Wiring sheet and method for producing same

Abstract

To provide a wiring sheet which can stabilize a resistance value of wiring, and can suppress occurrence of curling.SOLUTION: A wiring sheet 100 includes a first pseudo sheet structure 2 in which a plurality of first conductive linear bodies 21 are arranged with a space, a first resin layer 3 supporting the first pseudo sheet structure 2, a pair of electrodes 4, a second pseudo sheet structure 6 in which a plurality of second conductive linear bodies 61 are arranged with a space, and a second resin layer 7 supporting the second pseudo sheet structure 6, in which the pair of electrodes 4 are sandwiched between the first pseudo sheet structure 2 and the second sheet pseudo sheet structure 6.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a wiring sheet and a method for manufacturing the same. [Background technology]

[0002] A sheet-like conductive member (hereinafter also referred to as a "conductive sheet") having a pseudo-sheet structure in which a number of conductive linear elements are arranged at intervals may be useful as a component for a variety of items, such as a heating element for a heating device, a material for heat-generating textiles, and a protective film for displays (shatter-resistant film). As an example of a sheet used as a heating element, Patent Document 1 describes a conductive sheet having a pseudo-sheet structure in which multiple linear elements extending in one direction are arranged at intervals. A pair of electrodes is provided on both ends of the multiple linear elements, thereby obtaining a wiring sheet that can be used as a heating element. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2017 / 086395 Summary of the Invention [Problem to be solved by the invention]

[0004] However, it has been found that in a wiring sheet such as that described in Patent Document 1, the resistance value of the wiring may not be stable. Also, it has been found that in a wiring sheet such as that described in Patent Document 1, curling may occur. An object of the present invention is to provide a wiring sheet that can stabilize the resistance value of wiring and suppress the occurrence of curling, and a method for manufacturing the same. [Means for solving the problem]

[0005] According to one aspect of the present invention, a wiring sheet is provided comprising a first pseudo sheet structure in which a plurality of first conductive linear members are arranged at intervals, a first resin layer supporting the first pseudo sheet structure, a pair of electrodes, a second pseudo sheet structure in which a plurality of second conductive linear members are arranged at intervals, and a second resin layer supporting the second pseudo sheet structure, wherein the pair of electrodes are sandwiched between the first pseudo sheet structure and the second pseudo sheet structure.

[0006] In the wiring sheet according to one aspect of the present invention, it is preferable that the first conductive linear body and the second conductive linear body do not overlap in a plan view of the wiring sheet.

[0007] In a wiring sheet according to one embodiment of the present invention, when viewed in a plan view of the wiring sheet, it is preferable that the first conductive linear body and the second resin layer overlap, and that the second conductive linear body and the first resin layer overlap.

[0008] In the wiring sheet according to one aspect of the present invention, it is preferable that the first resin layer is made of a plurality of first resin strips, and the second resin layer is made of a plurality of second resin strips.

[0009] In the wiring sheet according to one aspect of the present invention, the first conductive linear body and the second conductive linear body preferably have a wave shape in a plan view of the wiring sheet.

[0010] The wiring sheet according to one aspect of the present invention preferably further includes a breathable substrate.

[0011] In the wiring sheet according to one aspect of the present invention, it is preferable that the first conductive linear body and the second conductive linear body are arranged at equal intervals in a plan view of the wiring sheet.

[0012] According to one aspect of the present invention, there is provided a method for manufacturing a wiring sheet relating to the above-mentioned one aspect of the present invention, the method comprising the steps of: forming a first pseudo sheet structure on the first resin layer to obtain a first sheet-like conductive member; forming a second pseudo sheet structure on the second resin layer to obtain a second sheet-like conductive member; attaching the pair of electrodes to both ends of a first conductive linear body in the first sheet-like conductive member; and attaching the second sheet-like conductive member on the pair of electrodes so that both ends of a second conductive linear body in the second sheet-like conductive member are in contact with the pair of electrodes. Effect of the Invention

[0013] According to the present invention, it is possible to provide a wiring sheet that can stabilize the resistance value of wiring and suppress the occurrence of curling, and a manufacturing method thereof. [Brief description of the drawings]

[0014] [Figure 1] 1 is a schematic diagram showing a wiring sheet according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view showing the II-II cross section of FIG. [Diagram 3] 3A to 3C are diagrams illustrating a method for manufacturing a wiring sheet according to the first embodiment of the present invention. [Figure 4] FIG. 4 is a schematic diagram showing a wiring sheet according to a second embodiment of the present invention. [Diagram 5] FIG. 5 is a cross-sectional view showing the VV cross section of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] [First embodiment] Hereinafter, the present invention will be described with reference to the drawings, taking an embodiment as an example. The present invention is not limited to the contents of the embodiment. In the drawings, some parts are illustrated enlarged or reduced in size for ease of explanation.

[0016] (Wiring sheet) 1 and 2, the wiring sheet 100 according to this embodiment includes a first substrate 1, a first pseudo sheet structure 2, a first resin layer 3, a pair of electrodes 4, a second substrate 5, a second pseudo sheet structure 6, and a second resin layer 7. The first pseudo sheet structure 2 has a plurality of first conductive linear members 21 arranged at intervals. The second pseudo sheet structure 6 has a plurality of second conductive linear members 61 arranged at intervals.

[0017] Specifically, the wiring sheet 100 includes a first sheet-like conductive member in which a first resin layer 3 is laminated on a first substrate 1 and a first pseudo sheet structure 2 is laminated on the first resin layer 3, a second sheet-like conductive member in which a second resin layer 7 is laminated on a second substrate 5 and a second pseudo sheet structure 6 is laminated on the second resin layer 7, and a pair of electrodes 4. The pair of electrodes 4 is disposed between the first sheet-like conductive member and the second sheet-like conductive member, and the pair of electrodes 4 is sandwiched between the first pseudo sheet structure 2 and the second pseudo sheet structure 6. With this configuration, even if the first sheet-like conductive member expands or contracts, the second sheet-like conductive member also expands or contracts in the same manner, so that the wiring sheet 100 is less likely to curl. Furthermore, with this configuration, the pair of electrodes 4, the first pseudo sheet structure 2, and the second pseudo sheet structure 6 are laminated so as to be sandwiched between the first resin layer 3 and the second resin layer 7 from both sides, so that the first resin layer 3 and the second resin layer 7 can fix and protect the pair of electrodes 4, the first pseudo sheet structure 2, and the second pseudo sheet structure 6 from both sides. Therefore, it is possible to prevent the first pseudo sheet structure 2 and the second pseudo sheet structure 6 from coming off the pair of electrodes 4, and also to prevent the pair of electrodes 4, etc. from deteriorating. In this way, the resistance value of the wiring can be stabilized.

[0018] (base material) Examples of the first substrate 1 and the second substrate 5 include synthetic resin films, paper, metal foils, nonwoven fabrics, cloths, and glass films. The first substrate 1 or the second substrate 5 can directly or indirectly support the first pseudo sheet structure 2 or the second pseudo sheet structure 6. The first substrate 1 and the second substrate 5 may be the same or different. Examples of synthetic resin films include polyethylene films, polypropylene films, polybutene films, polybutadiene films, polymethylpentene films, polyvinyl chloride films, vinyl chloride copolymer films, polyethylene terephthalate films, polyethylene naphthalate films, polybutylene terephthalate films, polyurethane films, ethylene-vinyl acetate copolymer films, ionomer resin films, ethylene-(meth)acrylic acid copolymer films, ethylene-(meth)acrylic acid ester copolymer films, polystyrene films, polycarbonate films, and polyimide films. Examples of the paper include fine paper, recycled paper, and craft paper. Examples of the nonwoven fabric include spunbond nonwoven fabric, needle punch nonwoven fabric, melt blown nonwoven fabric, and spunlace nonwoven fabric. Examples of the cloth include woven fabric and knitted fabric.

[0019] (pseudo seat structure) The first pseudo sheet structure 2 has a structure in which a plurality of first conductive linear members 21 are arranged at intervals from each other. The second pseudo sheet structure 6 has a structure in which a plurality of second conductive linear members 61 are arranged at intervals from each other. The first conductive linear members 21 and the second conductive linear members 61 are linear or wavy in a plan view of the wiring sheet 100. The first pseudo sheet structure 2 has a structure in which a plurality of first conductive linear members 21 are arranged in a direction intersecting with the axial direction of the first conductive linear members 21. The second pseudo sheet structure 6 has a structure in which a plurality of second conductive linear members 61 are arranged in a direction intersecting with the axial direction of the second conductive linear members 61. The first conductive linear body 21 and the second conductive linear body 61 preferably have a wave shape in a plan view of the wiring sheet 100. For example, the wave shape may be a sine wave, a circular wave, a rectangular wave, a triangular wave, a sawtooth wave, or the like. If the first pseudo sheet structure 2 and the second pseudo sheet structure 6 have such a structure, breakage of the first conductive linear body 21 and the second conductive linear body 61 can be suppressed when the wiring sheet 100 is stretched in the axial direction of the first conductive linear body 21 and the second conductive linear body 61.

[0020] The volume resistivity of the first conductive linear body 21 and the second conductive linear body 61 is 1.0×10 -9 Ω m or more 1.0×10 -3 It is preferable that the resistance is Ω·m or less, and 1.0×10 -8 Ω m or more 1.0×10 -4 It is more preferable that the volume resistivity is Ω·m or less. When the first conductive linear body 21 and the second conductive linear body 61 have a volume resistivity in the above range, the surface resistance of the first pseudo sheet structure 2 and the second pseudo sheet structure 6 tends to decrease. The volume resistivity of the first conductive linear body 21 and the second conductive linear body 61 is measured as follows. Silver paste is applied to one end of the first conductive linear body 21 or the second conductive linear body 61 and to a portion 40 mm long from the end, and the resistance of the end and the portion 40 mm long from the end is measured to determine the resistance value of the first conductive linear body 21 or the second conductive linear body 61. Then, the cross-sectional area (unit: m 2 ) is multiplied by the resistance value and the obtained value is divided by the measured length (0.04 m) to calculate the volume resistivity of the first conductive linear body 21 or the second conductive linear body 61.

[0021] The cross-sectional shape of the first conductive linear body 21 and the second conductive linear body 61 is not particularly limited and may be polygonal, flat, elliptical, circular, or the like. However, from the viewpoint of compatibility with the first resin layer 3 and the second resin layer 7, an elliptical or circular shape is preferable. When the first conductive linear body 21 and the second conductive linear body 61 have a circular cross section, the thickness (diameter) D (see FIG. 2) of the first conductive linear body 21 and the second conductive linear body 61 is preferably 5 μm or more and 3 mm or less. From the viewpoints of suppressing an increase in sheet resistance and improving heat generation efficiency and dielectric breakdown resistance characteristics when the wiring sheet 100 is used as a heating element, the diameter D of the first conductive linear body 21 and the second conductive linear body 61 is more preferably 8 μm or more and 1 mm or less, and further preferably 12 μm or more and 100 μm or less. When the cross section of the first conductive linear body 21 and the second conductive linear body 61 is elliptical, it is preferable that the major axis is in the same range as the diameter D described above.

[0022] The diameter D of the first conductive linear body 21 and the second conductive linear body 61 is determined by observing the first conductive linear body 21 and the second conductive linear body 61 using a digital microscope, measuring the diameters of the first conductive linear body 21 and the second conductive linear body 61 at five randomly selected points, and averaging the measured diameters.

[0023] In a plan view of the wiring sheet 100, it is preferable that the first conductive linear members 21 and the second conductive linear members 61 do not overlap. It is also preferable that the first conductive linear members 21 and the second conductive linear members 61 are arranged alternately. It is also preferable that the first conductive linear members 21 and the second conductive linear members 61 are arranged at equal intervals. With the above-mentioned configuration, it is possible to improve the functionality of the wiring sheet 100, such as making the distribution of temperature rise uniform when the wiring sheet 100 is used as a heating element. The distance L (see FIG. 2) between the first conductive linear body 21 and the second conductive linear body 61 is preferably 20 mm or less, more preferably 0.5 mm or more and 15 mm or less, and even more preferably 1 mm or more and 10 mm or less. If the spacing between the first conductive linear body 21 and the second conductive linear body 61 is within the above range, the conductive linear bodies are relatively densely packed, thereby improving the functionality of the wiring sheet 100, such as maintaining a low resistance of the pseudo sheet structure and making the distribution of temperature rise uniform when the wiring sheet 100 is used as a heating element.

[0024] The distance L between the first conductive linear body 21 and the second conductive linear body 61 is measured by observing the first conductive linear body 21 and the second conductive linear body 61 visually or using a digital microscope, and measuring the distance between adjacent first conductive linear bodies 21 and second conductive linear bodies 61. The interval between adjacent first conductive linear bodies 21 and second conductive linear bodies 61 is the length along the direction in which the first conductive linear bodies 21 and second conductive linear bodies 61 are arranged, and is the length between opposing portions of the first conductive linear bodies 21 and second conductive linear bodies 61 (see FIG. 2). When the first conductive linear bodies 21 and second conductive linear bodies 61 are arranged at uneven intervals, the interval L is the average value of the intervals between all adjacent first conductive linear bodies 21 and second conductive linear bodies 61.

[0025] The first conductive linear body 21 and the second conductive linear body 61 are not particularly limited, but may be linear bodies including metal wires (hereinafter also referred to as "metal wire linear bodies"). Metal wires have high thermal conductivity, high electrical conductivity, high handling properties, and versatility, so when metal wire linear bodies are used as the first conductive linear body 21 and the second conductive linear body 61, the resistance values ​​of the first pseudo sheet structure 2 and the second pseudo sheet structure 6 are reduced while the light transmittance is easily improved. In addition, when the wiring sheet 100 is used as a heating body, rapid heat generation is easily achieved. Furthermore, as described above, linear bodies having a small diameter are easily obtained. In addition, examples of the first conductive linear body 21 and the second conductive linear body 61 include, in addition to metal wire linear bodies, linear bodies including carbon nanotubes and linear bodies in which a conductive coating is applied to a thread.

[0026] The metal wire linear body may be a linear body made of a single metal wire, or may be a linear body made of a plurality of twisted metal wires. Examples of the metal wire include wires containing metals such as copper, aluminum, tungsten, iron, molybdenum, nickel, titanium, silver, and gold, or alloys containing two or more metals (for example, steels such as stainless steel and carbon steel, brass, phosphor bronze, zirconium-copper alloys, beryllium copper, iron-nickel, nichrome, nickel-titanium, Kanthal, Hastelloy, and rhenium-tungsten). The metal wire may be plated with tin, zinc, silver, nickel, chromium, nickel-chromium alloys, or solder, or may be surface-coated with a carbon material or polymer described below. In particular, wires containing one or more metals selected from tungsten and molybdenum and alloys containing these are preferred from the viewpoint of low volume resistivity. The metal wire may be a metal wire coated with a carbon material. When the metal wire is coated with a carbon material, the metallic luster is reduced, and the presence of the metal wire can be easily made less noticeable. In addition, when the metal wire is coated with a carbon material, metal corrosion is also suppressed. Examples of the carbon material that coats the metal wire include amorphous carbon (for example, carbon black, activated carbon, hard carbon, soft carbon, mesoporous carbon, and carbon fiber), graphite, fullerene, graphene, and carbon nanotubes.

[0027] A linear body containing carbon nanotubes can be obtained, for example, by drawing carbon nanotubes in a sheet shape from the end of a carbon nanotube forest (a growth body in which multiple carbon nanotubes are grown on a substrate so as to be aligned in a direction perpendicular to the substrate, and may also be called an "array"), bundling the drawn carbon nanotube sheets, and twisting the bundles of carbon nanotubes. In such a manufacturing method, if no twist is applied during twisting, a ribbon-shaped carbon nanotube linear body is obtained, and if twist is applied, a thread-shaped linear body is obtained. A ribbon-shaped carbon nanotube linear body is a linear body in which the carbon nanotubes do not have a twisted structure. In addition, a carbon nanotube linear body can be obtained by spinning a dispersion of carbon nanotubes. The carbon nanotube linear body can be produced by spinning, for example, by the method disclosed in U.S. Patent Application Publication No. 2013 / 0251619 (JP Patent Publication No. 2012-126635). From the viewpoint of obtaining uniformity in the diameter of the carbon nanotube linear body, it is preferable to use a thread-like carbon nanotube linear body, and from the viewpoint of obtaining a carbon nanotube linear body with high purity, it is preferable to obtain a thread-like carbon nanotube linear body by twisting a carbon nanotube sheet. The carbon nanotube linear body may be a linear body in which two or more carbon nanotube linear bodies are woven together. In addition, the carbon nanotube linear body may be a linear body in which a carbon nanotube is composited with another conductive material (hereinafter also referred to as a "composite linear body").

[0028] Examples of the composite linear body include (1) a composite linear body in which a metal or a metal alloy is supported on the surface of a forest, sheet or bundle of carbon nanotubes, or a twisted linear body, by vapor deposition, ion plating, sputtering, wet plating, or the like, in a process of obtaining a carbon nanotube linear body by drawing out carbon nanotubes from an end of a carbon nanotube forest into a sheet shape, bundling the drawn carbon nanotube sheet, and then twisting the bundles of carbon nanotubes, (2) a composite linear body in which bundles of carbon nanotubes are twisted together with a linear body of a metal element or a linear body of a metal alloy, or a composite linear body, and (3) a composite linear body in which a linear body of a metal element or a linear body of a metal alloy, or a composite linear body, is braided with a linear body of a carbon nanotube element or a composite linear body, etc. In the composite linear body of (2), when the bundles of carbon nanotubes are twisted, a metal may be supported on the carbon nanotubes as in the composite linear body of (1). In addition, the composite linear body of (3) is a composite linear body in which two linear bodies are woven together, but as long as it contains at least one linear body of a simple metal or a linear body of a metal alloy, or a composite linear body, it may be a composite linear body in which three or more carbon nanotube linear bodies, or linear bodies of a simple metal or a linear body of a metal alloy, or a composite linear body are woven together. Examples of metals for the composite linear body include elemental metals such as gold, silver, copper, iron, aluminum, nickel, chromium, tin, and zinc, as well as alloys containing at least one of these elemental metals (such as copper-nickel-phosphorus alloys and copper-iron-phosphorus-zinc alloys).

[0029] The first conductive linear body 21 and the second conductive linear body 61 may be linear bodies in which a conductive coating is applied to the thread. Examples of the thread include threads spun from resins such as nylon and polyester. Examples of the conductive coating include coatings of metals, conductive polymers, carbon materials, etc. The conductive coating can be formed by plating, vapor deposition, etc. A linear body in which a conductive coating is applied to the thread can improve the conductivity of the linear body while maintaining the flexibility of the thread. In other words, it becomes easy to reduce the resistance of the first pseudo sheet structure 2 and the second pseudo sheet structure 6.

[0030] (Resin layer) The first resin layer 3 and the second resin layer 7 are layers containing resin. The first resin layer 3 or the second resin layer 7 can directly or indirectly support the first pseudo sheet structure 2 or the second pseudo sheet structure 6. The first resin layer 3 can protect the second conductive linear body 61, and the second resin layer 7 can protect the first conductive linear body 21. From this perspective, it is preferable that the first conductive linear body 21 and the second resin layer 7 overlap, and the second conductive linear body 61 and the first resin layer 3 overlap, in a plan view of the wiring sheet 100. The first resin layer 3 and the second resin layer 7 are preferably layers containing an adhesive. For example, when the first pseudo sheet structure 2 is formed on the first resin layer 3, the adhesive makes it easy to attach the first conductive linear body 21 to the first resin layer 3.

[0031] The first resin layer 3 and the second resin layer 7 may be layers made of a dryable or hardenable resin. This provides the first resin layer 3 and the second resin layer 7 with sufficient hardness to protect the first pseudo sheet structure 2 and the second pseudo sheet structure 6, and the first resin layer 3 and the second resin layer 7 also function as a protective film. In addition, the first resin layer 3 and the second resin layer 7 after hardening or drying have impact resistance, and can also suppress deformation of the wiring sheet 100 due to impact.

[0032] The first resin layer 3 and the second resin layer 7 are preferably energy ray-curable such as ultraviolet rays, visible energy rays, infrared rays, and electron beams, since they can be easily cured in a short time. Note that "energy ray curing" also includes heat curing by heating using energy rays.

[0033] The adhesive for the first resin layer 3 and the second resin layer 7 may be a thermosetting adhesive that cures with heat, a so-called heat seal type adhesive that adheres with heat, or an adhesive that develops stickiness when moistened. However, from the perspective of ease of application, it is preferable that the first resin layer 3 and the second resin layer 7 are energy ray curable. Examples of energy ray curable resins include compounds having at least one polymerizable double bond in the molecule, and acrylate compounds having a (meth)acryloyl group are preferred.

[0034] Examples of the acrylate-based compound include (meth)acrylates containing a chain aliphatic skeleton (trimethylolpropane tri(meth)acrylate, tetramethylolmethane tetra(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol monohydroxypenta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, 1,4-butylene glycol di(meth)acrylate, and 1,6-hexanediol di(meth)acrylate. acrylates, etc.), alicyclic skeleton-containing (meth)acrylates (dicyclopentanyl di(meth)acrylate, dicyclopentadiene di(meth)acrylate, etc.), polyalkylene glycol (meth)acrylates (polyethylene glycol di(meth)acrylate, etc.), oligoester (meth)acrylates, urethane (meth)acrylate oligomers, epoxy-modified (meth)acrylates, polyether (meth)acrylates other than the above-mentioned polyalkylene glycol (meth)acrylates, and itaconic acid oligomers.

[0035] The weight average molecular weight (Mw) of the energy ray curable resin is preferably from 100 to 30,000, and more preferably from 300 to 10,000.

[0036] The adhesive composition may contain one or more types of energy ray curable resins, and when two or more types are contained, the combination and ratio thereof may be selected arbitrarily. Furthermore, the adhesive composition may be combined with a thermoplastic resin described later, and the combination and ratio thereof may be selected arbitrarily.

[0037] The first resin layer 3 and the second resin layer 7 may be adhesive layers formed from an adhesive (pressure-sensitive adhesive). The adhesive of the adhesive layer is not particularly limited. For example, examples of the adhesive include an acrylic adhesive, a urethane adhesive, a rubber adhesive, a polyester adhesive, a silicone adhesive, and a polyvinyl ether adhesive. Among these, the adhesive is preferably at least one selected from the group consisting of an acrylic adhesive, a urethane adhesive, and a rubber adhesive, and more preferably an acrylic adhesive.

[0038] Examples of acrylic adhesives include polymers containing structural units derived from alkyl (meth)acrylates having a straight-chain alkyl group or a branched-chain alkyl group (i.e., polymers obtained by polymerizing at least alkyl (meth)acrylates), acrylic polymers containing structural units derived from (meth)acrylates having a cyclic structure (i.e., polymers obtained by polymerizing at least (meth)acrylates having a cyclic structure), etc. Here, "(meth)acrylate" is used as a term indicating both "acrylate" and "methacrylate", and the same applies to other similar terms.

[0039] When the acrylic polymer is a copolymer, the form of the copolymerization is not particularly limited. The acrylic copolymer may be any of a block copolymer, a random copolymer, and a graft copolymer.

[0040] When the acrylic polymer is a copolymer, the form of the copolymerization is not particularly limited. The acrylic copolymer may be any of a block copolymer, a random copolymer, and a graft copolymer.

[0041] The acrylic copolymer may be crosslinked with a crosslinking agent. Examples of the crosslinking agent include known epoxy crosslinking agents, isocyanate crosslinking agents, aziridine crosslinking agents, and metal chelate crosslinking agents. When the acrylic copolymer is crosslinked, a hydroxyl group, a carboxyl group, or the like that reacts with these crosslinking agents can be introduced into the acrylic copolymer as a functional group derived from the monomer component of the acrylic polymer.

[0042] When the first resin layer 3 and the second resin layer 7 are formed from an adhesive, the first resin layer 3 and the second resin layer 7 may further contain the above-mentioned energy ray curable resin in addition to the adhesive. When an acrylic adhesive is applied as the adhesive, a compound having both a functional group that reacts with a functional group derived from a monomer component in an acrylic copolymer and an energy ray polymerizable functional group in one molecule may be used as the energy ray curable component. The reaction between the functional group of the compound and the functional group derived from the monomer component in the acrylic copolymer makes the side chain of the acrylic copolymer curable by energy ray irradiation. Even when the adhesive is other than an acrylic adhesive, a component whose side chain is energy ray polymerizable may be used as a polymer component other than the acrylic polymer.

[0043] The thermosetting resin used in the first resin layer 3 and the second resin layer 7 is not particularly limited, and specifically includes epoxy resin, phenol resin, melamine resin, urea resin, polyester resin, urethane resin, acrylic resin, benzoxazine resin, phenoxy resin, amine-based compound, acid anhydride-based compound, etc. These can be used alone or in combination of two or more. Among these, from the viewpoint of suitability for curing using an imidazole-based curing catalyst, it is preferable to use epoxy resin, phenol resin, melamine resin, urea resin, amine-based compound, and acid anhydride-based compound, and in particular, from the viewpoint of showing excellent curing properties, it is preferable to use epoxy resin, phenol resin, a mixture thereof, or a mixture of epoxy resin and at least one selected from the group consisting of phenol resin, melamine resin, urea resin, amine-based compound, and acid anhydride-based compound.

[0044] The moisture-curable resin used in the first resin layer 3 and the second resin layer 7 is not particularly limited, and examples thereof include urethane resins and modified silicone resins, which are resins that generate isocyanate groups when exposed to moisture.

[0045] When using an energy ray curable resin or a thermosetting resin, it is preferable to use a photopolymerization initiator, a thermal polymerization initiator, etc. By using a photopolymerization initiator, a thermal polymerization initiator, etc., a crosslinked structure is formed, and it becomes possible to more firmly protect the first pseudo sheet structure 2 and the second pseudo sheet structure 6.

[0046] Examples of the photopolymerization initiator include benzophenone, acetophenone, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, benzoin benzoic acid, benzoin methyl benzoate, benzoin dimethyl ketal, 2,4-diethylthioxanthone, 1-hydroxycyclohexyl phenyl ketone, benzyl diphenyl sulfide, tetramethylthiuram monosulfide, azobisisobutyronitrile, 2-chloroanthraquinone, diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, and bis(2,4,6-trimethylbenzoyl)-phenyl-phosphine oxide.

[0047] Examples of the thermal polymerization initiator include hydrogen peroxide, peroxodisulfates (ammonium peroxodisulfate, sodium peroxodisulfate, potassium peroxodisulfate, etc.), azo compounds (2,2'-azobis(2-amidinopropane) dihydrochloride, 4,4'-azobis(4-cyanovaleric acid), 2,2'-azobisisobutyronitrile, 2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile), etc.), and organic peroxides (benzoyl peroxide, lauroyl peroxide, peracetic acid, persuccinic acid, di-t-butyl peroxide, t-butyl hydroperoxide, cumene hydroperoxide, etc.).

[0048] These polymerization initiators can be used alone or in combination of two or more. When these polymerization initiators are used to form a crosslinked structure, the amount used is preferably 0.1 parts by mass or more and 100 parts by mass or less, more preferably 1 part by mass or more and 100 parts by mass or less, and particularly preferably 1 part by mass or more and 10 parts by mass or less, relative to 100 parts by mass of the energy ray-curable resin or the thermosetting resin.

[0049] The first resin layer 3 and the second resin layer 7 may not be curable and may be layers made of, for example, a thermoplastic resin composition. The thermoplastic resin layer can be softened by including a solvent in the thermoplastic resin composition. This makes it easier to attach the first conductive linear body 21 to the first resin layer 3, for example, when forming the first pseudo sheet structure 2 on the first resin layer 3. On the other hand, the thermoplastic resin layer can be dried and solidified by volatilizing the solvent in the thermoplastic resin composition.

[0050] Examples of the thermoplastic resin include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polyurethane, polyether, polyethersulfone, polyimide, and acrylic resin. Examples of the solvent include alcohol-based solvents, ketone-based solvents, ester-based solvents, ether-based solvents, hydrocarbon-based solvents, alkyl halide solvents, and water.

[0051] The first resin layer 3 and the second resin layer 7 may contain an inorganic filler. By containing an inorganic filler, the hardness of the first resin layer 3 and the second resin layer 7 after curing can be further improved.

[0052] Examples of inorganic fillers include inorganic powders (e.g., powders of silica, alumina, talc, calcium carbonate, titanium white, red iron oxide, silicon carbide, and boron nitride), beads obtained by sphering inorganic powders, single crystal fibers, and glass fibers. Among these, silica filler and alumina filler are preferred as inorganic fillers. The inorganic fillers may be used alone or in combination of two or more.

[0053] The first resin layer 3 and the second resin layer 7 may contain other components, such as well-known additives, such as an organic solvent, a flame retardant, a tackifier, an ultraviolet absorber, an antioxidant, a preservative, an antifungal agent, a plasticizer, an antifoaming agent, and a wettability adjuster.

[0054] The thicknesses of the first resin layer 3 and the second resin layer 7 are appropriately determined depending on the application of the wiring sheet 100. For example, from the viewpoint of adhesiveness, the thicknesses of the first resin layer 3 and the second resin layer 7 are preferably 3 μm or more and 150 μm or less, and more preferably 5 μm or more and 100 μm or less.

[0055] (electrode) The electrode 4 is used to supply a current to the first conductive linear body 21 and the second conductive linear body 61. The electrode 4 can be formed using a known electrode material. Examples of the electrode material include a conductive paste (such as silver paste), a metal foil (such as copper foil), and a metal wire. The electrode 4 is disposed so as to be electrically connected to both ends of the first conductive linear body 21 and the second conductive linear body 61. When the electrode material is a metal wire, the number of metal wires may be one, but is preferably two or more. Examples of the metal of the metal foil or metal wire include metals such as copper, aluminum, tungsten, iron, molybdenum, nickel, titanium, silver, and gold, or alloys containing two or more metals (for example, steels such as stainless steel and carbon steel, brass, phosphor bronze, zirconium copper alloys, beryllium copper, iron nickel, nichrome, nickel titanium, Kanthal, Hastelloy, and rhenium tungsten). The metal foil or metal wire may be plated with tin, zinc, silver, nickel, chromium, nickel chromium alloys, or solder. In particular, those containing one or more metals selected from copper and silver and alloys containing them are preferred from the viewpoint of metals with low volume resistivity.

[0056] The width of one of the pair of electrodes 4 is preferably 10 mm or less, more preferably 3000 μm or less, and even more preferably 1500 μm or less, in a plan view of the wiring sheet 100. When one of the electrodes is a metal wire, the width of the electrode is the diameter of the metal wire, and when two or more metal wires are used, the width of one of the electrodes refers to the sum of the diameters of the metal wires.

[0057] The thickness of the electrode 4 is preferably 2 μm or more and 200 μm or less, more preferably 2 μm or more and 170 μm or less, and particularly preferably 10 μm or more and 150 μm or less. If the thickness of the electrode is within the above range, the electrical conductivity is high and the resistance is low, and the resistance value with the pseudo sheet structure can be kept low. In addition, sufficient strength as an electrode is obtained. In addition, when the electrode 4 is a metal wire, the thickness of the electrode 4 is the diameter of the metal wire.

[0058] The ratio of the resistance value between the electrode 4 and the first pseudo sheet structure 2 and the second pseudo sheet structure 6 is preferably 0.0001 or more and 0.3 or less, more preferably 0.0005 or more and 0.1 or less. The ratio of the resistance value between the electrode 4 and the first pseudo sheet structure 2 and the second pseudo sheet structure 6 can be calculated by "[resistance value of the electrode 4]÷[combined resistance value in a form in which the first conductive linear body and the second conductive linear body used in the first pseudo sheet structure 2 and the second pseudo sheet structure 6 are connected in parallel with the electrode 4]". By being within this range, when the wiring sheet 100 is used as a heating element, abnormal heat generation at the electrode portion is suppressed. When the wiring sheet 100 is used as a sheet-like heater, only the first pseudo sheet structure 2 and the second pseudo sheet structure 6 generate heat, and a sheet-like heater with good heat generation efficiency can be obtained. The resistance values ​​of the electrode 4 and the first and second pseudo sheet structures 2 and 6 can be measured using a tester. First, the resistance value of the electrode 4 is measured, and then the resistance values ​​of the first and second pseudo sheet structures 2 and 6 to which the electrode 4 is attached are measured. Then, the measured value of the electrode 4 is subtracted from the resistance values ​​of the first and second pseudo sheet structures 2 and 6 to which the electrode 4 is attached, thereby calculating the respective resistance values ​​of the electrode 4 and the first and second pseudo sheet structures 2 and 6.

[0059] (Method of manufacturing wiring sheet) Next, a method for manufacturing interconnect sheet 100 according to the present embodiment will be described. Interconnect sheet 100 can be manufactured by this manufacturing method. The manufacturing method of the wiring sheet 100 according to this embodiment includes a step of forming a first pseudo sheet structure 2 on a first resin layer 3 to obtain a first sheet-like conductive member shown in FIG. 3(A) (hereinafter referred to as the "first sheet-like conductive member fabrication step"), a step of forming a second pseudo sheet structure 6 on a second resin layer 7 to obtain a second sheet-like conductive member shown in FIG. 3(B) (hereinafter also referred to as the "second sheet-like conductive member fabrication step"), a step of attaching a pair of electrodes 4 to both ends of a first conductive linear member 21 in the first sheet-like conductive member as shown in FIG. 3(C) (hereinafter also referred to as the "electrode attachment step"), and a step of attaching the second sheet-like conductive member on the pair of electrodes 4 so that both ends of a second conductive linear member 61 in the second sheet-like conductive member contact the pair of electrodes 4 as shown in FIG. 3(D) (hereinafter also referred to as the "overlapping step").

[0060] In the first sheet-shaped conductive member manufacturing process, a first pseudo sheet structure 2 having a plurality of first conductive linear members 21 arranged at intervals as shown in Figure 3 (A) is provided on a first resin layer 3 provided on a first substrate 1. The method of providing the first pseudo sheet structure 2 is not particularly limited, and a known method can be appropriately adopted. For example, the first base material 1 with the first resin layer 3 is arranged on the outer peripheral surface of a drum member (not shown) with the first resin layer 3 facing up, and while rotating the drum member, when the first resin layer 3 is in an adhesive state (uncured, before drying, heated by heat sealing, etc.), the first resin layer 3 and the first conductive linear body 21 are moved relative to each other so that the first conductive linear body 21 is formed into a predetermined shape such as a wave shape, and then wound into a roll. Thereafter, the first resin layer 3 is cured as necessary. Further, after that, the bundle of the first conductive linear body 21 wound in a spiral shape is cut along the axial direction of the drum member, and also cut in the flow direction as necessary to a predetermined dimension. As a result, the first pseudo sheet structure 2 is formed and placed on the first resin layer 3. Then, the first base material 1 on which the first pseudo sheet structure 2 is formed is taken out from the drum member. According to this method, for example, it is easy to adjust the spacing between adjacent first conductive linear bodies 21 in the first pseudo sheet structure 2 by moving the payout portion of the first conductive linear body 21 along a direction parallel to the axis of the drum member while rotating the drum member.

[0061] In the second sheet-shaped conductive member manufacturing process, a second pseudo sheet structure 6 having a plurality of second conductive linear members 61 arranged at intervals as shown in Figure 3 (B) is provided on a second resin layer 7 provided on a second substrate 5. The method for providing the second pseudo seat structure 6 is the same as the method for providing the first pseudo seat structure 2 described above.

[0062] In the electrode attachment step, as shown in FIG. 3(C), a pair of electrodes 4 are attached to both ends of the first conductive linear body 21 of the first sheet-shaped conductive member. The method for attaching the electrode 4 is not particularly limited, and any known method can be appropriately adopted. For example, the electrode 4 is disposed on the first resin layer 3 so that the first conductive linear body 21 and the electrode 4 are in contact with each other. Thereafter, the electrode 4 is pressure-bonded to the first resin layer 3, thereby attaching the electrode 4 to the first pseudo sheet structure 2.

[0063] In the overlapping process, as shown in Figure 3 (D), the second sheet-shaped conductive member is attached onto a pair of electrodes 4 so that both ends of the second conductive linear body 61 in the second sheet-shaped conductive member are in contact with the pair of electrodes 4. The method of attaching the second sheet-like conductive member is not particularly limited, and a known method can be appropriately adopted. For example, the second sheet-like conductive member is arranged on the pair of electrodes 4 provided on the first pseudo sheet structure 2 so that both ends of the second conductive linear body 61 and the pair of electrodes 4 come into contact with each other. Thereafter, the first resin layer 3 and the second resin layer 7 are pressed together to attach the second sheet-like conductive member to the first sheet-like conductive member with the electrodes 4. Furthermore, the first sheet-like conductive member is arranged on the pair of electrodes 4 provided on the second pseudo sheet structure 6 so that both ends of the first conductive linear body 21 and the pair of electrodes 4 come into contact with each other. Thereafter, the first resin layer 3 and the second resin layer 7 are pressed together to attach the first sheet-like conductive member to the second sheet-like conductive member with the electrodes 4.

[0064] (Effects of the First Embodiment) According to this embodiment, the following advantageous effects can be obtained. (1) In the present embodiment, two sheet-shaped conductive members (a first sheet-shaped conductive member and a second sheet-shaped conductive member) are disposed on either side of a pair of electrodes 4. Therefore, the sheet-shaped conductive member on one side does not expand or contract, and curling of the wiring sheet 100 is less likely to occur. (2) In this embodiment, the pair of electrodes 4 and the first pseudo sheet structure 2 and second pseudo sheet structure 6 are laminated so as to be sandwiched between the first resin layer 3 and the second resin layer 7 from both sides, so that the first resin layer 3 and the second resin layer 7 can fix and protect the pair of electrodes 4 and the first pseudo sheet structure 2 and second pseudo sheet structure 6 from both sides. This makes it possible to prevent the first pseudo sheet structure 2 and the second pseudo sheet structure 6 from coming off the pair of electrodes 4, and also to prevent deterioration of the pair of electrodes 4, etc. In this way, the resistance value of the wiring can be stabilized.

[0065] [Second embodiment] Next, a second embodiment of the present invention will be described with reference to the drawings. As shown in Figures 4 and 5, the wiring sheet 100A according to this embodiment includes a first substrate 1A, a first pseudo sheet structure 2, a first resin layer 3A, a pair of electrodes 4, a second substrate 5A, a second pseudo sheet structure 6, and a second resin layer 7A. The first pseudo sheet structure 2 includes a plurality of first conductive linear members 21 arranged at intervals. The second pseudo sheet structure 6 includes a plurality of second conductive linear members 61 arranged at intervals. The first resin layer 3A includes a plurality of first resin strips 31, and the second resin layer 7A includes a plurality of second resin strips 71. In this embodiment, the configuration is the same as that of the first embodiment except that the first substrate 1A and the second substrate 5A are used and the first resin layer 3A and the second resin layer 7A are formed in a striped pattern. Therefore, the first substrate 1A and the second substrate 5A, as well as the first resin layer 3A and the second resin layer 7A will be described below, and parts common to the previous description will be omitted.

[0066] First substrate 1A and second substrate 5A are preferably breathable substrates, and such a configuration provides wiring sheet 100A with good breathability. The first substrate 1A and the second substrate 5A may be a substrate formed to have holes or a substrate sheet having holes mechanically or chemically formed in the thickness direction. For example, the first substrate 1A and the second substrate 5A may be porous such as mesh, nonwoven fabric, woven fabric, knit, etc., but may also be perforated to further improve breathability. Therefore, examples of the substrates used for the first substrate 1A and the second substrate 5A before being imparted with breathability include the same substrates as the first substrate 1 and the second substrate 5 described above.

[0067] First resin layer 3A is made up of a plurality of first resin strips 31, and second resin layer 7A is made up of a plurality of second resin strips 71. With this configuration, air passes through areas without first resin strips 31 and second resin strips 71, thereby providing wiring sheet 100A with good breathability. 4 and 5, in a plan view of the wiring sheet 100, it is preferable that the first conductive linear body 21 and the second resin strip 71 overlap, and the second conductive linear body 61 and the first resin strip 31 overlap. With this configuration, the second conductive linear body 61 can be protected by the first resin strip 31, and the first conductive linear body 21 can be protected by the second resin strip 71. The first resin strip 31 and the second resin strip 71 can be formed by applying an adhesive in stripes. It is preferable to use a curable adhesive. The first resin strip 31 and the second resin strip 71 can firmly fix the first conductive linear body 21 and the second conductive linear body 61, thereby making it possible to further stabilize the resistance value of the wiring.

[0068] In wiring sheet 100A according to the present embodiment, the air volume was 350 cm in the Frazier test described in JIS-L1096:2010. 3 / (cm 2 s) or more, and 450 cm 3 / (cm 2 ·s) over 2000cm 3 / (cm 2 s) or less, and more preferably 600 cm 3 / (cm 2 ·s) more than 1000cm 3 / (cm 2 It is particularly preferable that the ratio is equal to or less than s.

[0069] (Effects of the second embodiment) According to the present embodiment, it is possible to achieve the same effects as the effects (1) and (2) in the first embodiment, as well as the following effect (3). (3) Air passes through areas where first resin strip 31 and second resin strip 71 are absent, resulting in wiring sheet 100A with good breathability.

[0070] [Modifications of the embodiment] The present invention is not limited to the above-described embodiment, and includes modifications and improvements within the scope of the present invention that can achieve the object of the present invention. For example, in the above-described embodiment, the wiring sheet 100 includes the first substrate 1 and the second substrate 5, but is not limited thereto. For example, the wiring sheet may be manufactured using a processing film instead of the first substrate 1 and the second substrate 5. In such a case, the processing film is peeled off after the wiring sheet is manufactured. Then, a wiring sheet including the first pseudo sheet structure 2, the first resin layer 3, the pair of electrodes 4, the second pseudo sheet structure 6, and the second resin layer 7 is obtained.

[0071] (Use of wiring sheet) The wiring sheet 100 is preferably used as a heating element (sheet heater) since it has unprecedented characteristics such as flexibility and uniform heat generation. In this case, examples of uses of the heating element include window defoggers and defrosters. In recent years, heaters have been used to control the temperature of batteries in electric vehicles, and thin heaters are suitable for individual temperature control of laminated cells. In addition to being used as a heating element, the wiring sheet 100 can also be used as a flat cable for wiring electrical signals. [Explanation of symbols]

[0072] 1,1A...first substrate, 2...first pseudo sheet structure, 21...first conductive linear body, 3,3A...first resin layer, 31...first resin strip, 4...electrode, 5,5A...second substrate, 6...second pseudo sheet structure, 61...second conductive linear body, 7,7A...second resin layer, 71...second resin strip, 100,100A...wiring sheet.

Claims

1. a first pseudo sheet structure in which a plurality of first conductive linear members are arranged at intervals, a first resin layer supporting the first pseudo sheet structure, a pair of electrodes, a second pseudo sheet structure in which a plurality of second conductive linear members are arranged at intervals, and a second resin layer supporting the second pseudo sheet structure; the pair of electrodes are arranged so as to be electrically connected to both ends of the first conductive linear body and the second conductive linear body, The pair of electrodes is sandwiched between the first pseudo sheet structure and the second pseudo sheet structure. Wiring sheet.

2. The wiring sheet according to claim 1 , the first conductive linear body and the second conductive linear body do not overlap each other in a plan view of the wiring sheet; Wiring sheet.

3. The wiring sheet according to claim 1 or 2, When viewed in a plan view of the wiring sheet, the first conductive linear body and the second resin layer overlap each other, and the second conductive linear body and the first resin layer overlap each other. Wiring sheet.

4. The wiring sheet according to claim 1 , the first resin layer is made of a plurality of first resin strips, The second resin layer is composed of a plurality of second resin strips. Wiring sheet.

5. The wiring sheet according to claim 1 , In a plan view of the wiring sheet, the first conductive linear body and the second conductive linear body have a wave shape. Wiring sheet.

6. The wiring sheet according to claim 1 , Further, the present invention includes a breathable substrate. Wiring sheet.

7. The wiring sheet according to claim 1 , In a plan view of the wiring sheet, the first conductive linear body and the second conductive linear body are arranged at equal intervals. Wiring sheet.

8. The wiring sheet according to claim 1, the first conductive linear bodies and the second conductive linear bodies are arranged alternately, and in a plan view of the wiring sheet, the first conductive linear bodies and the second conductive linear bodies are arranged at equal intervals. Wiring sheet.

9. A semiconductor device comprising a first pseudo sheet structure having a plurality of first conductive linear members arranged at intervals, a first resin layer supporting the first pseudo sheet structure, a pair of electrodes, a second pseudo sheet structure having a plurality of second conductive linear members arranged at intervals, and a second resin layer supporting the second pseudo sheet structure; A method for manufacturing a wiring sheet, the pair of electrodes being sandwiched between the first pseudo sheet structure and the second pseudo sheet structure, forming a first pseudo sheet structure on the first resin layer to obtain a first sheet-like conductive member; forming a second pseudo sheet structure on the second resin layer to obtain a second sheet-like conductive member; attaching the pair of electrodes to both ends of a first conductive linear body of the first sheet-shaped conductive member; and attaching the second sheet-shaped conductive member onto the pair of electrodes such that both ends of the second conductive linear body in the second sheet-shaped conductive member are in contact with the pair of electrodes. A method for manufacturing a wiring sheet.

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