heat-peeling step, producing a harmful influence on the product. Furthermore, the manufacturing method needs a heating step, and accordingly the installation of more equipment is required.
Furthermore, the above described temporary fixing sheet containing the side-chain crystallizable polymer cannot provide high cutting accuracy, although higher cutting accuracy in the cutting step (4) as well as the prevention of the readherence of the chips is demanded along with the miniaturization of chips.
In addition, the above described pressure-sensitive adhesive sheet using the side-chain crystallizable polymer can make the tack strength disappear by being cooled, but needs to introduce a large amount of crystalline materials so as to make the tack strength disappear. Then, the degree of freedom in designing will be lost. In addition, the crystalline material needs to have a melting temperature of the crystal equal to or higher than room temperature, in order that the temporary fixing sheet is peeled at room temperature, needs to be warmed when the pressure-sensitive adhesive tape is produced and consequently is poor in the handleability. Accordingly, it is difficult to handle in manufacturing.
The present invention is directed at solving the above described defects, and an object thereof is to provide a temporary fixing sheet for a manufacturing process of electronic parts, which firmly holds a ceramic sheet in a cutting step for the ceramic sheet, can provide high cutting accuracy, then can efficiently and easily peel the chip from itself by being cooled to a predetermined temperature or lower, gives a high degree of freedom to designing and has adequate handleability. Another object of the present invention is to provide a method for manufacturing electronic parts, which uses the temporary fixing sheet for the manufacturing process of the electronic parts.
As a result of having made an extensive investigation for solving the above described problems, the present inventors found out that a temporary fixing sheet which has an adequate balance between the tack strength when having been warmed and peelability when having been cooled to room temperature and has high elasticity imparted even when having been warmed can be obtained by using a material containing a urethane polymer content and a vinyl polymer as active ingredients.
Specifically,
1. A temporary fixing sheet comprising a resin layer which contains a urethane polymer component and a vinyl polymer, develops tack strength at a particular temperature equal to or higher than 40° C., and loses the tack strength at the particular temperature or lower;
2. The temporary fixing sheet according to aspect 1, wherein a storage modulus E′ at 80° C. is 106 Pa or more;
3. The temporary fixing sheet according to aspect 1 or 2, wherein the peak of a loss tangent (tan δ) of the resin layer exists in 25° C. or higher and 100° C. or lower;
4. The temporary fixing sheet according to any one of aspects 1 to 3, wherein tack strength shown when the PET film has been peeled under an atmosphere of 80° C. is 0.2 N/10 mm or more, and tack strength which has been measured under an atmosphere of 25° C. is less than 0.1 N/10 mm;
5. The temporary fixing sheet according to any one of aspects 1 to 4, wherein at least one part of the urethane polymer component is a urethane polymer component having an acryloyl group in a terminal end;
6. The temporary fixing sheet according to any one of aspects 1 to 5, wherein the vinyl polymer contains a carboxyl group;
7. The temporary fixing sheet according to any one of aspects 1 to 6, wherein the temporary fixing sheet is used for cutting in a manufacturing process of electronic parts;
8. The temporary fixing sheet according to any one of aspects 1 to 7, wherein the temporary fixing sheet is used for press cutting; and
9. The temporary fixing sheet according to aspect 8, wherein the temporary fixing sheet is used for cutting a multilayered ceramic sheet.
The temporary fixing sheet according to the present invention can be preferably used as a temporary fixing sheet for use in working on electronic parts such as stacked ceramic electronic parts. When the temporary fixing sheet is used in a press-cutting step of a multilayered ceramic sheet under a high-temperature atmosphere, for instance, the above described temporary fixing sheet can prevent the chip from being peeled during the operation because of having high tackiness under the high-temperature atmosphere, and the multilayered ceramic sheet can be cut with high accuracy because the temporary fixing layer has a high storage modulus in a range of a cutting temperature. Furthermore, the temporary fixing sheet is not one which can be peeled by heating, but can peel a chip from itself by simply being cooled to room temperature without undergoing a heating treatment step, and accordingly can prevent the chips from adhering to each other again in the heating treatment step.
Because the temporary fixing layer of the temporary fixing sheet does not need to employ a crystalline material, it shows adequate handleability when the sheet is prepared, is excellent in the productivity, does not need a heating step, and accordingly can provide an effect of temporary fixation with a simple and easy method.
The temporary fixing sheet according to the present invention can be extended by stretching, and can also further reduce the readherence of the chips because of being capable of forming a gap between the chips by being stretched after the cutting step.
The temporary fixing sheet for the manufacturing process of the electronic parts according to the present invention includes a resin layer which contains a urethane polymer component and a vinyl polymer, develops tack strength at a particular temperature equal to or higher than 40° C., and loses the tack strength at the particular temperature or lower. For information, in the present invention, the word “film” has a concept including a sheet, and the word “sheet” has a concept including a film.
In addition, the description that the temporary fixing layer contains the urethane polymer and the vinyl polymer means that these polymers may be blended and may also be bonded to each other.
(Resin Layer)
The urethane polymer which is used for a resin layer is obtained by making a polyol react with a diisocyanate. For a reaction of the hydroxyl group of the polyol and the isocyanate, a catalyst may also be used which is generally used in a urethane reaction, for instance, such as dibutyltin dilaurate, tin octoate and 1,4-diazabicyclo(2,2,2)octane.
The polyol includes: a polyether polyol obtained by addition-polymerizing ethylene oxide, propylene oxide, tetrahydrofuran and the like; a polyester polyol formed of a condensation polymer which is obtained by condensation-polymerizing the above described divalent alcohol with a divalent basic acid such as adipic acid, azelaic acid and sebacic acid; acrylic polyol; carbonate polyol; epoxy polyol; and caprolactone polyol. Among these polyols, a polyol to be preferably used is, for instance, a polyether polyol such as polyoxytetramethylene glycol (PTMG) and polyoxypropylene glycol (PPG); a noncrystalline polyester polyol; and a noncrystalline polycarbonate polyol. These polyols can be used solely or concomitantly with another polyol.
The diisocyanate includes an aromatic, an aliphatic and an alicyclic diisocyanate. The aromatic, the aliphatic and the alicyclic diisocyanates include tolylene diisocyanate, diphenylmethane diisocyanate, hexamethylene diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, isophorone diisocyanate, hydrogenated diphenylmethane diisocyanate, 1,5-naphthylene diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, butane-1,4-diisocyanate, 2,2,4-trimethyl hexamethylene diisocyanate, 2,4,4-trimethyl hexamethylene diisocyanate, cyclohexane-1,4-diisocyanate, dicyclohexylmethane-4,4-diisocyanate, 1,3-bis(isocyanatemethyl)cyclohexane, methyl cyclohexane diisocyanate, and m-tetramethyl xylylene diisocyanate. These diisocyanates can be used solely or concomitantly with another diisocyanate. The type, the combination and the like of the polyisocyanate can be appropriately selected from the viewpoint of urethane reactivity, compatibility with acrylic and the like.
The amounts of the above described polyol component and the above described diisocyanate component to be used for forming the urethane polymer are not limited in particular, but the amount of the polyol component to be used preferably satisfies, for instance, a condition that NCO/OH (equivalence ratio) with respect to the diisocyanate component is 1.0 or more and further preferably satisfies that the NCO/OH is 2.0 or less. When the NCO/OH is 1.0 or more, a functional group in the terminal of a urethane molecule chain becomes a hydroxyl group, and the strength decrease of the temporary fixing layer can be prevented. In addition, when the NCO/OH is 2.0 or less, moderate elongation and strength can be secured.
The molecular weight of the urethane polymer component in the present invention can be appropriately determined by the type and the NCO/OH ratio of the polyol and the diisocyanate to be used. The molecular weight is not limited in particular, but is preferably 5,000 or more by a number average molecular weight (Mw), and further preferably is 10,000 or more.
It is desirable to add a hydroxyl-group-containing acrylic monomer to the above described urethane polymer other than the vinyl polymer in the present invention. By the addition of the hydroxyl-group-containing acrylic monomer, an acryloyl group can be introduced into the molecule of a urethane polymer, and copolymerizability with the acrylic monomer can be imparted. The hydroxyl-group-containing acrylic monomer to be used includes hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate and hydroxyhexyl(meth)acrylate. The amount of the hydroxyl-group-containing acrylic monomer to be used is desirably 0.1 to 10 parts by weight with respect to 100 parts by weight of the urethane polymer, and further desirably is 0.1 to 5 parts by weight.
A vinyl polymer to be used for a resin layer according to the present invention may be obtained by blending the above described urethane polymer and the following vinyl polymer, and may also be obtained by preparing a mixture of the urethane polymer and the vinyl polymer, and then polymerizing the vinyl polymer.
Among the methods, it is preferable to form the vinyl polymer by making a polyol react with an isocyanate in a single vinyl polymer or in a mixture of two or more vinyl polymers to form a urethane polymer, applying the obtained mixture containing the urethane polymer and the vinyl monomer onto a substrate, and irradiating the wet film with a radiation to cure the wet film, from the points of the type of a usable monomer, workability in forming a sheet and the like. The vinyl monomer is preferably a (meth)acrylic monomer.
As was described above, it is also possible to form a resin in which an acryloyl group is polymerized with a vinyl group and the urethane polymer is coupled with the vinyl polymer, by introducing the acryloyl group into the urethane polymer with the use of the hydroxyl-group-containing acrylic monomer and polymerizing the vinyl monomer.
The vinyl polymer in the present invention is a polymer which is obtained by polymerizing a vinyl monomer, and a (meth)acrylic monomer is preferably used for the vinyl monomer as was described above. The (meth)acrylic monomer includes, for instance: a carboxyl-group-containing monomer such as ethyl(meth)acrylate, n-propyl (meth)acrylate, isopropyl(meth)acrylate, n-butyl (meth)acrylate, sec-butyl(meth)acrylate, t-butyl (meth)acrylate, n-octyl(meth)acrylate, isooctyl (meth)acrylate, 2-ethylhexyl(meth)acrylate, isononyl (meth)acrylate, dodecyl(meth)acrylate, n-octadecyl (meth)acrylate, acrylic acid, methacrylic acid, carboxyethyl acrylate, carboxypentyl acrylate, itaconic acid, maleic acid and crotonic acid; a hydroxyl-group-containing monomer such as 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl(meth)acrylate, 4-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl(meth)acrylate, 8-hydroxyoctyl(meth)acrylate, 10-hydroxydecyl (meth)acrylate, 12-hydroxylauryl(meth)acrylate and (4-hydroxymethyl cyclohexyl)-methyl acrylate; a monomer having an alicyclic structure such as cyclohexyl (meth)acrylate and isobornyl acrylate; an acid anhydride monomer such as maleic anhydride and itaconic anhydride; a sulfonate-group-containing monomer such as 2-acrylamide-2-methylpropanesulfonic acid and sulfopropyl acrylate; and a phosphate-containing monomer such as 2-hydroxyethyl acryloyl phosphate. In addition, the vinyl polymer in the present invention can employ one or more monomers of: an amide-based monomer such as (meth)acrylamide and an N-substituted (meth)acrylamide such as N-methylolacrylamide; a succinimido-based monomer such as N-(meth)acryloyloxymethylene succinimido, N-(meth)acryloyl-6-oxyhexamethylene succinimido and N-(meth)acryloyl-8-oxyoctamethylene succinimido; a vinyl monomer such as vinyl acetate, N-vinyl pyrrolidone, N-vinyl carboxylic amides and N-vinyl caprolactam; a cyanoacrylate-based monomer such as acrylonitrile and methacrylonitrile; an acrylic ester-based monomer such as glycidyl(meth)acrylate, tetrahydrofurfuryl (meth)acrylate, polyethylene glycol (meth)acrylate, polypropylene glycol (meth)acrylate, a fluorine-containing (meth)acrylate, a silicone (meth)acrylate, and 2-methoxyethyl acrylate; and a monomer such as methyl (meth)acrylate and octadecyl(meth)acrylate. The type, combination, amount to be used and the like of these (meth)acrylic monomers are appropriately determined in consideration of compatibility with urethane, polymerizability when being cured with light such as radiation and characteristics of a high polymer to be obtained.
When the (meth)acrylic acid is used, the amount to be added is preferably 5 parts by weight or more and less than 80 parts by weight when the whole amount of the urethane polymer and the vinyl polymer is supposed to be 100 parts by weight, and further preferably is 10 parts by weight or more and less than 70 parts by weight. When the amount to be added is set to 5 parts by weight or more, the temporary fixing sheet tends to easily acquire the balance of the tack strengths between the warmed period and the cooled and peeled period, and when the amount to be added is set to less than 80 parts by weight, the temporary fixing sheet acquires flexibility and an enhanced tack strength in the warmed period.
In the present invention, another polyfunctional monomer in such a range as not to impair the characteristics can also be added. The polyfunctional monomer includes hexanediol diacrylate, trimethylolpropane triacrylate and dipentaerythritol hexaacrylate.
The resin layer according to the present invention contains a urethane polymer and a vinyl polymer as active ingredients. The ratio of the urethane polymer and the vinyl polymer is not limited in particular, but is preferably 10% or more and less than 90% by the weight of the urethane polymer occupying in the total amount of the urethane polymer and the vinyl polymer, and further preferably is 20% or more and less than 80%. When the ratio of the urethane polymer is less than 10%, the resin layer shows a lowered elastic modulus at a high temperature and resists to develop sufficient working accuracy. When the ratio is 90% or more, the handleability when a sheet is produced is poor and the productivity becomes poor.
(Method of Forming Resin Layer)
The temporary fixing sheet according to the present invention can be obtained by: forming an urethane polymer by making a polyol react with a diisocyanate in a vinyl monomer which constitutes a vinyl polymer by polymerization solely or in a mixture of two or more vinyl monomers; applying the mixture containing the urethane polymer and the vinyl monomer onto a peelable supporting substrate; and irradiating the wet film with an ionizing radiation such as α rays, β rays, γ rays, neutron rays and an electron beam, a radiation such as ultraviolet rays, visible light and the like according to the type of a photopolymerization initiator and the like to photo-cure the wet film.
In addition, when the above described hydroxyl-group-containing acrylic monomer is used, the temporary fixing sheet can be obtained by: forming a urethane polymer by making a polyol react with an isocyanate in a vinyl monomer which constitutes a vinyl polymer by polymerization solely or in a mixture of two or more vinyl monomers; adding the hydroxy-group-containing acrylic monomer to the urethane polymer to make the acrylic monomer react with the urethane polymer; applying the obtained mixture onto a supporting substrate; and irradiating the wet film with an ionizing radiation such as α rays, β rays, γ rays, neutron rays and an electron beam, a radiation such as ultraviolet rays, a visible light and the like according to the type of the photopolymerization initiator and the like to cure the wet film.
Specifically, the temporary fixing sheet can also be obtained by: dissolving a polyol in a vinyl monomer; adding a diisocyanate or the like to the polyol to make the diisocyanate react with the polyol; adjusting the viscosity; coating a peelable supporting substrate with the reaction product; curing the wet film with the use of a low-pressure mercury lamp or the like; and subsequently peeling the cured resin layer from the peelable supporting substrate. In this method, the vinyl monomer may be added at a time during the synthesis of the urethane, and may also be added at several divided times. According to this method, the molecular weight of the urethane to be finally obtained can be designed so as to become an arbitrary size, because the molecular weight is not limited and polyurethane with a high molecular weight can also be produced.
On this occasion, in order to avoid polymerization inhibition due to oxygen, a substrate which has been subjected to peeling treatment may be placed on the mixture of the urethane polymer and the vinyl monomer to block oxygen, which has been coated onto the peelable supporting substrate, or a peeling liner may be put into a container which has been filled with an inactive gas, to lower the oxygen concentration.
In addition, a small amount of a solvent may also be added to the mixture for adjusting the viscosity to an adequate value for coating. The solvent can be appropriately selected from solvents to be usually used, but includes, for instance, ethyl acetate, toluene, chloroform and dimethylformamide.
In the present invention, the type of radiation and the like and the type of a lamp to be used for irradiation can be appropriately selected. A usable lamp includes a low-pressure lamp such as a fluorescent chemical lamp, a black light and a bactericidal lamp, and a high-pressure lamp such as a metal halide lamp and a high-pressure mercury lamp.
The amount of irradiation with ultraviolet rays and the like can be arbitrarily set according to characteristics to be required for a temporary fixing layer. The amount of irradiation with the ultraviolet rays is generally 50 to 5,000 mJ/cm2, preferably is 100 to 4,000 mJ/cm2, and further preferably is 100 to 3,000 mJ/cm2. When the amount of irradiation with the ultraviolet rays is in the range of 50 to 5,000 mJ/cm2, a sufficient polymerization ratio is obtained without causing degradation.
A photopolymerization initiator is included in the mixture which contains the urethane polymer and the vinyl monomer as a main component. The photopolymerization initiator includes: a benzoin ether such as benzoin methyl ether, benzoin isopropyl ether and 2,2-dimethoxy-1,2-diphenylethane-1-on; a substituted benzoin ether such as anisole methyl ether; a substituted acetophenone such as 2,2-diethoxyacetophenone, 2,2-dimethoxy-2-phenyl acetophenone and 1-hydroxy-cyclohexyl-phenyl ketone; a substituted α-ketol such as 2-methyl-2-hydroxypropiophenone; an aromatic sulfonyl chloride such as 2-naphthalene sulfonyl chloride; a photoactive oxime such as 1-phenyl-1,1-propanedione-2-(o-ethoxycarbonyl)-oxime; and acyl phosphine oxide such as 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide and bis(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide.
The thickness of the resin layer in the present invention can be appropriately selected according to the purpose and the like, but is generally 5 to 500 μm and preferably is approximately 10 to 50 μm.
In the present invention, the description that the temporary fixing layer develops tack strength at a particular temperature equal to or higher than 40° C. means that the temporary fixing layer develops the tack strength only when having reached a certain temperature equal to or higher than 40° C., means that the temporary fixing layer does not develop the tack strength at a temperature lower than the certain temperature, and eventually means that the temporary fixing layer does not show the tack strength at a temperature lower than 40° C. at lowest.
It is preferable that the temporary fixing sheet according to the present invention shows a tack strength of 0.2 N/10 mm or more, when stuck to a PET film having the thickness of 25 μm under an atmosphere of 80° C. and when peeling the same PET film under an atmosphere of 80° C., and a tack strength to the PET film of 0.1 N/10 mm or less, which has been measured under an atmosphere of 25° C. In recent years, the press-cutting step is often conducted under a temperature around 80° C. so as to enhance the cutting accuracy. When the tack strength under the temperature is 0.2 N/10 mm or more, the ceramic sheet can be held without causing displacement when having been cut. When the tack strength is preferably 0.25 N/10 mm or more and is further preferably 0.30 N/10 mm or more, the ceramic sheet can be more surely held. In addition, when the temporary fixing sheet has been cooled to room temperature, if the tack strength to the PET film is set at less than 0.08 N/10 mm, and more preferably at 0.06 N/10 mm or less, the chip which has been cut can be easily peeled from the temporary fixing sheet.
The resin layer in the present invention has a storage modulus G′ of 105 Pa or more at 80° C., preferably of 1.5×105 Pa or more, and further preferably of 2.0×105 Pa or more. When the storage modulus G′ is 105 Pa or less, high working accuracy cannot be obtained in the cutting step or the like.
The temporary fixing sheet according to the present invention can be used as a pressure-sensitive adhesive sheet for use in temporarily fixing, storing or transporting various adherends. The application is not limited in particular, but the temporary fixing sheet is particularly suitable as a material for temporarily fixing electronic parts when the electronic parts are worked, and the like.
By using the temporary fixing sheet according to the present invention, chip-shaped electronic parts, for instance, such as a multilayered ceramic capacitor and a multilayered ceramic varistor, can be preferably manufactured.
The temporary fixing sheet according to the present invention preferably has the peak of a loss tangent (tan δ) existing in 25° C. or higher and 100° C. or lower, and further preferably in 30° C. or higher and 70° C. or lower. When the peak of the tan δ exists in 25° C. or higher and 100° C. or lower, at 25° C. or higher, the temporary fixing sheet does not show a behavior close to rubber elasticity and shows adequate peelability when having been cooled, and at 100° C. or lower, the temporary fixing sheet does not show a behavior close to a glass state and develops adhesiveness when having been warmed.
In the present invention, it is preferable that the rupture strength of the temporary fixing sheet at 25° C. is 3.0 MPa or more, and that the rupture elongation at 25° C. is 10% or more. The rupture strength is preferably 5 Mpa or more, and further preferably is 10 Mpa or more. The rupture elongation is preferably 30% or more, and further preferably is 50% or more. When the rupture strength is 3.0 MPa or more, a sufficient strength required as a film can be obtained, and when the rupture elongation is 10% or more, the temporary fixing sheet does not become brittle.
The thickness of the temporary fixing sheet having no substrate for use in press cutting in the present invention can be appropriately selected according to the purpose and the like, but is generally 5 to 500 μm and preferably is approximately 50 to 200 μm.
The temporary fixing sheet having no substrate for use in press cutting in the present invention is not a sheet having such a so-called substrate as will be described below. The substrate is generally an appropriate tissue body including a plastic film or sheet of PET or the like, for instance, such as paper, cloth, non-woven fabric and metal foil, a laminate thereof with plastic, and a laminate of plastic films (or sheets), and is a layer for imparting a mechanical strength to the temporary fixing sheet having no substrate for use in press cutting.
The state having no substrate in the present invention means a state in which there is no so-called substrate as was described above, but a sheet formed of a plurality of laminated resin layers having the tack strength is not considered to be a sheet having the substrate, and is included in the temporary fixing sheet having no substrate for use in press cutting, which is included in the present invention.
For instance, the temporary fixing sheet having no substrate for use in press cutting according to the present invention may be a sheet made of only one tackiness agent layer, and may also be a sheet made of three layers, which has a temporary fixing layer having tackiness provided on a side which will stick to a member to be cut such as a ceramic sheet, and has a release layer provided in a side of a pedestal which is an object on which the member to be cut is fixed.
In the case in which the temporary fixing sheet does not use the substrate in the present invention, the temporary fixing sheet makes a gap formed between the chips by being stretched after the operation of temporary fixation such as the cutting step, subsequently can take out the chips, and thereby can reduce a defect due to the readherence of the chips.
(Application of Temporary Fixing Sheet)
The temporary fixing sheet having no substrate for use in press cutting according to the present invention can be used as a pressure-sensitive adhesive sheet for use in temporarily fixing, storing or transporting various adherends. The application is not limited in particular, but is particularly suitable as a material for temporarily fixing electronic parts when the electronic parts are worked and the like.
By using the temporary fixing sheet having no substrate for use in press cutting according to the present invention, chip-shaped electronic parts, for instance, such as a multilayered ceramic capacitor and a multilayered ceramic varistor, can be preferably manufactured.
A method for cutting the multilayered ceramic sheet which uses the temporary fixing sheet having no substrate for use in press cutting according to the present invention will be described below with reference to
Reference numeral 1 denotes a temporary fixing sheet having no substrate for use in press cutting according to the present invention.
Though being not shown in the FIGURE, a release sheet can also be stacked on the surface of the temporary fixing sheet having no substrate for use in press cutting. Reference numeral 2 denotes a pedestal and reference numeral 3 denotes a multilayered ceramic sheet. Reference numeral 4 denotes a press-cutting blade for cutting the multilayered ceramic sheet 3. The temporary fixing sheet having no substrate for use in press cutting according to the present invention firmly fixes the multilayered ceramic sheet 3 which is a body to be worked, by affixing its pressure-sensitive adhesive layer for temporary fixation onto the pedestal, and affixing the thermally expansive pressure-sensitive adhesive layer onto the multilayered ceramic sheet 3.
A step of cutting the multilayered ceramic sheet 3 is conducted under a high-temperature atmosphere (60 to 100° C., for instance) for the purpose of enhancing cutting accuracy. The temporary fixing sheet having no substrate for use in press cutting according to the present invention is excellent in a cohesive force and an adhesive force under room-temperature and high-temperature atmospheres, and accordingly can firmly fix the multilayered ceramic sheet 3 through the whole period also before and after the cutting step. Particularly, the temporary fixing sheet does not cause lifting and deformation under a temperature in the cutting operation, and accordingly prevents the displacement of the multilayered ceramic sheet 3, which is induced by the intrusion of the press-cutting blade 4 in the cutting operation. As a result, the chips can be precisely cut into a form of chip elements which are units of parts, with high accuracy.
After the cutting operation has been finished, the worked body (multilayered ceramic sheet 3 which has been cut) can be removed from the temporary fixing sheet 1 having no substrate for use in press cutting.
The multilayered ceramic sheet 3 which has been cut is collected by an appropriate method, and then the temporary fixing sheet 1 having no substrate for use in press cutting according to the present invention can be peeled from the pedestal 2 by a peeling operation or the like.
The present invention will be described below in detail with reference to Examples, but the present invention is not limited to the Examples. In addition, in the following Examples, “part” means “part by weight” and “%” means “wt %” unless otherwise specifically notified.
A urethane polymer-acrylic monomer mixture was obtained by: charging 50 parts by weight of isobornyl acrylate (IBXA) which functions as a (meth)acrylic monomer, and 72.8 parts by weight of poly(tetramethylene) glycol having a number average molecular weight of 650 (PTMG, made by Mitsubishi Chemical Corporation), which functions as a polyol, into a reaction container provided with a cooling pipe, a thermometer and a stirring device; adding 27.2 parts by weight of hydrogenated xylylene diisocyanate (HXDI, made by Mitsui Chemicals Polyurethanes, Inc.) dropwise into the mixture while stirring the mixture; and making the compounds react with each other at 65° C. for 10 hours. After that, 6.5 parts by weight of 2-hydroxyethyl acrylate (HEA) were added dropwise into the mixture, the compounds were reacted further for 3 hours, and then 50 parts by weight of acrylic acid (AA) and 0.3 parts by weight of 2,2-dimethoxy-1,2-diphenylethane-1-one (IRGACURE 651, made by Ciba Japan K.K.) which functions as a photopolymerization initiator were added to the reaction product. Incidentally, the ratio of the used amounts of a polyisocyanate component and a polyol component was 1.25 by NCO/OH (equivalence ratio).
The mixture of the urethane polymer and the acrylic monomer was applied onto a PET film having a thickness of 38 μm and was peelably treated so that the thickness of the film after having been cured became 100 μm. A urethane-acrylic composite film was formed on the PET film, by placing the PET film which was peelably treated on the mixture and covered the mixture with the film, and then irradiating the face of this covered PET film with ultraviolet rays (illumination of 5 mW/cm2 and light quantity of 1000 mJ/cm2) by using a black light to cure the mixture.
A urethane polymer-acrylic monomer mixture was obtained by: charging 80 parts by weight of isobornyl acrylate (IBXA) which functions as a (meth)acrylic monomer, 20 parts by weight of butyl acrylate (BA), and 72.8 parts by weight of poly(tetramethylene)glycol (PTMG, made by Mitsubishi Chemical Corporation), which has a number average molecular weight of 650 and functions as a polyol, into a reaction container provided with a cooling pipe, a thermometer and a stirring device; adding 27.2 parts by weight of HXDI dropwise into the mixture while stirring the mixture; and making the compounds react with each other at 65° C. for 10 hours. After that, 6.5 parts by weight of 2-hydroxyethyl acrylate (HEA) were added dropwise into the mixture, the compounds were reacted further for 3 hours, and then 30 parts by weight of acrylic acid (AA) and 0.3 parts by weight of IRGACURE 651 which functions as a photopolymerization initiator were added to the reaction product. Incidentally, the ratio of the used amounts of a polyisocyanate component and a polyol component was 1.25 by NCO/OH (equivalence ratio).
The mixture of the urethane polymer and the acrylic monomer was applied onto a PET film having a thickness of 38 μm and was peelably treated so that the thickness of the film after having been cured became 100 μm. A urethane-acrylic composite film was formed on the PET film, by placing the PET film which was peelably treated on the mixture and covered the mixture with the film, and then irradiating the face of this covered PET film with ultraviolet rays (illumination of 5 mW/cm2 and light quantity of 1000 mJ/cm2) by using a black light to cure the mixture.
An urethane polymer-acrylic monomer mixture was obtained by: charging 100 parts by weight of isobornyl acrylate (IBXA) which functions as a (meth)acrylic monomer, and 72.8 parts by weight of poly(tetramethylene)glycol (PTMG, made by Mitsubishi Chemical Corporation) having a number average molecular weight of 650, which functions as a polyol, into a reaction container provided with a cooling pipe, a thermometer and a stirring device; adding 27.2 parts by weight of HXDI dropwise into the mixture while stirring the mixture; and making the compounds react with each other at 65° C. for 10 hours. After that, 6.5 parts by weight of 2-hydroxyethyl acrylate (HEA) were added dropwise into the mixture, the compounds were reacted further for 3 hours, and then 0.3 parts by weight of IRGACURE 651 which functions as a photopolymerization initiator were added to the reaction product. Incidentally, the ratio of the used amounts of a polyisocyanate component and a polyol component was 1.25 by NCO/OH (equivalence ratio).
The mixture of the urethane polymer and the acrylic monomer was applied onto a PET film having a thickness of 38 μm and was peelably treated so that the thickness of the film after having been cured became 100 μm. A urethane-acrylic composite film was formed on the PET film, by placing the PET film which was peelably treated on the mixture and covered the mixture with the film, and then irradiating the face of this covered PET film with ultraviolet rays (illumination of 5 mW/cm2 and light quantity of 1000 mJ/cm2) by using a black light to cure the mixture.
A film was produced so as to become 100 μm by extruding a copolymer (EVA) resin of ethylene-vinyl acetate having a melting point of 84° C. [trade name: EVAFLEX P-1905, made by DUPONT-MITSUI POLYCHEMICALS CO., LTD.], at a melt flow rate of 2.5 g/10 min with a T-die extrusion process.
A film of soft polyvinyl chloride was prepared which employed vinyl chloride (with thickness of 70 μm; trade name “KM film”, made by Mitsubishi Chemical MKV Company).
A partial polymer (monomer syrup) was obtained by: charging 85 parts by weight of cetyl acrylate, 10 parts by weight of methyl acrylate, 5 parts by weight of acrylic acid, 0.1 parts by weight of 2,2-dimethoxy-1,2-diphenylethane-1-on, into a four neck flask; and exposing the compounds to ultraviolet rays under nitrogen atmosphere to partially photopolymerize the compounds. A photopolymerized composition was prepared by adding 0.1 parts by weight of hexanediol diacrylate as a crosslinking agent to 100 parts by weight of this partial polymer, and uniformly mixing the compounds.
The above described photopolymerized composition was applied onto the peelably treated face of a polyethylene terephthalate film having the thickness of 38 μm, of which the one face was peelably treated with silicone, so that the thickness of the composition became 100 μm; furthermore, the composition was covered with a polyethylene terephthalate film having the thickness of 38 μm, of which the one face was peelably treated; and then the applied layer was formed. A target pressure-sensitive adhesive sheet was obtained by irradiating this sheet with ultraviolet rays having an illuminance of 5 mW/cm2 (measured with TOPCON UVR-T1 having the maximum peak-sensitivity wave of 350 nm) by a light quantity of 1,000 mJ/cm2 with the use of a black light (15 W/cm).
Tack strength, a storage modulus, sheet retainability, peelability for the chip, a readherence rate and the squareness of the chip were evaluated on the sheets obtained in Examples 1 to 3 and Comparative Examples 1, 2 and 3 according to the methods described below. The results are shown in Tables 2 and 3.
Method for Measuring Tack Strength at 80° C.
Each of the sheets prepared in Examples and Comparative Examples was cut into a tape shape with a width of 10 mm and a length of 140 mm; the cut film was affixed to a PET film (20 mm width) having a thickness of 25 μm, on a hot plate at 80° C. in conformity with JIS Z 0237; the affixed film was then set on a variable-angle peel test machine with a plate stand at 80° C., and was left there for 3 minutes; and the load was measured which was applied to a film when the film was peeled with a tensile angle of 180° C. at a peeling speed of 300 mm/min.
Method for Measuring Tack Strength at 25° C.
Each of the films was affixed to the PET film as in a method of measuring the tack strength at 80° C.; the affixed film was left for 10 minutes on the hot plate at 80° C., then was cooled to 25° C., was set on a variable-angle peel test machine; and the load was measured which was applied to the film when the film was peeled with a tensile angle of 180° C. at a peeling speed of 300 mm/min at a measurement temperature of 25° C.
Method for Measuring Storage Modulus E′
A storage modulus (E′) was measured by “ARES” (made by TA Instruments Japan, Inc.). In the above procedure, the storage modulus was measured on conditions that the temperature range was −60° C. to 200° C., a temperature-raising speed was 5° C./min and the frequency was 1 Hz.
Method for Measuring Sheet Retainability
Each multilayered ceramic sheet (*1) was affixed to each of the pressure-sensitive adhesive sheets obtained in Examples and Comparative Examples; the affixed sheet was left in an atmosphere of 80° C. for 5 minutes; and then, the ceramic sheet was subjected to a press-cutting work (*2) so that the cut chip became the shape with a 0402 size (0.4 mm×0.2 mm). The retainability for the ceramic sheet at this time was visually evaluated. Specifically, the case in which the ceramic sheet could be worked without causing the peeling and a displacement of the ceramic sheet or the cut chip when the ceramic sheet was cut was evaluated as “◯”, the case in which the ceramic sheet could be worked although a slight displacement was caused was evaluated as “Δ”, and the other cases were evaluated as “x”.
<*1 Method for Preparing Multilayered Ceramic Sheet>
A coating liquid for producing a ceramic sheet was prepared by mixing 100 parts by weight of barium titanate (made by Sakai Chemical Industry Co., Ltd.: trade name “BT-03/high purity perovskite”), 100 parts by weight (product dissolved in propylene glycol monoethylene ether, 10% base) of polyvinyl butyral (made by DENKI KAGAKU KOGYO KABUSHIKI KAISHA: trade name (PVB)), 6 parts by weight of bis-phthalate (made by J-PLUS Co., Ltd.: trade name DOP), 2 parts by weight of diglycerol oleate (Riken Vitamin Co., Ltd.: trade name RIKEMAL 0-71-D (E)) and 80 parts by weight of toluene while stirring the mixture. Subsequently, the above described coating liquid was applied onto a separator which had a silicone release agent applied to one face, so that the thickness of the film after having been dried became approximately 50 pm; the wet film was dried at 80° C. for 5 minutes; and the ceramic sheet was obtained by being peeled from the separator. Ten sheets of the above ceramic sheets were stacked and pressed by a pressure of 300 kg/cm2 to form the multilayered ceramic sheet.
<*2 Press-Cutting Condition>
Maker of cutting apparatus: UHT Inc., Cutting temperature: 80° C., Cutting depth (amount of remnant from table face): approximately 75 um, and Cutting blade: thickness/100 pm and tip-part angle/15°
Peelability for Chip
<Sheet of Examples 1, 2 and 3 and Comparative Example 3>
Peelability for a chip was evaluated by: cooling the sheet after having been subjected to the above described stretching process (though Comparative Example 3 was not stretched) under the conditions of a temperature of 25° C. and a humidity of 65%; and peeling the cut chip from the temporary fixing sheet. Specifically, the case in which the chip was easily peeled from the temporary fixing sheet without causing damage or deformation in the chip was evaluated as “◯”, and the other cases were evaluated as “x”.
Chip Readherence Rate
A readherence rate of chips was calculated from the rate of the number of the chips fusion-bonded to two or more adjacent chips with respect to the number of the whole cut chips.
Squareness of Chip
The squareness of the chip was measured by sampling each ten chips which were press-cut on each sheet, and observing the angle formed by the cut face and the bottom of the chip with a microscope.
The temporary fixing sheet according to the present invention (Examples 1 to 3) firmly held the ceramic sheet with a sufficient tack strength in a cutting step for the ceramic sheet at 80° C., also could provide high cutting accuracy, and could efficiently and easily peel the chip from itself by subsequently being cooled to a predetermined temperature or lower to decrease the tack strength to a level as shown in a tack strength at 25° C. In addition, the temporary fixing sheet was produced in a high degree of freedom in designing and with adequate handleability.
The temporary fixing sheet in Example 3 was fundamentally the same as the temporary fixing sheets in Examples 1 and 2, but had smaller tack strength at 80° C. than that of the temporary fixing sheets in Examples 1 and 2, and accordingly a part of the chip was slightly peeled off or was displaced when the chips were cut during a press-cutting work.
In contrast to this, the sheet in Comparative Example 1 was displaced when the chips were cut during the press-cutting operation, and also the chip after having been cut was not peeled from the sheet. In addition, on the sheet of Comparative Example 2, many chips resulted in adhering to each other again because of undergoing a heating treatment step. The sheet in Comparative Example 3 showed an inferior result to the sheets in Examples 1 and 2, in the working accuracy (squareness of chip) of the chip after having been press-cut.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-196249 | Sep 2010 | JP | national |
