Reel body, reel body manufacturing method, and article manufacturing method

Abstract

To provide a reel body which can save a labor of positioning when set at an unwinding device, a reel body manufacturing method, and an article manufacturing method.SOLUTION: A reel body 1 is a reel body 1 formed by winding an adhesive film 2 having an adhesive layer 8 on a base material layer 7 around a winding core 3, in which the adhesive film 2 does not have a protective layer on the adhesive layer 8, the adhesive layer 8 and the base material layer 7 are wound around the winding core 3 in a state in which the layers are adjacent to each other in a radial direction of the winding core 3, a width W1 in an axial direction L of the winding core 3 is smaller than a width W2 of the adhesive film 2, and a wound body 4 of the adhesive film 2 is provided with an overhanging part 5 overhanging in the axial direction L of the winding core 3.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a reel body, a method for manufacturing a reel body, and a method for manufacturing an article. [Background technology]

[0002] As a method for manufacturing an article using an adhesive film, for example, there is a method in which an adhesive film is attached as a temporary protective tape to the back surface of a lead frame, as described in Patent Document 1. In the method of Patent Document 1, a semiconductor element is encapsulated in a state in which the back surface of the lead frame is temporarily protected with an adhesive film, and then the adhesive film is peeled off from the back surface of the lead frame. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2001 / 035460 Summary of the Invention [Problem to be solved by the invention]

[0004] In manufacturing the adhesive film, a reel body is formed by winding the adhesive film around a core. The manufactured adhesive film is distributed in the form of a reel body and is used by being set in a user's unwinding device. In a typical reel body, the axial width of the core and the width of the adhesive film are the same, and when the reel body is set in the unwinding device, it is aligned with the axial end face of the wound adhesive film as a reference.

[0005] However, in the conventional reel body, if the adhesive film is displaced even slightly in the axial direction during winding, the winding core protrudes in the axial direction from the wound body of the adhesive film. If the winding core protrudes in the axial direction, the axial end face of the wound body of the adhesive film cannot be used as a reference, and it is troublesome to align the core when setting it on the unwinding device. In particular, in the adhesive film that does not have a protective layer on the adhesive layer and is wound around the winding core with the adhesive layer and the base layer adjacent to each other in the radial direction of the winding core, it is difficult to move the position of the adhesive film relative to the winding core even if a force is applied to the winding body, and it may become necessary to align the core for each reel body to be set.

[0006] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a reel body that eliminates the need for the labor of alignment when setting it on a unwinding device, a method for manufacturing a reel body, and a method for manufacturing an article. [Means for solving the problem]

[0007] A reel body according to one aspect of the present disclosure is a reel body formed by winding an adhesive film having an adhesive layer on a base material layer around a winding core, the adhesive film does not have a protective layer on the adhesive layer, the adhesive layer and the base material layer are wound around the winding core with the adhesive layer and the base material layer adjacent in the radial direction of the winding core, the axial width of the winding core is smaller than the width of the adhesive film, and the wound body of the adhesive film is provided with a protruding portion that protrudes in the axial direction of the winding core.

[0008] In this reel body, the axial width of the core is smaller than the width of the adhesive film, and the wound body of the adhesive film protrudes in the axial direction of the core. Therefore, even if the adhesive film is slightly misaligned in the axial direction of the core during winding, the core can be prevented from protruding in the axial direction from the wound body of the adhesive film. By preventing the core from protruding, it becomes easy to align the reel body with respect to the axial end face of the wound body of the adhesive film when setting the reel body in the unwinding device, and the effort of aligning the reel body can be reduced.

[0009] The protruding portions may be provided on both sides in the axial direction of the core, in which case misalignment of the adhesive film during winding can be tolerated on both sides in the axial direction of the core.

[0010] The overhanging portion may be provided only on one of the axial sides. In this case, a large tolerance for misalignment of the adhesive film during winding can be ensured on one of the axial sides. Also, on the opposite side of the overhanging portion, the axial end face of the wound body and the axial end face of the winding core are aligned. Therefore, when the end face opposite to the overhanging portion is used as a reference for alignment, restrictions on setting the reel body in the unwinding device can be avoided, regardless of the axial width of the overhanging portion.

[0011] A removable auxiliary core having the same diameter as the core may be disposed on the inner periphery of the protruding portion. In this case, it is possible to suppress the occurrence of undulations in the adhesive film at the protruding portion. When the reel body is set on the unwinding device, the auxiliary core can be removed to easily align the reel body with respect to the axial end face of the wound adhesive film.

[0012] A guide plate for aligning the widthwise edge of the adhesive film at the end face in the axial direction of the roll of the adhesive film may be arranged on the end face of the roll of the adhesive film. By arranging the guide plate in this manner, it is possible to protect the end face in the axial direction of the roll of the adhesive film, which serves as a reference for alignment in the unwinding device.

[0013] A method for manufacturing a reel body according to one aspect of the present disclosure is a method for manufacturing a reel body that includes a winding step of winding an adhesive film having an adhesive layer on a base material layer around a winding core, in which a winding core having an axial width smaller than the width of the adhesive film is used, and an adhesive film that does not have a protective layer on the adhesive layer is wound around the winding core while the adhesive layer and the base material layer are adjacent in the radial direction of the winding core, thereby forming a protruding portion that protrudes in the axial direction of the winding core in the wound body of the adhesive film.

[0014] In this method of manufacturing a reel body, a core whose axial width is smaller than that of the adhesive film is used, and a protruding portion that protrudes in the axial direction of the core is formed on the wound body of the adhesive film. In the obtained reel body, even if the adhesive film is slightly misaligned in the axial direction of the core during winding, the core can be prevented from protruding in the axial direction from the wound body of the adhesive film. By preventing the core from protruding, it becomes easy to align the reel body with respect to the axial end face of the wound body of the adhesive film when setting the reel body on the unwinding device, and the labor of alignment can be eliminated.

[0015] A method for manufacturing an article according to one aspect of the present disclosure is a method for manufacturing an article having a joining step of joining an adhesive film unwound from the reel body to an adherend, in which the inner side of the protruding portion of the reel body is fixed to a winding core jig on the unwinding device side, and the adhesive film is unwound toward the adherend with the axial end face of the wound body of the adhesive film at the protruding portion abutted against a guide plate on the unwinding device side.

[0016] In this method of manufacturing an article, the core of the reel is prevented from protruding in the axial direction from the wound body of the adhesive film, which makes it easy to align the reel body with respect to the axial end face of the wound body of the adhesive film when setting the reel body on the unwinding device, thereby reducing the effort required for alignment. Effect of the Invention

[0017] According to the present disclosure, it is possible to eliminate the need for the labor of alignment when setting the reel body on the unwinding device. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a perspective view of a reel body according to an embodiment of the present disclosure. [Diagram 2] 2 is a cross-sectional view of the reel body shown in FIG. 1. [Diagram 3] 4 is a cross-sectional view of the reel body with the auxiliary core attached. FIG. [Figure 4] FIG. 2 is a cross-sectional view showing the layer structure of the adhesive film together with the roll. [Diagram 5] FIG. 2 is a schematic perspective view showing an example of a reel body manufacturing apparatus. [Figure 6] FIG. 1 is a schematic diagram showing an example of an article manufacturing device using a reel body. [Figure 7] 13(a) and 13(b) are cross-sectional views of a reel body according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, preferred embodiments of a reel body, a method for manufacturing a reel body, and a method for manufacturing an article according to one aspect of the present disclosure will be described in detail with reference to the drawings. In this specification, a numerical range indicated using "to" includes the numerical values ​​before and after "to" as the minimum and maximum values, respectively. [Reel body configuration]

[0020] FIG. 1 is a perspective view of a reel body according to an embodiment of the present disclosure. FIG. 2 is a cross-sectional view thereof. As shown in FIGS. 1 and 2, the reel body 1 is configured by winding an adhesive film 2 around a winding core 3. The adhesive film 2 is a film used for temporarily protecting a lead frame, for example, in a sealing process for sealing a semiconductor element mounted on the lead frame. The adhesive film 2 is attached to the back surface of the lead frame (the surface opposite to the surface on which the semiconductor element is formed) in the sealing process, and temporarily protects the lead frame while a sealing layer for sealing the semiconductor element is being formed. The adhesive film 2 is peeled off from the back surface of the lead frame after the sealing process is completed.

[0021] The winding core 3 is a portion around which the adhesive film 2 is wound. The winding core 3 has, for example, a hollow cylindrical shape and extends along the axial direction L. Examples of materials for forming the winding core 3 include polyvinyl chloride (PVC), ABS resin, and fiber reinforced plastic (FRP). The outer diameter of the winding core 3 is, for example, 80 mm to 95 mm, more preferably 82 mm to 92 mm, and even more preferably 80 mm to 90 mm. The inner diameter of the winding core 3 is, for example, 70 mm to 85 mm, more preferably 72 mm to 82 mm, and even more preferably 75 mm to 80 mm. The length of the winding core 3 in the axial direction L is, for example, 40 mm to 100 mm, more preferably 50 mm to 90 mm, and even more preferably 60 mm to 80 mm.

[0022] The width W1 of the winding core 3 in the axial direction L is smaller than the width W2 of the adhesive film 2. Therefore, the wound body 4 in which the adhesive film 2 is wound around the winding core 3 is provided with an overhanging portion 5 that overhangs in the axial direction L of the winding core 3. In this embodiment, the overhanging portion 5 is provided on one side and the other side of the axial direction L of the winding core 3. The overhanging width W3 of the overhanging portion 5 on one side and the other side of the axial direction L of the winding core 3 is, for example, 1 mm to 15 mm, more preferably 2 mm to 10 mm, and further preferably 3 mm to 7 mm. The overhanging width W3 of the overhanging portion 5 on one side of the axial direction L of the winding core 3 and the overhanging width W3 of the overhanging portion 5 on the other side of the axial direction L of the winding core 3 may be equal to or different from each other.

[0023] The reel body 1 may be handled in a state of being housed in a packaging bag during storage or transportation. A single reel body 1 may be housed in the packaging bag, or multiple reel bodies 1 may be housed in the packaging bag. The packaging bag may be formed of a resin film, or may be formed of a composite resin film having an aluminum layer. Specific examples of packaging bags include bags made of aluminum-coated plastic. Examples of materials for the resin film include plastics such as polyethylene, polyester, polyvinyl chloride, and polyethylene terephthalate.

[0024] The reel body 1 may be housed in a packaging bag in a vacuum-packed state, for example. The packaging bag may contain a desiccant together with the reel body 1. An example of the desiccant is silica gel. The package may further be wrapped in a cushioning material. The package may be housed in a packaging box such as a cardboard box.

[0025] In addition, when storing or transporting the reel body 1, an auxiliary core 6 may be disposed on the inner periphery side of the protruding portion 5 of the wound body 4 of the adhesive film 2, as shown in Fig. 3. The auxiliary core 6 has a hollow cylindrical shape with the same diameter as the winding core 3. The auxiliary core 6 is formed separately from the winding core 3, for example, from the same material as the winding core 3, and is detachably attached to the inner periphery side of the protruding portion 5. In the example of Fig. 3, the auxiliary core 6 is disposed on the inner periphery side of the protruding portion 5 on one side of the wound body 4 in the axial direction L, and on the inner periphery side of the protruding portion 5 on the other side of the wound body 4 in the axial direction L.

[0026] In this embodiment, the width W4 of the auxiliary core 6 in the axial direction L is larger than the protruding width W3 of the protruding portion 5. One end 6a of the auxiliary core 6 in the axial direction L abuts against the end face 3a of the winding core 3 in the axial direction L on the inner peripheral side of the wound body 4, and the other end 6b of the auxiliary core 6 in the axial direction L protrudes beyond the end face 4a of the wound body 4 in the axial direction L. There is no particular limit to the protruding width (= W4 - W3) of the auxiliary core 6 from the end face 4a, but the protruding width is, for example, 5 mm to 10 mm. The protruding width may be 2 mm to 5 mm, or 0 mm to 2 mm.

[0027] The auxiliary core 6 does not necessarily have to protrude beyond the end face 4a. For example, the width W4 of the auxiliary core 6 in the axial direction L and the protruding width W3 of the protruding portion 5 may be equal, and the other end 6b of the auxiliary core 6 in the axial direction L may be aligned with the end face 4a. Alternatively, the width W4 of the auxiliary core 6 in the axial direction L may be smaller than the protruding width W3 of the protruding portion 5, and the other end 6b of the auxiliary core 6 in the axial direction L may be located on the inner periphery side of the wound body 4. [Adhesive film composition]

[0028] 4, the adhesive film 2 is configured in two layers, that is, a base layer 7 and an adhesive layer 8 provided on one side of the base layer 7. In this embodiment, the adhesive film 2 does not have a protective layer on the adhesive layer 8, and is wound around the winding core 3 with the adhesive layer 8 and the base layer 7 adjacent to each other in the radial direction of the winding core 3. In the state of the wound body 4, the adhesive layer 8 is located on the radial outside, and the base layer 7 is located on the radial inside.

[0029] The width of the adhesive film 2 (i.e., the width W2 in the axial direction L of the roll 4) is, for example, 50 mm or more. The width of the adhesive film 2 may be 100 mm or more, or 200 mm or more. The width of the adhesive film 2 may be 600 mm or less. The width of the adhesive film 2 may be, for example, 50 mm or more and 600 mm or less, 100 mm or more and 600 mm or less, or 200 mm or more and 600 mm or less.

[0030] The linear expansion coefficient of the adhesive film 2 in the in-plane direction at 30°C to 200°C is, for example, 16 ppm / °C or more and 20 ppm / °C or less. The in-plane direction may be, for example, either the MD (machine direction) direction or the TD (transverse direction). The MD direction is usually the longitudinal direction of the adhesive film 2. The TD direction is the direction (width direction) perpendicular to the MD direction. The linear expansion coefficient can be measured using a thermomechanical analyzer (for example, SSC5200 manufactured by Seiko Instruments Inc.). The linear expansion coefficient of the adhesive film 2 in the in-plane direction at 30°C to 200°C can be adjusted, for example, by changing the thickness of the adhesive layer 8.

[0031] The elastic modulus of the adhesive film 2 at 30°C is, for example, 9 GPa or less. The elastic modulus of the adhesive film 2 at 30°C may be 8 GPa or less, or 7 GPa or less. The elastic modulus of the adhesive film 2 at 30°C may be 4 GPa or more, or 5 GPa or more. The elastic modulus of the adhesive film 2 at 30°C can be measured by a dynamic viscoelasticity measuring device (for example, Rheogel-E4000 manufactured by UBM Co., Ltd.). In this case, the adhesive film 2 is cut into a test piece having a size of, for example, 4 mm x 30 mm, and the test piece is set in the dynamic viscoelasticity measuring device with a chuck distance of 20 mm. The elastic modulus of the adhesive film 2 at 30°C can be obtained by measuring the tensile elastic modulus of the test piece under the conditions of a sine wave, a temperature range of 30°C (constant), and a frequency of 10 Hz.

[0032] The base layer 7 is made of a material that has heat resistance to heat used in each process such as the process of forming the adhesive layer 8, the process of assembling the semiconductor package, etc. Examples of such materials include at least one polymer selected from the group consisting of aromatic polyimide, aromatic polyamide, aromatic polyamideimide, aromatic polysulfone, aromatic polyethersulfone, polyphenylene sulfide, aromatic polyetherketone, polyarylate, aromatic polyetheretherketone, and polyethylene naphthalate.

[0033] From the viewpoint of improving heat resistance, the glass transition temperature of the base material layer 7 may be 200°C or higher, or may be 250°C or higher. This suppresses softening of the base material layer 7 in processes in which heat is applied, such as a process of adhering a semiconductor element to a die pad, a wire bonding process, a sealing process, and a process of peeling off a temporary protective film from a sealed molded body, thereby improving work efficiency. In addition, the elastic modulus of the base material layer 7 at 230°C is higher than the elastic modulus of the adhesive layer 8 at 230°C.

[0034] The base layer 7 preferably has sufficient adhesion to the adhesive layer 8. When the base layer 7 has sufficient adhesion to the adhesive layer 8, peeling can be suppressed at the interface between the adhesive layer 8 and the base layer 7 when the adhesive film 2 is peeled off from the lead frame and the sealing material at a temperature of, for example, 100° C. to 300° C. This can suppress resin from remaining on the lead frame and the sealing material.

[0035] From the viewpoint of having sufficient heat resistance and adhesion to the adhesive layer 8, the base layer 7 may be made of polyimide. The linear expansion coefficient of the base layer 7 made of polyimide at 30° C. to 200° C. is 3.0×10 -5 / ℃ or less, 2.5 × 10 -5 °C or less, and may be 2.0 x 10 -5 / ° C. or less. The heat shrinkage rate of the base layer 7 when heated at 200° C. for 2 hours may be 0.15% or less, 0.1% or less, or 0.05% or less.

[0036] The material constituting the base layer 7 is not limited to the above-mentioned resin, but may be selected from the group consisting of copper, aluminum, stainless steel, and nickel. When the base layer 7 is made of these metals, it is possible to make the linear expansion coefficient of the adhesive film 2 close to that of the lead frame. In this case, it is possible to suitably reduce warping of the lead frame when the adhesive film 2 is attached to the lead frame.

[0037] The substrate layer 7 may be subjected to a surface treatment. Examples of the surface treatment include chemical treatments such as alkali treatment and silane coupling treatment, physical treatments such as sand mat treatment, plasma treatment, corona treatment, etc. By performing the surface treatment, the adhesion to the adhesive layer 8 can be further sufficiently improved.

[0038] The thickness of the base material layer 7 may be, for example, 100 μm or less, 50 μm or less, or 25 μm or less from the viewpoint of reducing warpage of the lead frame when the adhesive film 2 is attached to the lead frame. The thickness of the base material layer 7 may be 5 μm or more, or 10 μm or more.

[0039] The adhesive layer 8 is composed of a thermoplastic resin having, for example, an amide group (-NHCO-), an ester group (-CO-O-), an imide group (-NR2, where R is each -CO-), an ether group (-O-), or a sulfone group (-SO2-). These resins may be thermoplastic resins having an amide group, an ester group, an imide group, or an ether group. Specifically, such thermoplastic resins include aromatic polyamide, aromatic polyester, aromatic polyimide, aromatic polyamideimide, aromatic polyether, aromatic polyetheramideimide, aromatic polyetheramide, aromatic polyesterimide, and aromatic polyetherimide. From the viewpoint of heat resistance and adhesiveness, the thermoplastic resin may be at least one resin selected from the group consisting of aromatic polyetheramideimide, aromatic polyetherimide, and aromatic polyetheramide.

[0040] The above resins can be prepared by polycondensation of aromatic diamines or bisphenols, which are base components, and dicarboxylic acids, tricarboxylic acids, tetracarboxylic acids, aromatic chlorides, or their reactive derivatives, which are acid components. That is, the above resins can be prepared by a conventional method used for the reaction of amines with acids, and there are no particular limitations on the conditions, etc. Conventional methods are also used for the polycondensation reaction of aromatic dicarboxylic acids, aromatic tricarboxylic acids, or their reactive derivatives with diamines.

[0041] Examples of base components that can be used in the synthesis of aromatic polyetherimides, aromatic polyetheramideimides, and aromatic polyetheramides include aromatic diamines having an ether group, such as 2,2-bis[4-(4-aminophenoxy)phenyl]propane, bis[4-(4-aminophenoxy)phenyl]sulfone, 4,4'-diaminodiphenyl ether, bis[4-(4-aminophenoxy)phenyl]ether, and 2,2-bis[4-(4-aminophenoxy)]hexafluoropropane; aromatic diamines not having an ether group, such as 4,4'-methylenebis(2,6-diisopropylamine); siloxane diamines such as 1,3-bis(3-aminopropyl)-tetramethyldisiloxane; and α,ω-diaminoalkanes, such as 1,12-diaminododecane and 1,6-diaminohexane.

[0042] In the total amount of the base components, the aromatic diamine having an ether group may be used in an amount of 40 to 100 mol % or 50 to 97 mol %, and at least one selected from the aromatic diamine having no ether group, the siloxane diamine, and the α,ω-diaminoalkane may be used in an amount of 0 to 60 mol % or 3 to 50 mol %. Specific examples of the base component include (1) a base component consisting of 60 to 89 mol % or 68 to 82 mol % of an aromatic diamine having an ether group, 1 to 10 mol % or 3 to 7 mol % of a siloxane diamine, and 10 to 30 mol % or 15 to 25 mol % of an α,ω-diaminoalkane; (2) a base component consisting of 90 to 99 mol % or 93 to 97 mol % of an aromatic diamine having an ether group, and 1 to 10 mol % or 3 to 7 mol % of a siloxane diamine; and (3) a base component consisting of 40 to 70 mol % or 45 to 60 mol % of an aromatic diamine having an ether group, and 30 to 60 mol % or 40 to 55 mol % of an aromatic diamine not having an ether group.

[0043] Examples of acid components used in the synthesis of aromatic polyetherimides, aromatic polyetheramideimides, and aromatic polyetheramides include (A) reactive derivatives of trimellitic anhydride, such as trimellitic anhydride and trimellitic anhydride chloride, mononuclear aromatic tricarboxylic anhydrides, such as pyromellitic dianhydride, and mononuclear aromatic tetracarboxylic dianhydrides, (B) polynuclear aromatic tetracarboxylic dianhydrides, such as bisphenol A bistrimellitate dianhydride and oxydiphthalic anhydride, and (C) aromatic dicarboxylic acids, such as reactive derivatives of phthalic acid, such as terephthalic acid, isophthalic acid, terephthalic acid chloride, and isophthalic acid chloride. Among these, aromatic polyetheramideimides obtained by reacting 0.95 to 1.05 mol or 0.98 to 1.02 mol of the acid component (A) with 1 mol of the base component (1) or (2), and aromatic polyetherimides obtained by reacting 0.95 to 1.05 mol or 0.98 to 1.02 mol of the acid component (B) with 1 mol of the base component (3) can be used.

[0044] The adhesive layer 8 may contain other components in addition to the above-mentioned resin. Examples of the other components include fillers such as ceramic powder, glass powder, silver powder, copper powder, resin particles, and rubber particles, antioxidants, and coupling agents. When the adhesive layer 8 contains a filler as another component, the content of the filler may be 1 to 30 parts by mass, or 5 to 15 parts by mass, relative to 100 parts by mass of the resin.

[0045] As the coupling agent, for example, vinyl silane, epoxy silane, amino silane, mercapto silane, titanate, aluminum chelate, zircoaluminate, etc. can be used. The coupling agent may be a silane coupling agent. As the silane coupling agent, vinyl trimethoxy silane, vinyl triethoxy silane, vinyl tris (β-methoxyethoxy) silane, β- (3, 4-epoxycyclohexyl) ethyl trimethoxy silane, γ-glycidoxy propyl trimethoxy silane, γ-glycidoxy propyl methyl diethoxy silane, N-β- (aminoethyl) -γ-aminopropyl methyl dimethoxy silane, γ-aminopropyl triethoxy silane, N-phenyl-γ-aminopropyl trimethoxy silane, γ-mercaptopropyl trimethoxy silane, etc., have an organic reactive group at the end, and among these, an epoxy silane coupling agent having an epoxy group can be used.

[0046] The organic reactive group is a functional group such as an epoxy group, a vinyl group, an amino group, or a mercapto group. The addition of a silane coupling agent improves the adhesion of the adhesive layer 8 to the base layer 7, and has the effect of suppressing the occurrence of peeling at the interface between the base layer 7 and the adhesive layer 8 when peeling at a temperature of 100 to 300° C. When the adhesive layer 8 contains a coupling agent, the content of the coupling agent may be 1 to 15 parts by mass, or 2 to 10 parts by mass, relative to 100 parts by mass of the resin.

[0047] The thickness of the adhesive layer 8 is, for example, 20 μm or less. The thickness of the adhesive layer 8 may be 18 μm or less, 16 μm or less, 14 μm or less, 12 μm or less, 10 μm or less, 9 μm or less, or 8 μm or less. The thickness of the adhesive layer 8 is, for example, 1 μm or more. The thickness of the adhesive layer 8 may be 2 μm or more, 3 μm or more, 4 μm or more, 5 μm or more, 6 μm or more, 7 μm or more, or 8 μm or more. The thickness of the adhesive layer 8 may be 1 μm or more and 20 μm or less, 1 μm or more and 15 μm or less, or 1 μm or more and 8 μm or less.

[0048] When the thickness of the adhesive layer 8 is 1 μm or more, sufficient adhesion can be ensured and leakage of the sealing material during sealing can be suppressed. When the thickness of the adhesive layer 8 is 20 μm or less, the overall layer thickness of the adhesive film 2 can be reduced, which not only reduces costs but also suppresses the generation of voids during heat treatment at 300° C. or more. Furthermore, when the thickness of the adhesive layer 8 is 20 μm or less, an increase in wettability during heat treatment can be suppressed. This prevents the adhesive layer 8 from sticking to the lead frame with excessive adhesive strength, ensuring peelability.

[0049] The ratio of the thickness of the adhesive layer 8 to the thickness of the base layer 7 is, for example, 0.2 or less. The ratio of the thickness of the adhesive layer 8 to the thickness of the base layer 7 may be 0.1 or less, or may be 0.05 or less. This suppresses warping caused by a volume reduction when removing the solvent after the adhesive layer 8 is applied to the base layer 7, and improves the workability when attaching the adhesive film 2 to the lead frame.

[0050] The adhesive layer 8 has a glass transition temperature (Tg) higher than room temperature (e.g., 25°C). The adhesive layer 8 may have a glass transition temperature (Tg) of, for example, 100°C or higher, or 150°C or higher. The adhesive layer 8 may have a glass transition temperature of, for example, 300°C or lower, or 250°C or lower. When the adhesive layer 8 has a glass transition temperature of 100°C or higher, peeling at the interface between the base layer 7 and the adhesive layer 8 is suppressed and cohesive failure of the adhesive layer 8 is suppressed when the adhesive film 2 is peeled off from the lead frame and the sealing material.

[0051] When the glass transition temperature of the adhesive layer 8 is 100°C or higher, the adhesive layer 8 can be prevented from remaining on the lead frame and the sealing material. In addition, the adhesive layer 8 can be prevented from softening due to heat in the wire bonding process, thereby reducing the occurrence of poor wire bonding. In addition, the adhesive layer 8 can be prevented from softening due to heat in the sealing process, thereby preventing problems such as the sealing material getting between the lead frame and the adhesive layer 8. When the glass transition temperature of the adhesive layer 8 is within 300°C, the adhesive layer 8 is sufficiently prevented from softening during bonding. In addition, the peel strength at a peel angle of 90° between the adhesive film 2 and the lead frame at room temperature (e.g., 25°C) can be sufficiently ensured.

[0052] The glass transition temperature of the adhesive layer 8 can be measured by a thermomechanical analyzer (SSC5200 type manufactured by Seiko Instruments Inc.) The measurement conditions can be, for example, a chuck distance of 10 mm, a temperature range of 30° C. to 300° C., and a temperature rise rate of 10° C. / min in a tensile mode.

[0053] The 5% weight loss temperature of the adhesive layer 8 may be 300°C or higher, 350°C or higher, or 400°C or higher. When the 5% weight loss temperature of the adhesive layer 8 is 300°C or higher, outgassing due to heat when attaching the adhesive film 2 to the lead frame and heat during the wire bonding process is less likely to occur, and contamination of the lead frame, wires, etc. can be suppressed. The 5% weight loss temperature can be measured using a differential thermobalance (for example, SSC5200 type manufactured by Seiko Instruments Inc.). The measurement conditions can be, for example, in an air atmosphere, with a heating rate of 10°C / min.

[0054] The adhesive layer 8 has an elastic modulus of, for example, 1 MPa or more at 230°C. The adhesive layer 8 may have an elastic modulus of, for example, 3 MPa or more at 230°C. In the manufacturing process of a semiconductor package, the temperature during the wire bonding process (wire bonding temperature) is not particularly limited, but is generally about 200 to 260°C, and is around 230°C. Therefore, when the adhesive layer 8 has an elastic modulus of, for example, 1 MPa or more at 230°C, the adhesive layer 8 is prevented from softening due to heat in the wire bonding process, and the occurrence of poor bonding of the wire can be prevented. The adhesive layer 8 has an elastic modulus of, for example, 2000 MPa or less at 230°C. The adhesive layer 8 may have an elastic modulus of, for example, 1500 MPa or less at 230°C, and may have an elastic modulus of, for example, 1000 MPa or less at 230°C.

[0055] The elastic modulus of the adhesive layer 8 at 230° C. can be measured by a dynamic viscoelasticity measuring device (e.g., Rheogel-E4000 manufactured by UBM Corp.) In this case, the measurement conditions can be a tensile mode with a chuck distance of 20 mm, a sine wave, a frequency of 10 Hz, and a temperature rise rate of 5° C. / min.

[0056] The method of forming the adhesive layer 8 on the base layer 7 is not particularly limited, but for example, a method can be used in which a resin varnish prepared by dissolving a resin in a solvent is applied to the surface of the base layer 7, and then the solvent is removed by heat treatment. Examples of the solvent that can be used include N-methyl-2-pyrrolidone, dimethylacetamide, diethylene glycol dimethyl ether, tetrahydrofuran, cyclohexanone, methyl ethyl ketone, and dimethylformamide. A method can also be used in which a precursor varnish prepared by dissolving a resin precursor in a solvent is applied to the surface of the base layer 7, and then the solvent is removed by heat treatment. When the resin constituting the adhesive layer 8 is a polyimide resin, the precursor is, for example, a polyamic acid.

[0057] The heat treatment temperature may be different between when a resin varnish is used and when a precursor varnish is used. In the case of a resin varnish, the heat treatment temperature may be any temperature at which the solvent can be removed. In the case of a precursor varnish, the heat treatment temperature may be equal to or higher than the glass transition temperature of the adhesive layer 8 in order to form a resin from the precursor (e.g., imidization).

[0058] The method for applying the resin varnish or precursor varnish to the surface of the base layer 7 is not particularly limited, and may be, for example, roll coating, reverse roll coating, gravure coating, bar coating, comma coating, die coating, or reduced pressure die coating. The resin varnish or precursor varnish may be applied to the surface of the base layer 7 by immersing the base layer 7 in the resin varnish or precursor varnish.

[0059] The adhesive film 2 may further include a non-adhesive layer (not shown) on the other side of the base layer 7 (opposite side of the adhesive layer 8) to form a three-layer structure. The non-adhesive layer may be a resin layer that does not have substantial adhesion (or pressure-sensitive adhesion) to the lead frame at 0°C to 270°C. For example, a thermoplastic resin or a thermosetting resin may be used to form the non-adhesive layer. For example, a resin having an amide group, an ester group, an imide group, or an ether group may be used as the thermoplastic resin. For example, an epoxy resin, a phenolic resin, or a bismaleimide resin (for example, a bismaleimide resin having bis(4-maleimidophenyl)methane as a monomer) may be used as the thermoplastic resin. A combination of a thermoplastic resin and a thermosetting resin may be used. When such a non-adhesive layer is provided on the other side of the base layer 7, the warping of the adhesive film 2 caused by the volumetric reduction of the adhesive layer 8 can be offset by the volumetric reduction of the non-adhesive layer when the solvent is removed, the imidization of the non-adhesive layer, the contraction of the non-adhesive layer when the thermosetting resin is cured, etc. [Reel body manufacturing method]

[0060] In manufacturing the reel body 1, a winding step is performed in which the adhesive film 2 having the adhesive layer 8 on the base material layer 7 is wound around the winding core 3. In the winding step, a winding core 3 having a width W1 in the axial direction L smaller than the width W2 of the adhesive film 2 is used, and the adhesive film 2 having no protective layer on the adhesive layer 8 is wound around the winding core 3 while the adhesive layer 8 and the base material layer 7 are adjacent in the radial direction of the winding core 3. As a result, an overhanging portion 5 that overhangs in the axial direction L of the winding core 3 is formed in the wound body 4 of the adhesive film 2.

[0061] The winding step can be performed, for example, by using a manufacturing apparatus 11 shown in FIG. 5. In FIG. 5, the left-right direction is the horizontal direction, and the up-down direction is the vertical direction. The manufacturing apparatus 11 shown in the figure cuts out a plurality of adhesive films 2 from a base material B of the adhesive film 2, and forms a reel body 1 by winding up each of the cut out adhesive films 2. As shown in FIG. 5, the manufacturing apparatus 11 includes a payout roller 12, a cutting section 13, and a plurality of winding cores 3.

[0062] The pay-out roller 12 is a section that pays out the base material B of the adhesive film 2. The base material B of the adhesive film 2 paid out from the pay-out roller 12 is transported horizontally toward the cutting section 13 at a predetermined speed. The cutting section 13 is a section that cuts out a plurality of adhesive films 2 of a predetermined width from the base material B of the adhesive film 2. The cutting section 13 has an upper shaft 16 and a lower shaft 17 that are arranged in a pair above and below with the base material B between them, a plurality of disc-shaped upper blades 18 provided on the upper shaft 16, and a plurality of disc-shaped lower blades (not shown) provided on the lower shaft 17.

[0063] The upper blade 18 and the lower blade, for example, are in a state where the side surfaces of the blade tips are in sliding contact with each other, and cut the base material B by a shear cut method. The width of the multiple adhesive films 2 cut out by the cutting unit 13 is adjusted by changing the axial distance between the upper blade 18 and the lower blade. In this embodiment, the cutting unit 13 cuts out multiple adhesive films 2 of different widths from the base material B of the adhesive film 2.

[0064] A winding tension is applied to the base material B and the multiple adhesive films 2 from the pay-out roller 12 through the cutting section 13 to the core 3. A tension roller may be used to apply the winding tension to the base material B and the multiple adhesive films 2, or an adjustment mechanism for adjusting the axial positions of the pay-out roller 12 and the core 3 may be used. The winding tension is not particularly limited, but is, for example, 60 N / m or more. The winding tension may be 70 N / m or more, or 80 N / m or more. The winding tension is, for example, 150 N / m or less. The winding tension may be 140 N / m or less, or 130 N / m or less.

[0065] The multiple winding cores 3 are portions around which the multiple adhesive films 2 are wound. The winding cores 3 set in the manufacturing device 11 become the winding cores 3 of the reel body 1 as they are. The adhesive film 2 is wound around the winding cores 3 so that the adhesive layer 8 faces outward in the radial direction. In this embodiment, the multiple winding cores 3 are set on the first shaft G1 and the second shaft G2. The first shaft G1 and the second shaft G2 are shifted from each other at least in the horizontal direction. The winding cores 3 of the first shaft G1 and the winding cores 3 of the second shaft G2 are alternately arranged in the axial direction. Each of these winding cores 3 has a width W1 in the axial direction L that is smaller than the width W2 of the adhesive film 2 to be wound. As a result, in the reel body 1 in which the adhesive film 2 has been wound around each of the winding cores 3, a protruding portion 5 that protrudes in the axial direction L of the winding cores 3 is formed in the wound body 4. [Production method]

[0066] In the method for manufacturing an article using the reel body 1, a bonding step is performed in which the adhesive film 2 unwound from the reel body 1 is bonded to the adherend P. Here, the adherend P is a lead frame on which a semiconductor element is mounted. The adherend P is placed, for example, on a transport stage S and can be transported in the bonding direction of the adhesive film 2. In the bonding step, for example, an unwinding device 21 as shown in FIG. 6 can be used. In the example of FIG. 6, the unwinding device 21 is configured to include a core jig 22 and a guide plate 23, and is disposed above the transport stage S on which the adherend P is placed.

[0067] The core jig 22 is a jig in which a protrusion 25 is provided on the circumferential surface of a core 24 that can rotate around an axis. The protrusion 25 is provided so as to be able to protrude in the radial direction from the circumferential surface of the core 24. The protrusion 25 is driven, for example, by air, and is freely protruding and retracting from the circumferential surface of the core 24. The reel body 1 is set in the core jig 22 by passing the reel body 1 through the core 24 and supporting the inner peripheral side of the core 3 of the reel body 1 with the protrusion 25. If an auxiliary core 6 is provided in the reel body 1, the auxiliary core 6 may be removed from the reel body 1 just before the reel body 1 is set in the core jig 22.

[0068] The guide plate 23 is a plate-like member used for aligning the adhesive film 2 unwound from the reel body 1 by the unwinding device 21. The guide plate 23 is, for example, disk-shaped with a sufficiently large diameter compared to the diameter of the reel body 1. The winding core 24 of the winding core jig 22 is inserted into the guide plate 23. After the reel body 1 is passed through the winding core 3, an end face 4a in the axial direction L of the wound body 4 is brought into contact with one side of the guide plate 23, whereby the adhesive film 2 unwound from the reel body 1 by the unwinding device 21 can be aligned with the end face 4a in the axial direction L of the wound body 4 as a reference. In this state, the winding core jig 22 is rotated to unwind the adhesive film 2 toward the adherend P, whereby the adhesive film 2 is bonded to the adherend P.

[0069] A pressure plate 26 may be disposed opposite guide plate 23 across reel body 1. Pressure plate 26 is, for example, disk-shaped and has the same diameter as guide plate 23. The position of pressure plate 26 can further stabilize the position of reel body 1 during unwinding. The position of pressure plate 26 may be omitted. [Effects]

[0070] In a typical reel body, the axial width of the core and the width of the adhesive film are the same, and when the reel body is set in the unwinding device, the positioning is performed based on the axial end face of the wound body of the adhesive film. However, in the conventional reel body, if the adhesive film is displaced even slightly in the axial direction during winding, the core protrudes in the axial direction from the wound body of the adhesive film. If the core protrudes in the axial direction, it is no longer possible to use the axial end face of the wound body of the adhesive film as a reference, and it becomes difficult to align the core when setting it in the unwinding device. In particular, in an adhesive film that does not have a protective layer on the adhesive layer and is wound around the core with the adhesive layer and the base layer adjacent to each other in the radial direction of the core, it is difficult to move the position of the adhesive film relative to the core even if a force is applied to the wound body, and there is a risk that it will be necessary to align the core for each reel body to be set.

[0071] In contrast, in the reel body 1 of this embodiment, the width W1 in the axial direction L of the core 3 is smaller than the width W2 of the adhesive film 2, and the wound body 4 of the adhesive film 2 protrudes in the axial direction L of the core 3. Therefore, even if the adhesive film 2 is slightly shifted in the axial direction L of the core 3 during winding, the core 3 can be prevented from protruding in the axial direction L from the wound body 4 of the adhesive film 2. By suppressing the protrusion of the core 3, when setting the reel body 1 in the unwinding device 21, it becomes easy to align the end face 4a in the axial direction L of the wound body 4 of the adhesive film 2 as a reference, and the effort of aligning the position can be saved. In addition, since it is not necessary to match the width W1 in the axial direction L of the core 3 to the width W2 of the adhesive film 2, it is possible to use the core 3 in common for adhesive films 2 having different widths.

[0072] In this embodiment, the protruding portions 5 are provided on both sides of the winding core 3 in the axial direction L. This allows for misalignment of the adhesive film 2 during winding on both sides of the winding core 3 in the axial direction L.

[0073] In this embodiment, a removable auxiliary core 6 having the same diameter as the core 3 is disposed on the inner peripheral side of the overhanging portion 5. The auxiliary core 6 supports the overhanging portion 5 from the inner peripheral side, thereby suppressing the occurrence of undulations of the adhesive film 2 at the overhanging portion 5. When setting the reel body 1 on the unwinding device 21, the auxiliary core 6 can be removed to easily align the adhesive film 2 with respect to the end face 4a of the wound body 4 of the adhesive film 2 in the axial direction L. [Variations]

[0074] The present disclosure is not limited to the above embodiment. For example, in the above embodiment, the overhanging portion 5 is provided on one side and the other side of the axial direction L of the winding core 3, but as shown in Figures 7(a) and 7(b), the overhanging portion 5 may be provided only on one side or the other side of the axial direction L of the winding core 3. In this case, a large tolerance for the positional deviation of the adhesive film 2 during winding can be ensured on one side or the other side in the axial direction L.

[0075] 7(a) and 7(b), the end face 4a in the axial direction L of the wound body 4 and the end face 3a in the axial direction L of the winding core 3 are aligned on the opposite side of the overhanging portion 5. Therefore, when the end face 4a on the opposite side of the overhanging portion 5 is used as a reference for positioning, restrictions on setting the reel body 1 on the unwinding device 21 can be avoided regardless of the width W3 in the axial direction L of the overhanging portion 5. For example, if the width in the axial direction L of the winding core jig 22 in the unwinding device 21 is less than the width W3 in the axial direction of the overhanging portion 5 and the winding core jig 22 does not reach the winding core 3 of the reel body 1 when the winding core jig 22 is passed through the reel body 1 from the overhanging portion 5 side, the winding core jig 22 may be passed through the reel body 1 from the opposite side of the overhanging portion 5.

[0076] In the examples of Fig. 7(a) and Fig. 7(b), the auxiliary core 6 is disposed on the inner periphery side of the protruding portion 5, as in Fig. 3. In addition, on the opposite side of the protruding portion 5, a guide plate 31 may be disposed on the end face 4a in the axial direction L of the wound body 4, which aligns the edge of the adhesive film 2 in the width direction at the end face 4a. In the examples of Fig. 7(a) and Fig. 7(b), the guide plate 31 is disk-shaped with a diameter larger than the diameter of the wound body 4. On the inner surface side of the guide plate 31, a convex portion 32 that fits into the hollow part of the winding core 3 is provided. The convex portion 32 allows the guide plate 31 to be freely attached and detached to the winding core 3. In a state in which the convex portion 32 is fitted into the hollow part of the winding core 3, the inner surface of the guide plate 31 abuts against the end face 4a in the axial direction L of the wound body 4. By disposing the guide plate 31 in this way, the end face 4a in the axial direction L of the wound body 4, which serves as a reference for alignment in the unwinding device 21, can be protected.

[0077] The guide plate 31 can also be applied to the reel body 1 shown in Fig. 2. In this case, the guide plate 31 may be disposed on both the end face 4a of the protruding portion 5 on one side in the axial direction L and the end face 4a of the protruding portion 5 on the other side in the axial direction L, or may be disposed on only one of them. Also, the guide plate 31 can be used in combination with the auxiliary core 6. [Explanation of symbols]

[0078] 1...reel body, 2...adhesive film, 3...winding core, 4...wound body, 4a...end surface, 5...projection portion, 6...auxiliary core, 7...base material layer, 8...adhesive layer, 21...unwinding device, 22...winding core jig, 31...guide plate, L...axial direction, P...adherend, W1...axial width of winding core, W2...width of adhesive film.

Claims

1. A reel body in which an adhesive film having an adhesive layer on a base layer is wound around a core, the adhesive film does not have a protective layer on the adhesive layer, and the adhesive layer and the base material layer are wound around the core in a state where they are adjacent to each other in a radial direction of the core, The width of the core in the axial direction is smaller than the width of the adhesive film, The roll of the adhesive film is provided with a protruding portion that protrudes in the axial direction of the core, The protruding portions are provided on one and the other sides of the winding core in the axial direction of the reel body.

2. 2. The reel body according to claim 1, wherein a detachable auxiliary core having the same diameter as the winding core is disposed on the inner peripheral side of the protruding portion.

3. 3. The reel body according to claim 1, wherein a guide plate is disposed on an end surface of the wound adhesive film in the axial direction, for aligning an edge of the adhesive film in the width direction at the end surface.

4. A reel body in which an adhesive film having an adhesive layer on a base layer is wound around a core, the adhesive film does not have a protective layer on the adhesive layer, and the adhesive layer and the base material layer are wound around the core in a state where they are adjacent to each other in a radial direction of the core, The width of the core in the axial direction is smaller than the width of the adhesive film, The roll of the adhesive film is provided with a protruding portion that protrudes in the axial direction of the core, A reel body in which a removable auxiliary core having the same diameter as the winding core is disposed on the inner peripheral side of the protruding portion.

5. 5. The reel body according to claim 4, wherein a guide plate is disposed on an end surface of the wound adhesive film in the axial direction, for aligning an edge of the adhesive film in the width direction at the end surface.

6. A reel body in which an adhesive film having an adhesive layer on a base layer is wound around a core, the adhesive film does not have a protective layer on the adhesive layer, and the adhesive layer and the base material layer are wound around the core in a state where they are adjacent to each other in a radial direction of the core, The width of the core in the axial direction is smaller than the width of the adhesive film, The roll of the adhesive film is provided with a protruding portion that protrudes in the axial direction of the core, a reel body having a guide plate disposed on an axial end face of the wound adhesive film for aligning the widthwise edge of the adhesive film at the end face;

7. A method for producing a reel body, comprising a winding step of winding an adhesive film having an adhesive layer on a base layer around a core, the method comprising: In the winding step, a core having an axial width smaller than the width of the adhesive film is used, and the adhesive film having no protective layer on the adhesive layer is wound around the core while the adhesive layer and the base material layer are adjacent in the radial direction of the core, thereby forming protruding portions that protrude on both sides of the axial direction of the core in the wound body of the adhesive film.

8. A method for producing a reel body, comprising a winding step of winding an adhesive film having an adhesive layer on a base layer around a core, the method comprising: In the winding step, a core having an axial width smaller than the width of the adhesive film is used, and the adhesive film having no protective layer on the adhesive layer is wound around the core while the adhesive layer and the base material layer are adjacent in the radial direction of the core, thereby forming a protruding portion that protrudes in the axial direction of the core into a wound body of adhesive film, and a removable auxiliary core having the same diameter as the core is positioned on the inner side of the protruding portion.

9. A method for producing a reel body, comprising a winding step of winding an adhesive film having an adhesive layer on a base layer around a core, the method comprising: In the winding step, a core having an axial width smaller than the width of the adhesive film is used, and the adhesive film having no protective layer on the adhesive layer is wound around the core while the adhesive layer and the base material layer are adjacent in the radial direction of the core, thereby forming a protruding portion that protrudes in the axial direction of the core into a wound body of adhesive film, and a guide plate that aligns the widthwise edge of the adhesive film at the axial end face of the wound body of adhesive film is disposed on the axial end face of the wound body of adhesive film.

10. A method for producing an article, comprising a bonding step of bonding an adhesive film unwound from a reel body formed by winding an adhesive film having an adhesive layer on a base layer around a core to an adherend, comprising: In the reel body, the adhesive film does not have a protective layer on the adhesive layer, and the adhesive layer and the base material layer are wound around the core in a state where they are adjacent to each other in a radial direction of the core, The width of the core in the axial direction is smaller than the width of the adhesive film, The roll of the adhesive film is provided with a protruding portion that protrudes in the axial direction of the core, In the joining step, the inner side of the protruding portion of the reel body is fixed to a winding core jig on the unwinding device side, and the adhesive film is unwound toward the substrate while the axial end face of the wound body of the adhesive film at the protruding portion is abutted against a guide plate on the unwinding device side.

Images