Long film and method for manufacturing connected structure

Abstract

To provide a long film and a method for manufacturing a connected structure that can maintain the performance of individual pieces of adhesive film.SOLUTION: A long film 10 includes a long base film 11, and individual pieces 21 to 15 of an adhesive film arranged in the longitudinal direction of the base film 11, and an identification mark 30 is provided on at least one of the predetermined pieces or the base film on which the predetermined pieces are arranged. Therefore, when using individual pieces, it is possible to avoid defective pieces by identifying the identification mark, and it is possible to maintain the performance of the individual pieces of the adhesive film.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This technology relates to a long film in which pieces are arranged in the longitudinal direction of a base film and a method for manufacturing a connection structure.

Background Art

[0002] In recent years, adhesive films such as anisotropic conductive films (ACF), conductive films, and adhesive films (NCF: Non Conductive Film) are punched into pieces of arbitrary shapes, for example, and a long film in which the pieces are arranged in the longitudinal direction of the base film is wound around a reel and shipped (see, for example, Patent Document 1).

[0003] However, for example, during punching, remnants of fragments, transfer of fragments to the pieces, and curling of the pieces may occur. Therefore, it is necessary to inspect and pick up defective pieces from each piece of the long film.

[0004] Since the pickup of defective pieces is performed after inspection, there is a possibility that the pieces at both ends of the defective pieces will be affected. In addition, a small fragment of the adhesive film may remain on the base film and become a foreign object in the manufacturing line of the connection structure. Thus, it is difficult to maintain the performance of the pieces of the long film in the pickup of defective pieces.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] This technology was proposed in light of the conventional situation described above, and provides a long film that can maintain the performance of individual pieces of adhesive film, and a method for manufacturing a connecting structure. [Means for solving the problem]

[0007] The long film according to this technology comprises a long base film and individual pieces of adhesive film arranged in the longitudinal direction of the base film, wherein an identification mark is provided on at least one of the predetermined individual pieces or the base film on which the predetermined individual pieces are arranged. [Effects of the Invention]

[0008] According to this technology, when using individual pieces, defective pieces can be avoided by image recognition of the identification marks, thereby maintaining the performance of the individual pieces of adhesive film. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 shows an example of a long film roll. [Figure 2] Figure 2 is a schematic diagram showing an example of a defective piece with a window frame portion. Figure 2(A) shows a state where foreign matter is mixed in, Figure 2(B) shows a state where warping has occurred, and Figure 2(C) shows a state where chipping has occurred. [Figure 3] Figure 3 shows an example of an identification mark. [Figure 4] Figure 4 shows an example of the configuration of an inspection marking device. [Figure 5] Figure 5 is a diagram illustrating the operation of the detection sensor. Figure 5(A) shows the detection sensor that detects each individual piece of the transported long film, and Figure 5(B) shows the detection signal of the individual piece detected by the detection sensor. [Figure 6] Figure 6 is a diagram illustrating the detection timing of the detection sensor. [Figure 7] Figure 7 is a diagram illustrating the NG signal and OK signal in the inspection and judgment process. [Figure 8]Figure 8 shows an example of applying identification marks using a laser marker. [Figure 9] Figure 9 shows an example of acceleration and deceleration waveforms for a long film supply motor or retrieval motor. [Figure 10] Figure 10 is a flowchart showing the inspection method for long films. [Modes for carrying out the invention]

[0010] Hereinafter, embodiments of the present invention will be described in detail in the following order with reference to the drawings. 1. Long film 2. Inspection and marking device 3. Method for manufacturing long films 4. Manufacturing method of the connecting structure

[0011] <1. Long film rolls> The long film according to this embodiment comprises a long base film and individual adhesive film pieces arranged in the longitudinal direction of the base film. An identification mark is provided on at least one of the individual pieces or the base film on which the individual pieces are arranged so that defective pieces can be identified. As a result, when using the adhesive pieces, defective pieces can be avoided by identifying the identification mark, for example, by image recognition, and the performance of the adhesive film pieces can be maintained.

[0012] Figure 1 shows an example of a long film. As shown in Figure 1, the long film 10 has a long base film 11 and adhesive film pieces 21 to 25 arranged in the longitudinal direction of the base film 11, and an identification mark 30 is attached to a defective piece 23 and to the base film 11 on which the defective piece 23 is placed.

[0013] It is preferable that the long film 10 is provided with an end region made of a base film 11 at the end in the width direction. The length W in the width direction of the end region made of the base film 11 is preferably 100 μm or more, more preferably 500 μm or more, and still more preferably 1000 μm or more. Thereby, an identification mark can be imparted to the end region made of the base film 11, and a decrease in printing quality can be suppressed as compared with the case where the identification mark is imparted to individual pieces. Further, due to the presence of such an end region, it is difficult for the adhesive to protrude, which is likely to occur when the film is long. This is because it is difficult for the adhesive to reach the end of the base film, so-called blocking is less likely to occur, and the practical convenience is improved. As will be described later, when the individual pieces are separated from the end of the base film, blocking is less likely to occur, which can also contribute to productivity.

[0014] The long film 10 may be such that the individual pieces 21 to 25 are continuously arranged in the longitudinal direction for each unit region and wound around a reel. Here, the "unit region" refers to a region having a predetermined length in the length direction of the base material, for example, a rectangular region, and may be considered as the region between the center lines of adjacent individual pieces or the region where one individual piece is sandwiched between the center lines of the individual pieces. This adhesive film is to be peeled off and separated from the base film. In the present technology, the adhesive film of the individual piece has no corresponding support and is composed only of a layer made of an adhesive (in some cases, a cover film having substantially the same width as the base material is laminated).

[0015] The base film 11 is a support film that supports a plurality of individual pieces. Examples of the base film 11 include PET (Poly Ethylene Terephthalate), OPP (Oriented Polypropylene), PMP (Poly-4-methylpentene-1), PTFE (Polytetrafluoroethylene), and the like. Further, the base film 11 in which at least the surface on the individual piece side is subjected to a peeling treatment with, for example, a silicone resin can be preferably used.

[0016] The thickness of the base film 11 is not particularly limited. From the perspective of peeling, the lower limit of the thickness of the base film 11 is preferably 10 μm or more, more preferably 25 μm or more, and still more preferably 38 μm or more. The upper limit of the thickness of the base film is preferably 200 μm or less, more preferably 100 μm or less, still more preferably 75 μm or less, and may be 50 μm or less, because if it is too thick, there is a concern that excessive pressure is applied to the adhesive film. Also, when a cover film is provided on a single piece of the adhesive film, the thickness of the cover film is also in the same range, but the cover film is preferably thinner than the base film.

[0017] Also, the width of the base film 11 is not particularly limited. From the perspective of winding, the lower limit of the width of the base film 11 is preferably 1 mm or more, more preferably 2 mm or more, and still more preferably 4 mm or more. The upper limit of the width of the base film 11 is preferably 500 mm or less, more preferably 250 mm or less, still more preferably 120 mm or less, because if it is too large, there is a concern that handling and operation will be difficult.

[0018] There is no particular limitation on the adhesive film, and examples include anisotropic conductive films (ACF), conductive films in which conductive particles are contained in an adhesive, adhesive films (NCF), solder-containing films containing solder particles, and the like. The binder of the adhesive film may be thermosetting or thermoplastic.

[0019] When containing conductive particles such as metal particles, resin core metal-coated particles, and solder particles, the single piece may have a region containing conductive particles and a region not containing conductive particles. Also, the single piece may have a two-layer or more structure, a two-layer or more structure of a layer containing conductive particles or solder particles and a layer not containing them, a two-layer or more structure of layers containing conductive particles, or a two-layer or more structure of layers not containing conductive particles.

[0020] The shape of the individual pieces of adhesive film is not particularly limited, and may be, for example, a U-shape with two horizontal sides and one vertical side, a square shape with two horizontal sides and two vertical sides, an L-shape, a U-shape, a C-shape, etc., as described in Japanese Patent Publication No. 2020-198422. Furthermore, if conductive particles are included, the conductive particles may be embedded in the insulating resin, as described in Japanese Patent Publication No. 6187665. The conductive particles may be arranged randomly or regularly, and it is preferable that the conductive particles are aligned in the direction of the film thickness. Furthermore, when solder particles are included, it is preferable to blend a thermoplastic resin that is solid at room temperature and has a melt flow rate of 10 g / 10 min or more, measured under conditions of a temperature of 190°C and a load of 2.16 kg, as described in Japanese Patent Publication No. 6898413, and to have a thickness of 50% to 300% of the average particle size of the solder particles, and it is preferable that the minimum melt viscosity of the adhesive film is less than 100 Pa·s, as described in Japanese Patent Publication No. 7032367. The binder of the adhesive film may be thermosetting or thermoplastic. It may also be a single layer or laminated in multiple layers.

[0021] The thickness of each piece is not particularly limited, but the lower limit of the thickness of each piece is preferably 1 μm or more, more preferably 3 μm or more, and even more preferably 4 μm or more, and the upper limit of the thickness of each piece is preferably 50 μm or less, more preferably 20 μm or less, and even more preferably 10 μm or less.

[0022] The thickness of each individual piece can be measured using a known micrometer or digital thickness gauge (e.g., with a minimum display of 0.0001 mm). However, if the thickness of the individual piece is thinner than the particle diameter of the conductive particles, a contact-type thickness gauge is unsuitable, and it is preferable to use a laser displacement meter (e.g., a spectral interference displacement type). Here, the thickness of the individual piece refers only to the thickness of the binder resin layer and does not include the particle diameter of the conductive particles.

[0023] Furthermore, as shown in Figure 1, each piece has a window frame portion in which the base film 11 is exposed, and an identification mark 30 may be applied to the base film of the window frame portion. Pieces having a window frame portion are prone to becoming defective pieces, so the application of this technology is particularly useful.

[0024] Figure 2 is a schematic diagram showing an example of a defective piece of individual pieces having a window frame. Figure 2(A) shows a state where foreign matter is mixed in, Figure 2(B) shows a state where warping has occurred, and Figure 2(C) shows a state where chipping has occurred. As shown in Figure 2(A), foreign matter H1 mixed in on the individual piece or on the base film is identified as a defective piece in visual inspection if, for example, it is a metallic or non-metallic object larger than the particle size of conductive particles. Also, as shown in Figure 2(B), warping H2 that occurs on the outer shape of the individual piece is identified as a defective piece in visual inspection if, for example, the warping is ±50 μm or more. Also, as shown in Figure 2(C), chipping H3 that occurs on the outer shape of the individual piece is identified as a defective piece in visual inspection if, for example, the chipping is ±50 μm or more.

[0025] The identification mark 30 can be applied using a laser marker, inkjet, punching, etc., and among these, laser printing using a laser marker is preferred. For example, when applying the identification mark 30 using an inkjet, ink may scatter around, which may lead to misidentification of defective pieces or the creation of new defects due to contamination. Also, when marking defective areas by punching without stopping the transport, when winding the long film on which the pieces are placed onto the reel, the shape change caused by the punching holes may worsen the winding quality, or the punching marks may be transferred to pieces in adjacent winding layers, and waste from the punching will need to be collected. Furthermore, the film vibration caused by punching may adversely affect the focus of the preceding inspection camera, making it difficult to mark without stopping the transport. Applying the identification mark 30 by laser marking can eliminate these concerns.

[0026] Furthermore, the width of the identification mark 30 is greater than or equal to the particle diameter of the conductive particles if conductive particles are included, preferably 20 μm or more, more preferably 50 μm or more, and even more preferably 100 μm or more. This improves the distinctiveness of the identification mark 30.

[0027] Furthermore, the printing position of the identification mark 30 is not limited as long as the defective piece can be identified. For example, if a base film area is provided at the end of the long film in the width direction, the mark may be printed only on the base film at the end of the defective piece, or only on the defective piece, or on both the defective piece and the base film at the end of the defective piece. Also, for example, if a base film area is provided at the end of the long film in the width direction, the mark may be printed only on the base film at the end of the normal piece, or on the base film at the end of the piece preceding the defective piece.

[0028] Figure 3 shows an example of an identification mark. For example, as shown in Figure 3(A), the identification mark M1 may be a line in the width direction printed from the center of the window frame portion of the individual piece to the end region made of the base film. Also, as shown in Figure 3(B), the identification mark M2 may be a line in the transport direction printed on the end region made of the base film. Also, as shown in Figure 3(C), the identification mark M3 may be a line in the transport direction printed inside the window frame portion of the individual piece. Also, as shown in Figure 3(D), the identification mark M4 may be a zigzag line in the transport direction printed on the end region made of the base film. Also, as shown in Figure 3(E), the identification mark M5 may be a circle printed from the center of the window frame portion of the individual piece to the end region made of the base film. Also, as shown in Figure 3(F), the identification mark M6 may be a diagonal line printed on the inside of both ends in the transport direction of the individual piece. Furthermore, as shown in Figure 3(G), for example, the identification mark M7 is not limited in any way as long as it does not need to be printed on adjacent pieces and can still identify defective pieces.

[0029] With such long films, when using individual pieces, defective pieces can be avoided by identifying them using, for example, image recognition, thereby maintaining the performance of each piece of adhesive film. Furthermore, each piece can be managed by the user to ensure safe use, and the product's bonding characteristics (conductivity, adhesive strength, insulation, reliability, etc.) can be maintained more stably.

[0030] <2. Inspection and Marking Device> The inspection marking device according to this embodiment includes a transport unit that transports a long film in the longitudinal direction, on which individual pieces of adhesive film are arranged in the longitudinal direction of a base film; a detection unit that detects each individual piece of the transported long film; an inspection unit that inspects each individual piece of the transported long film; a marking unit that marks an identification mark on a predetermined individual piece of the transported long film or on at least one of the base film on which the predetermined individual pieces are arranged; and a control unit that acquires position information including the detection position of each individual piece in the longitudinal direction of the long film from the detection unit, acquires inspection information for each individual piece from the inspection unit based on the position information of each individual piece, and causes the marking unit to mark an identification mark based on the position information and inspection information of each individual piece. This makes it possible to inspect individual pieces of adhesive film at high speed and improve productivity, and when using the individual pieces, defective pieces can be avoided by image recognition of the identification marks.

[0031] Furthermore, it is preferable that the control unit records the detection position of each piece along with the placement position of each piece in the placement unit as position information, and the placement unit then places an identification mark on each piece based on the placement position. This allows for easy output of a printing trigger and stabilizes the position of the identification mark even when the transport speed is increased.

[0032] Furthermore, it is preferable that the control unit records the detection position of each individual piece along with the inspection position of each individual piece in the inspection unit as positional information, and the inspection unit inspects each individual piece of the transported long film based on the inspection position of each piece. This makes it easy to output an imaging trigger and stabilizes the inspection position of each piece even when the transport speed is increased.

[0033] Furthermore, it is preferable that the control unit controls the timing of applying identification marks in the marking unit based on the transport speed of the long film. This makes it possible to suppress misalignment of the printing position during acceleration and deceleration, for example.

[0034] Furthermore, the marking process can utilize methods such as laser markers, inkjet printing, and punching, with laser markers being preferred for marking identification. For example, when using an inkjet printer to mark identification, ink may scatter around, potentially leading to misidentification of defective pieces or the creation of new defects due to contamination. Additionally, when marking defective areas by punching without stopping transport, there is a risk that the shape of the punched holes may change when winding the long film containing the individual pieces onto a reel, potentially degrading the winding quality or transferring punch marks to pieces in adjacent winding layers. Moreover, waste generated by punching needs to be collected. Additionally, film vibration caused by punching can negatively affect the focus of the preceding inspection camera, impacting the transport speed and potentially reducing productivity. For these reasons, using laser marking as the marking method can avoid these concerns.

[0035] Figure 4 shows an example of the configuration of an inspection marking device. As shown in Figure 4, the inspection marking device 40 includes an unwinding mechanism 41, a detection sensor 42, an inspection camera 43, a laser marker 44, and a winding mechanism 45. The visual inspection marking device also includes a control unit that controls the unwinding mechanism 41, the detection sensor 42, the inspection camera 43, the laser marker 44, and the winding mechanism 45. Here, the unwinding mechanism 41 and the winding mechanism 45 correspond to the transport unit described above, the detection sensor 42 corresponds to the detection unit described above, the inspection camera 43 corresponds to the inspection unit described above, and the laser marker 44 corresponds to the marking unit described above.

[0036] The unwinding mechanism 41, although not shown, includes, for example, a supply reel in which a long film is stored, a supply motor that rotates the supply reel so that the long film is unwound from the supply reel, and rollers that support the long film in a rolling contact state, and unwinds the long film from the supply reel and conveys it in the longitudinal direction. Also, although not shown, the long film from the unwinding mechanism 41 to the winding mechanism 45 is subjected to a tensile force in the longitudinal direction of the long film, for example, by the action of the rollers.

[0037] The detection sensor 42 can be composed of, for example, a line sensor camera or an area line camera, and detects each individual piece of the transported long film. For example, by using a line sensor camera to image the width direction of the transported long film and detecting the difference in reflected light between when an individual piece is present on the base film and when there is no individual piece, individual pieces can be detected.

[0038] Figure 5 is a diagram illustrating the operation of the detection sensor. Figure 5(A) shows the detection sensor that detects each individual piece of the conveyed long film, and Figure 5(B) shows the detection signal of the individual piece detected by the detection sensor. As shown in Figures 5(A) and 5(B), the detection sensor 42 outputs a detection signal, for example, Hi when an individual piece is present in the conveyed long film, and Lo when no individual piece is present. The control unit detects each individual piece 50 at the timing when the detection signal changes from Lo to Hi.

[0039] Figure 6 is a diagram illustrating the detection timing of the detection sensor. The detection sensor 42 takes images at timings t=0, t=1, t=2, t=3, t=4, and t=5, for example, as shown in Figure 6, and the control unit detects individual pieces at timings t=1 and t=5 when the detection signal changes from Lo to Hi.

[0040] As described later, when the imaging trigger of the inspection camera 43 and the printing trigger of the laser marker 44 are set to offset, shortening the imaging interval of the detection sensor 42 reduces the error in the detection position and improves the positional accuracy of the imaging position of the inspection camera 43 and the laser marker 44. For this reason, the imaging interval of the detection sensor 42 is preferably 1 to 50 milliseconds, more preferably 1 to 10 milliseconds, and even more preferably 1 to 5 milliseconds.

[0041] The inspection camera 43 is composed of, for example, an area line camera, and takes images for visual inspection, such as the presence of fragments on the base film, the transfer of fragments to individual pieces, and the peeling of individual pieces, and records the results of the visual inspection in the individual piece information memory of the control unit. Preferably, the visual inspection makes two inspection judgments: an OK judgment for a normal individual piece and an NG judgment for a defective individual piece, and outputs an NG signal and an OK signal for the inspection judgment of one individual piece.

[0042] Figure 7 is a diagram illustrating the NG signal and OK signal in the inspection judgment. Visual inspection outputs an NG signal and an OK signal for the inspection judgment of a single piece, as shown in Figure 7. For example, an NG signal (Hi) is output for a defective piece number 3, and an OK signal (Hi) is output for normal pieces numbers 1, 2, 4, and 5. This allows for a delay in the judgment process, even if the NG judgment of a defective piece number 3 is delayed and the output of the NG signal is delayed, as long as the NG result for piece number 3 is recorded as piece information in memory before the defective piece number 3 reaches the printing trigger of the laser marker 44.

[0043] The laser marker 44 irradiates the object with laser light to change the state of the object's surface by oxidation, peeling, color development, etc., and applies an identification mark to at least one of a predetermined piece or base film without stopping transport or causing excessive influence on transport (such as vibration). The laser marker 44 preferably uses a scanning method that irradiates with a single point of laser light and prints in a single stroke. The laser used in the laser marker 44 can be appropriately selected according to the material of the base film, the adhesive film material of the piece, etc., and for example, a fiber laser, UV laser, YVO4 laser, CO2 laser, YAG laser, etc. can be selected. In addition, it is preferable to provide a vacuum in the printing part of the laser marker 44 to suppress the effect of dust generation.

[0044] Figure 8 shows an example of applying identification marks using a laser marker. As shown in Figure 8, the laser marker 44 applies identification marks M1 to M3 to defective pieces 52, 54, and 56, respectively, but does not apply identification mark M to normal pieces 51, 53, and 55. The identification marks are preferably applied within a unit area, and more preferably near the center of the unit area. This improves the ability to identify defective pieces. In the example of applying identification marks shown in Figure 8, the marks are printed on both the defective piece and the base film at the edge of the defective piece, but this technology is not limited to this.

[0045] The winding mechanism 45 includes, for example, a recovery reel from which the long film is collected, a recovery motor that rotates the recovery reel so that the long film is wound up from the recovery reel, and rollers that support the long film in a rolling contact state, and winds the long film, after individual piece inspection and marking have been completed, onto the recovery reel.

[0046] The control unit is composed of a memory-equipped device, such as a PLC (Programmable Logic Controller), and measures the transport distance traveled by the long film based on the length of the long film pulled out from the unwinding mechanism 41 or the length of the long film retrieved to the winding mechanism 45. The control unit also controls the supply motor and retrieval motor for the long film to transport it at a predetermined transport speed. The transport speed of the long film is preferably 1 to 50 m / min, more preferably 5 to 50 m / min, and even more preferably 10 to 50 m / min.

[0047] The control unit also acquires position information from the detection sensor 12, including the detection position of each individual piece in the longitudinal direction of the long film, and records the position information in memory as individual piece information. Based on the position information of each individual piece, the control unit acquires inspection information for each individual piece from the inspection camera 43 and records the inspection information in memory as individual piece information. Based on the individual piece information of each individual piece, the control unit causes the laser marker 44 to apply an identification mark. Based on the individual piece information, the control unit controls the imaging timing of the inspection camera 43, the printing timing of the laser marker 44, and so on.

[0048] Table 1 shows an example of individual piece information recorded in memory. As shown in Table 1, the individual piece information includes the individual piece number (Individual Piece No.), the length measurement value of individual piece detection by the detection sensor 42 (Presence / absence detection length measurement), the length measurement value of the imaging trigger of the inspection camera 43 (Camera trigger length measurement), the inspection result based on the inspection judgment (Inspection result), and the length measurement value of the printing trigger of the laser marker 44 (Laser length measurement).

[0049] [Table 1]

[0050] Each time the control unit detects a piece with the detection sensor 42, it records the piece number and the measured length value of the piece detection, which indicates the detection position of each piece in the longitudinal direction of the long film, in the piece information. The control unit also records the measured length value of the imaging trigger, which indicates the inspection position of each piece in the inspection camera 43, along with the detection position of each piece, in the piece information. Preferably, the inspection camera 43 inspects each piece of the transported long film based on the measured length value of the imaging trigger for each piece. In other words, the control unit can easily output the imaging trigger of the inspection camera 13 by offsetting the distance from the detection sensor 42 to the inspection camera 43, which is set in advance (300.00 mm in the example of piece information shown in Table 1).

[0051] Furthermore, the control unit preferably records the measured length of the print trigger, which is the placement position for each piece on the laser marker 44, along with the detection position of each piece, in the piece information, and the laser marker 44 preferably places an identification mark based on the measured length of the print trigger for each piece. That is, the control unit can easily output the print trigger of the laser marker 44 by offsetting the distance from the detection sensor 42 to the laser marker 44, which is set in advance (600.00 mm in the example of piece information shown in Table 1).

[0052] Furthermore, it is preferable that the control unit controls the timing of marking identification marks on the laser marker 44 based on the transport speed of the long film. For example, it is preferable that the control unit corrects the printing trigger based on the region of the acceleration / deceleration waveform of the supply motor or the retrieval motor.

[0053] Figure 9 shows an example of the acceleration and deceleration waveforms of a long film supply motor or retrieval motor. As shown in Figure 9, the acceleration and deceleration waveforms of the supply motor or retrieval motor are, for example, accelerated by acceleration control and decelerated by deceleration control. The acceleration and deceleration waveforms can be divided into seven speed regions, for example, the acceleration start region S1, the constant speed increase region S2, the acceleration end region S3, the constant speed region S4, the deceleration start region S5, the constant deceleration region S6, and the deceleration end region S7. The control unit monitors the speed regions of the supply motor or retrieval motor and sets correction values ​​corresponding to the speed regions S1 to S7 for the print trigger, thereby suppressing, for example, print position deviations during acceleration and deceleration.

[0054] Next, an example of the operation of the inspection marking device shown in Figure 4 will be described. The detection sensor 42 detects individual pieces of adhesive film being transported from the unwinding mechanism 41, and each time an individual piece is detected, the measured length value of the transport distance traveled by the long film is recorded in memory as individual piece information. In addition, each time an individual piece is detected, the control unit offsets the individual piece information by a preset distance from the detection sensor 42 to the inspection camera 43 (measured length value for image capture trigger) and a preset distance from the detection sensor 42 to the laser marker 44 (measured length value for printing trigger).

[0055] When the control unit has traveled the distance measured by the imaging trigger, it outputs a camera imaging trigger to the inspection camera 43 to perform a visual inspection and associates the individual pieces with the inspection results by adding the inspection results to the individual piece information. Then, when an individual piece whose inspection result in the individual piece information is NG has traveled the distance measured by the printing trigger, the control unit outputs a printing trigger to the laser marker 44 to print an identification mark on the defective individual piece.

[0056] Such an inspection and marking device allows for high-speed inspection of individual pieces of adhesive film without stopping the conveyance, and enables the application of identification marks to at least one of a predetermined individual piece or base film, thereby improving productivity.

[0057] <2. Manufacturing method of long film> The method for manufacturing a long film according to this embodiment includes a manufacturing step of producing a long film in which individual pieces of adhesive film are arranged in the longitudinal direction of a base film; a transport step of transporting the long film in the longitudinal direction; a detection step of detecting each individual piece of the transported long film and acquiring position information including the detection position of each individual piece in the longitudinal direction of the long film; an inspection step of inspecting each individual piece of the transported long film based on the position information of each individual piece and acquiring inspection information for each individual piece; and an application step of applying an identification mark to at least one of a predetermined individual piece of the transported long film or the base film on which the predetermined individual piece is arranged, based on the position information and inspection information of each individual piece. This makes it possible to inspect the individual pieces of adhesive film at high speed and improve productivity.

[0058] In this process, it is preferable that the placement position of each piece in the placement process is recorded in the position information during the detection process, and that an identification mark is applied to each piece based on its placement position during the placement process. This allows for easy output of the printing trigger and stabilizes the position of the identification mark even when the transport speed is increased.

[0059] Furthermore, in the detection process, it is preferable to record the inspection position of each individual piece in the inspection process as positional information, and in the inspection process, to inspect each individual piece of the transported long film based on the inspection position of each piece. This makes it possible to easily output an imaging trigger and stabilize the inspection position of each piece even when the transport speed is increased.

[0060] Furthermore, in the marking process, it is preferable to control the timing of marking based on the transport speed of the long film. This makes it possible to suppress misalignment of the printing position during acceleration, deceleration, etc.

[0061] Furthermore, the marking process can utilize methods such as laser markers, inkjet printing, and punching, and among these, it is preferable to apply identification marks using a laser marker. For example, when applying identification marks using an inkjet printer, ink may scatter around, potentially leading to misidentification of defective pieces or the creation of new defects due to contamination. Additionally, when marking defective areas by punching without stopping the transport, there is a risk that the winding quality may deteriorate due to shape changes caused by the punching holes when winding the long film on which the pieces are placed onto the reel, or that the punching marks may transfer to pieces in adjacent winding layers. Moreover, waste generated by punching needs to be collected. Furthermore, the film vibration caused by punching negatively affects the focus of the preceding inspection camera, making it difficult to mark without stopping the transport. These risks can be eliminated by using laser marking as the marking process.

[0062] The following describes the manufacturing process (A), transport process (B), detection process (C), inspection process (D), and application process (E) using the inspection marking device shown in Figures 4 to 9 and the flowchart showing the inspection method for long films shown in Figure 10.

[0063] [Manufacturing Process (A)] In manufacturing step (A), a long film is produced in which individual pieces of adhesive film are arranged along the longitudinal direction of the base film. The individual pieces are preferably formed on the base film by half-cutting, screen printing, or inkjet printing. Half-cutting involves cutting only the adhesive film with a die without cutting the base film, and removing unnecessary parts by die-cutting or the like. Screen printing involves passing the adhesive through the mesh of a screen mask using pressure from a squeegee or the like, printing (coating) it onto the base film, and producing individual pieces of a predetermined thickness, for example, by the thickness of the screen mask. The screen mask is a plate using a screen mesh woven from synthetic fibers such as polyester or stainless steel or various metal fibers. If the adhesive contains conductive particles or solder particles, the mesh should be made larger than the maximum diameter of the conductive particles or solder particles. Inkjet printing does not require a plate and patterns are created directly from data, and individual pieces of a predetermined thickness are produced by controlling the amount of coating, for example, by the nozzle diameter.

[0064] Furthermore, each piece may consist of two or more layers, including a layer containing conductive particles or solder particles and a layer not containing them, two or more layers containing conductive particles or solder particles, or two or more layers not containing conductive particles or solder particles. When each piece consists of two or more layers, it is preferable to form a base material of two or more layers by coating or lamination before performing the half-cutting process. Alternatively, the pieces may be manufactured by screen printing and then laminated and molded. Alternatively, the pieces may be manufactured by nozzle jet printing (inkjet printing) and then laminated and molded.

[0065] [Conveying process (B)] In the next transport process (B), the long film is transported in the longitudinal direction. In step S11, the control unit unwinds the long film on which the individual pieces of adhesive film are arranged from the unwinding mechanism 41 and measures the transport distance indicating the longitudinal position of the long film.

[0066] [Detection process (C)] In the next detection step (C), each individual piece of the transported long film is detected, and position information including the detection position of each individual piece in the longitudinal direction of the long film is acquired. First, in step S12, the control unit uses the detection sensor 42 to determine whether or not there are individual pieces on the base film, and acquires the measured length value of the transport distance, which is the position information of each individual piece in the longitudinal direction of the long film.

[0067] Then, in step S13, the control unit records the piece number (piece No.) each time the detection sensor 42 detects a piece, as shown in Table 1, and also records the measured length value of the piece detection (presence / absence detection length) indicating the detection position of each piece in the longitudinal direction of the long film in the piece information.

[0068] Furthermore, the control unit records the measured length value of the imaging trigger (camera trigger measurement) indicating the inspection position of each individual piece in the inspection camera 43, as shown in Table 1, for example, in the individual piece information. That is, the control unit offsets the distance from the detection sensor 42 to the inspection camera 43 to the individual piece information by a preset distance (300.00 mm in the example of individual piece information shown in Table 1).

[0069] Furthermore, the control unit records the measured length value (laser measurement) of the printing trigger, which is the placement position of each piece on the laser marker 14, in the piece information, for example, as shown in Table 1. That is, the control unit offsets the distance from the detection sensor 42 to the laser marker 44, which is set in advance, in the piece information (600.00 mm in the example piece information shown in Table 1).

[0070] [Inspection Process (D)] In the next inspection step (D), each individual piece of the transported long film is inspected based on the positional information of each piece, and inspection information for each piece is acquired. First, in step S14, the control unit determines whether or not the measured length value of the imaging trigger (camera trigger measurement) indicating the inspection position of each piece in the inspection camera 13 has been reached. If it determines that the measured length value of the imaging trigger has been reached, the unit proceeds to step S15.

[0071] Next, in step S15, the control unit images the individual pieces with the inspection camera 13 based on the measured length value of the imaging trigger and performs a visual inspection. The visual inspection performs two inspection judgments: an OK judgment for a normal piece and an NG judgment for a defective piece, and preferably outputs an NG signal and an OK signal for the inspection judgment of one piece. The control unit records the inspection information of the OK or NG judgment result of the visual inspection as piece information in memory.

[0072] [Applying process (E)] In the next marking step (E), based on the position information and inspection information of each individual piece, an identification mark is applied to at least one of the predetermined individual pieces of the conveyed long film or the base film on which the predetermined individual pieces are placed. First, in step S16, the control unit determines whether the laser marker 44 has traveled to the length value of the printing trigger, which is the marking position of each individual piece. If it determines that it has traveled to the length value of the imaging trigger, the unit proceeds to step S17.

[0073] Next, in step S17, the control unit determines whether the inspection result of a predetermined piece is OK or not based on the piece information recorded in memory. If the inspection result is OK, the unit proceeds to step S19; if the inspection result is NG, the unit proceeds to step S18.

[0074] In step S18, the control unit causes the laser marker 44 to apply an identification mark to defective pieces whose individual piece information inspection result is NG, and proceeds to step S19. In step S19, the control unit winds the long film, on which the individual piece inspection and marking have been completed, onto the recovery reel of the winding mechanism 45.

[0075] According to this method for manufacturing long films, individual pieces of adhesive film can be inspected at high speed without stopping the transport, and identification marks can be applied to at least one of the predetermined individual pieces or the base film, thereby improving productivity.

[0076] <4. Manufacturing method of connecting structure> The manufacturing method for the connecting structure according to this embodiment includes a long base film and individual pieces of adhesive film arranged in the longitudinal direction of the base film, wherein an identification mark is applied to at least one of the predetermined pieces or the base film on which the predetermined pieces are arranged so that defective pieces can be identified, and the manufacturing method includes an attachment step of attaching only normal pieces to a first electronic component or a second electronic component having a row of terminals based on the identification mark, and a connection step of connecting the terminals of the first electronic component and the terminals of the second electronic component via the normal pieces.

[0077] [Pasting process] In the attachment process, the aforementioned long film is used, and only normal pieces are attached to the first or second electronic component having a terminal row based on identification marks. For example, instead of identifying and using defective pieces by image recognition, normal pieces are pressed from the base film side using an attachment device and attached to the mounting surface of the first or second electronic component on the stage. The long film with the attached pieces is wound up as only the base film, while defective pieces may be wound up together with the base film, or they may be attached to a recovery member and then wound up as only the base film.

[0078] [Connection process] In the connection process, the terminals of the first electronic component and the terminals of the second electronic component are connected via a normal individual piece. For example, a crimping tool is used to press the terminal rows of the first and second electronic components together with a cushioning material in between. Depending on the curing type of the adhesive film of the individual piece, heating, light irradiation, etc., are performed to cure the individual piece.

[0079] According to this method of manufacturing the connecting structure, the performance of individual pieces of adhesive film used can be maintained, and excellent crimping characteristics (conductivity, adhesive strength, insulation, reliability, etc.) of the connecting structure can be obtained. [Explanation of symbols]

[0080] 10 Long film, 11 Base film, 21-25 Individual pieces, 30 Identification marks, 40 Inspection marking device, 41 Unwinding mechanism, 42 Detection sensor, 43 Inspection camera, 44 Laser marker, 45 Winding mechanism, 50-56 Individual pieces

Claims

1. The long film has a long base film and individual pieces of adhesive film arranged in the longitudinal direction of the base film, and an identification mark is provided on at least one of the predetermined pieces or the base film on which the predetermined pieces are arranged so that defective pieces can be identified.

2. 2. The long film according to claim 1, wherein an end region made of the base film is provided at an end in a width direction of the long film, and the identification mark is provided in the end region.

3. 3. The long film according to claim 2, wherein the length in the width direction of the end region is 100 μm or more.

4. The long film according to claim 1 , wherein the individual pieces have a window frame portion where the base film is exposed, and the identification mark is provided on the base film of the window frame portion.

5. The long film according to claim 1 , wherein the identification mark is printed by a laser.

6. 6. The long film according to claim 1, wherein the long film is wound on a reel.

7. A long film described in any one of claims 1 to 6, wherein the adhesive film contains conductive particles.

8. A manufacturing process for manufacturing a long film in which individual pieces of adhesive film are arranged in the longitudinal direction of a base film; a step of inspecting each piece of the long film and providing an identification mark to at least one of a predetermined piece or a base film on which the predetermined piece is arranged so that a defective piece can be identified; A method for producing a long film having the above structure.

9. A method for producing a long film as described in claim 8, wherein the adhesive film contains conductive particles.

10. a bonding step of bonding only normal pieces to a first electronic component or a second electronic component having a terminal row based on the identification mark using a long base film having adhesive film pieces arranged in a longitudinal direction of the base film, the long film having an identification mark on at least one of the predetermined pieces or the base film on which the predetermined pieces are arranged so that defective pieces can be identified; a connecting step of connecting a terminal of the first electronic component and a terminal of the second electronic component via the normal piece; A method for manufacturing a connection structure having the above structure.

11. A method for manufacturing a connection structure as described in claim 10, wherein the adhesive film contains conductive particles.

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