Adhesive Film

Abstract

An adhesive film for use in the manufacturing process of electronic devices, the adhesive film having a deformation rate of 2.0% or more and 70.0% or less at 100°C and a deformation rate of 25.0% or less at 150°C.

Description

[Technical field]

[0001] The present invention relates to an adhesive film. [Background technology]

[0002] Some manufacturing methods for electronic devices include a process of forming a circuit of an electronic component, and then performing processes such as back grinding, ion implantation, laser annealing, sputtering, etc. on the surface of the electronic component opposite to the surface on which the circuit is formed. In these processes, an adhesive film is used to protect the surface on which the circuit is formed of the electronic component. An example of a technique relating to such an adhesive film is described in Patent Document 1 (WO 2015 / 152010).

[0003] Patent Document 1 describes a protective film that has a polyimide base material and a thermosetting adhesive layer provided on one surface of the polyimide base material and obtained from a composition containing an acrylic polymer (a), a thermal radical generator (b) having a 1-minute half-life temperature of 140°C or more and 200°C or less, and a crosslinking agent (c), and that is to be attached to the circuit-forming surface of a semiconductor wafer. Patent Document 1 describes that when the protective film is applied to a semiconductor device manufacturing method including a step of attaching the protective film to the circuit-forming surface of a semiconductor wafer, thermally curing the thermosetting adhesive layer, and then performing vacuum heating while the protective film is still attached to the semiconductor wafer, it is possible to provide a protective film that protects the circuit-forming surface of the semiconductor wafer, suppresses the occurrence of lifting, and has excellent removability when peeled off from the semiconductor wafer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2015 / 152010 Summary of the Invention [Problem to be solved by the invention]

[0005] In such a method for manufacturing an electronic device, if the adhesion between the electronic component and the adhesive film is insufficient, water or chemicals may penetrate between the electronic component and the adhesive film, causing deterioration of the electronic component.

[0006] According to the inventors' investigations, it was found that in order to improve the adhesion between the electronic component and the adhesive film and protect the electronic component, the adhesive film needs to be able to follow the irregularities of the circuit-forming surface when attached to the circuit-forming surface of the electronic component (irregularity-following ability), and the adhesive film attached to the electronic component needs to not float even in a vacuum atmosphere (vacuum resistance).

[0007] Furthermore, according to the study by the present inventors, it has been found that, although a method of making the adhesive film flexible can be adopted to improve the conformability to uneven surfaces, the adhesive film is easily deformed in a vacuum atmosphere and easily lifted from the electronic component. On the other hand, a method of making the adhesive film hard can be adopted to improve the vacuum resistance, but it has been found that the conformability to uneven surfaces when attached to the electronic component is insufficient. In other words, it has been found that there is a trade-off between the conformability to uneven surfaces and the vacuum resistance of the adhesive film.

[0008] The present invention has been made in consideration of the above circumstances, and provides an adhesive film having an improved balance of properties of conformability to irregularities and vacuum resistance. [Means for solving the problem]

[0009] According to the present invention, there is provided the following pressure-sensitive adhesive film.

[0010] [1] An adhesive film for use in a manufacturing process of an electronic device, comprising: The deformation rate at 100°C calculated by the following method 1 is 2.0% or more and 70.0% or less, An adhesive film having a deformation rate at 150°C of 25.0% or less, as calculated by the following method 2. [Method 1] A measurement sample is prepared by stacking n sheets of the adhesive film until the thickness is 1.4±0.1 mm, and the measurement sample is cut to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 10 N is continuously applied to the measurement sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is defined as the deformation rate [%] at 100°C. [Method 2] A sample in which n sheets of the adhesive film are laminated until the thickness is 1.4±0.1 mm is prepared by heat treatment at 130°C for 30 minutes. The measurement sample is cut to a width of 10 mm, and the deformation amount when a load of 5 N is continuously applied to the measurement sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen, is measured. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is defined as the deformation rate [%] at 150°C. [2] An adhesive film for use in a manufacturing process of an electronic device, comprising: The deformation amount at 100 ° C. calculated by the following method 3 is 1.0 μm or more and 100.0 μm or less, An adhesive film having a deformation amount at 150°C of 35.0 μm or less, as calculated by the following method 4. [Method 3] A measurement sample is prepared by stacking n sheets of the adhesive film until the thickness is 1.4±0.1 mm, and the measurement sample is cut to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 10 N is continuously applied to the measurement sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers of the measurement sample n" is defined as the deformation amount at 100°C [μm]. [Method 4] A sample in which n sheets of the adhesive film are laminated until the thickness is 1.4±0.1 mm is prepared by heat treatment at 130°C for 30 minutes, and the measurement sample is cut to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 5 N is continuously applied using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen, and the value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers of the measurement sample n" is defined as the deformation amount at 150°C [μm]. [3] The adhesive film according to [1] or [2] above, comprising a base layer, an irregularity-absorbing resin layer, and a thermosetting adhesive layer in this order. [4] The adhesive film according to [3] above, wherein the unevenness-absorbing resin layer and the thermosetting adhesive layer are provided so as to be in direct contact with each other. [5] The pressure-sensitive adhesive film according to [3] or [4] above, wherein the thermosetting pressure-sensitive adhesive layer contains a (meth)acrylic resin and a thermal polymerization initiator. [6] The adhesive film according to any one of [3] to [5], wherein the resin constituting the unevenness-absorbing resin layer includes at least one selected from the group consisting of ethylene-vinyl acetate copolymer, (meth)acrylic resin, ethylene-α-olefin copolymer, and low-density polyethylene. [7] The pressure-sensitive adhesive film according to any one of the above [3] to [6], wherein the thickness of the irregularity-absorbing resin layer is from 20 μm to 500 μm. [8] The pressure-sensitive adhesive film according to any one of the above [3] to [7], wherein the resin constituting the base layer includes at least one selected from the group consisting of polyethylene naphthalate, polyethylene terephthalate, and polyimide. [9] The manufacturing process of the electronic device includes a step (A) of preparing a structure including an electronic component having a circuit formation surface and the adhesive film attached to the circuit formation surface side of the electronic component, and a step (B) of treating the surface of the electronic component opposite the circuit formation surface side in a vacuum atmosphere, the adhesive film described in any one of [1] to [8].

[10] The pressure-sensitive adhesive film according to any one of the above [1] to [9], wherein the electronic device is a power semiconductor device. Effect of the Invention

[0011] According to the present invention, it is possible to provide an adhesive film having an improved balance of properties of conformability to irregularities and vacuum resistance. [Brief description of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view showing a schematic diagram of a preferred layer structure of an adhesive film according to an embodiment of the present invention. [Diagram 2] 1 is a cross-sectional view showing a structure in step (A) of a method for producing an electronic device according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In all drawings, similar components are given the same reference numerals, and the description will be omitted as appropriate. The drawings are schematic diagrams and do not correspond to the actual dimensional ratios. Furthermore, the numerical range "A to B" represents A or more and B or less unless otherwise specified. Furthermore, in this embodiment, "(meth)acrylic" means acrylic, methacrylic, or both acrylic and methacrylic. Furthermore, unless otherwise specified, "the adhesive film of the present embodiment" refers to an embodiment including both the "adhesive film of the first embodiment" and the "adhesive film of the second embodiment."

[0014] <Adhesive film> The adhesive film of the first embodiment is an adhesive film used in the manufacturing process of an electronic device, and has a deformation rate at 100°C of 2.0% to 70.0% and a deformation rate at 150°C of 25.0% or less. Here, the deformation ratio at 100° C. means a value calculated by the following method 1. Moreover, the deformation ratio at 150° C. means a value calculated by the following method 2. [Method 1] A measurement sample is prepared by stacking n sheets of adhesive film until the thickness is 1.4±0.1 mm, and the measurement sample is cut to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 10 N is continuously applied to the measurement sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is the deformation rate [%] at 100°C. [Method 2] A sample in which n sheets of adhesive film are laminated until the thickness is 1.4±0.1 mm is prepared by heat treatment at 130°C for 30 minutes, and a measurement sample is prepared by cutting the measurement sample to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 5 N is continuously applied to the sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is defined as the deformation rate [%] at 150°C.

[0015] The adhesive film of the second embodiment is an adhesive film used in the manufacturing process of an electronic device, and has a deformation amount at 100°C of 1.0 μm or more and 100.0 μm or less, and a deformation amount at 150°C of 35.0 μm or less. Here, the deformation amount at 100° C. means a value calculated by the following method 3. Moreover, the deformation amount at 150° C. means a value calculated by the following method 4. [Method 3] A measurement sample is prepared by stacking n sheets of adhesive film until the thickness is 1.4±0.1 mm, and the measurement sample is cut to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 10 N is continuously applied to the measurement sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers of the measurement sample n" is defined as the deformation amount at 100°C [μm]. [Method 4] A sample in which n sheets of adhesive film are laminated until the thickness is 1.4±0.1 mm is prepared by heat treatment at 130°C for 30 minutes, and a measurement sample is prepared by cutting the measurement sample to a width of 10 mm. The measurement sample is measured for deformation amount when a load of 5 N is continuously applied to the sample using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers of the measurement sample n" is defined as the deformation amount at 150°C [μm].

[0016] As described above, the adhesive films used in the conventional manufacturing process for electronic devices have a trade-off between conformability to irregularities and vacuum resistance. The present inventors have conducted extensive research to achieve the above object. As a result, they have found that the scales of the deformation rate of an adhesive film at 100°C and the deformation rate at 150°C are effective as design indicators for improving the balance of the performance of the conformability to unevenness and the vacuum resistance. Furthermore, they have found that the scales of the deformation amount of an adhesive film at 100°C and the deformation amount at 150°C are effective as design indicators for improving the balance of the performance of the conformability to unevenness and the vacuum resistance. As described above, the pressure-sensitive adhesive film of the present embodiment can improve the balance of properties of conformability to irregularities and vacuum resistance.

[0017] The pressure-sensitive adhesive film of the first embodiment has a deformation rate at 100°C of 2.0% or more and 70.0% or less, and a deformation rate at 150°C of 25.0% or less. The deformation rate of the adhesive film of the first embodiment at 100°C is, from the viewpoint of further improving the adhesive film's ability to conform to uneven surfaces, preferably 2.5% or more, more preferably 3.0% or more, even more preferably 3.5% or more, even more preferably 4.0% or more, and even more preferably 4.5% or more, and from the viewpoint of further improving the handleability of the adhesive film, it is preferably 65.0% or less, more preferably 60.0% or less, even more preferably 55.0% or less, even more preferably 50.0% or less, even more preferably 45.0% or less, and even more preferably 42.0% or less. The deformation rate of the adhesive film of the first embodiment at 150°C is, from the viewpoint of further improving the vacuum resistance of the adhesive film, preferably 23.0% or less, more preferably 20.0% or less, even more preferably 18.0% or less, and even more preferably 15.0% or less, and the lower limit is not particularly limited, but may be, for example, 0.2% or more, or 0.5% or more. The deformation rate of the adhesive film of the first embodiment at 100°C and at 150°C can be controlled, for example, by the layer structure of the adhesive film, the thickness and material of each layer, etc., and specifically, by the resin used in the unevenness-absorbing resin layer and the thermal polymerization initiator contained in the thermosetting adhesive layer, etc.

[0018] The pressure-sensitive adhesive film of the second embodiment has a deformation amount at 100°C of 1.0 µm or more and 100.0 µm or less, and a deformation amount at 150°C of 35.0 µm or less. The deformation amount of the adhesive film of the second embodiment at 100°C is, from the viewpoint of further improving the adhesive film's ability to conform to unevenness, preferably 2.0 μm or more, more preferably 3.0 μm or more, even more preferably 4.0 μm or more, and even more preferably 5.0 μm or more, and from the viewpoint of further improving the handleability of the adhesive film, preferably 95.0 μm or less, more preferably 90.0 μm or less, even more preferably 88.0 μm or less, even more preferably 85.0 μm or less, even more preferably 82.0 μm or less, and even more preferably 80.0 μm or less. The deformation amount of the adhesive film of the second embodiment at 150°C is preferably 32.0 μm or less, more preferably 30.0 μm or less, from the viewpoint of further improving the vacuum resistance of the adhesive film, and the lower limit is not particularly limited, but may be, for example, 0.1 μm or more, or 0.5 μm or more. The deformation amount of the adhesive film of the second embodiment at 100°C and at 150°C can be controlled, for example, by the layer structure of the adhesive film, the thickness and material of each layer, etc., and specifically, by the resin used in the unevenness-absorbing resin layer and the thermal polymerization initiator contained in the thermosetting adhesive layer, etc.

[0019] The overall thickness of the adhesive film of this embodiment is, from the viewpoint of further improving the handleability of the adhesive film, preferably 10 μm or more, more preferably 20 μm or more, even more preferably 40 μm or more, even more preferably 60 μm or more, even more preferably 80 μm or more, and even more preferably 100 μm or more, and from the viewpoint of further improving the unevenness-following ability of the adhesive film, is preferably 700 μm or less, more preferably 500 μm or less, even more preferably 300 μm or less, even more preferably 250 μm or less, and even more preferably 200 μm or less.

[0020] The layer structure of the pressure-sensitive adhesive film of the present embodiment is not particularly limited, and may be a single-layer structure or a multi-layer structure, but a multi-layer structure is preferable. FIG. 1 is a cross-sectional view that illustrates a preferred layer structure of an adhesive film according to an embodiment of the present invention. As shown in FIG. 1, the adhesive film 50 of this embodiment preferably comprises a base layer 20, an unevenness-absorbing resin layer 30, and a thermosetting adhesive layer 40, in that order, and more preferably, the unevenness-absorbing resin layer 30 and the thermosetting adhesive layer 40 are arranged so as to be in direct contact with each other.

[0021] Hereinafter, each layer constituting the adhesive film 50 of this embodiment will be described.

[0022] [Base material layer] The base layer 20 is a layer provided for the purpose of improving the balance of performance of the adhesive film 50, such as ease of handling, mechanical properties, and heat resistance. The base layer 20 is not particularly limited, but may be, for example, a resin film. The resin constituting the base layer 20 preferably contains at least one selected from the group consisting of polyethylene naphthalate, polyethylene terephthalate, and polyimide, and from the viewpoint of further improving vacuum resistance, it is more preferable that the resin contains polyethylene naphthalate.

[0023] The substrate layer 20 may be a single layer or two or more layers. The resin film used to form the base layer 20 may be in the form of an unstretched film, or a uniaxially or biaxially stretched film.

[0024] From the viewpoint of further improving the handleability of the adhesive film 50, the thickness of the base layer 20 is preferably 10 μm or more, more preferably 20 μm or more, even more preferably 30 μm or more, and even more preferably 40 μm or more, and from the viewpoint of further improving the unevenness-following ability of the adhesive film 50, the thickness is preferably 500 μm or less, more preferably 300 μm or less, even more preferably 200 μm or less, even more preferably 100 μm or less, even more preferably 80 μm or less, and even more preferably 60 μm or less.

[0025] The substrate layer 20 may be subjected to a surface treatment in order to further improve adhesion to other layers. Specifically, corona treatment, plasma treatment, undercoat treatment, primer coat treatment, etc. may be performed.

[0026] [Roughness-absorbing resin layer] The irregularity-absorbing resin layer 30 is a layer provided to further improve the balance of the performance of the adhesive film 50 between its irregularity-following ability and vacuum resistance.

[0027] The resin constituting the unevenness-absorbing resin layer 30 preferably contains at least one selected from the group consisting of ethylene-vinyl acetate copolymer, (meth)acrylic resin, ethylene-α-olefin copolymer, and low-density polyethylene, more preferably contains one or two selected from the group consisting of ethylene-vinyl acetate copolymer and (meth)acrylic resin, and even more preferably contains ethylene-vinyl acetate copolymer.

[0028] The ethylene-vinyl acetate copolymer of the present embodiment is a copolymer of ethylene and vinyl acetate, for example, a random copolymer. The content of structural units derived from vinyl acetate in the ethylene-vinyl acetate copolymer is preferably 5 mass% or more, more preferably 10 mass% or more, and even more preferably 15 mass% or more, from the viewpoint of further improving the performance balance between the conformability to uneven surfaces and vacuum resistance of the adhesive film 50, and is preferably 50 mass% or less, more preferably 45 mass% or less, even more preferably 40 mass% or less, even more preferably 35 mass% or less, even more preferably 30 mass% or less, and even more preferably 25 mass% or less, from the viewpoint of further improving the performance balance between the conformability to uneven surfaces and vacuum resistance of the adhesive film 50. The vinyl acetate content can be measured in accordance with JIS K7192:1999.

[0029] The ethylene-vinyl acetate copolymer is preferably a binary copolymer consisting of only ethylene and vinyl acetate, but may contain, in addition to ethylene and vinyl acetate, at least one copolymer component selected from, for example, vinyl ester monomers such as vinyl formate, vinyl glycolate, vinyl propionate, vinyl benzoate, etc.; acrylic monomers such as acrylic acid, methacrylic acid, ethacrylic acid, or salts or alkyl esters thereof; etc. When a copolymer component other than ethylene and vinyl acetate is contained, the amount of the copolymer component other than ethylene and vinyl acetate in the ethylene-vinyl acetate copolymer is preferably 0.5% by mass or more and 5% by mass or less.

[0030] The melt flow rate (MFR) of the ethylene-vinyl acetate copolymer, measured in accordance with JIS K7210:1999 under conditions of 190°C and a load of 2.16 kg, is preferably 0.1 g / 10 minutes or more, more preferably 0.5 g / 10 minutes or more, even more preferably 1.0 g / 10 minutes or more, even more preferably 1.5 g / 10 minutes or more, and even more preferably 2.0 g / 10 minutes or more, from the viewpoint of further improving the formability of the unevenness absorbent resin layer 30, and is preferably 50 g / 10 minutes or less, more preferably 40 g / 10 minutes or less, even more preferably 20 g / 10 minutes or less, even more preferably 10 g / 10 minutes or less, even more preferably 5.0 g / 10 minutes or less, and even more preferably 3.0 g / 10 minutes or less, from the viewpoint of further improving the storage stability of the adhesive film 50.

[0031] The ethylene-α-olefin copolymer of the present embodiment is, for example, a copolymer obtained by copolymerizing ethylene with an α-olefin having 3 or more and 20 or less carbon atoms. As the α-olefin, for example, α-olefins having 3 to 20 carbon atoms can be used alone or in combination of two or more. Preferably, the α-olefin has 3 to 10 carbon atoms, and more preferably, the α-olefin has 3 to 8 carbon atoms. Specific examples of the α-olefin include propylene, 1-butene, 1-pentene, 1-hexene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, 1-octene, 1-decene, and 1-dodecene. Among them, propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene are preferred from the viewpoint of availability. The ethylene-α-olefin copolymer may be a random copolymer or a block copolymer, but a random copolymer is preferred from the viewpoint of flexibility.

[0032] The melting point of the resin constituting the unevenness-absorbing resin layer 30 is preferably 40°C or higher, more preferably 50°C or higher, even more preferably 60°C or higher, even more preferably 70°C or higher, and even more preferably 80°C or higher, from the viewpoint of further improving the storage stability of the adhesive film 50, and is preferably 100°C or lower, more preferably 95°C or lower, more preferably 90°C or lower, and even more preferably 85°C or lower, from the viewpoint of further improving the unevenness-following ability of the adhesive film 50. When the unevenness-absorbing resin layer 30 is made up of two or more kinds of resins, the melting point of the resin that makes up the unevenness-absorbing resin layer 30 is the peak temperature of the maximum melting peak measured by DSC.

[0033] The irregularity-absorbing resin layer 30 can be obtained, for example, by dry-blending or melt-kneading a resin and an additive to obtain a resin composition, and then extruding or coating and drying the resin composition. The additives may be added as necessary. Specific examples of the additives include a crosslinking agent and an antioxidant.

[0034] The content of the thermal polymerization initiator contained in the resin composition for forming the unevenness-absorbing resin layer 30 is preferably less than 0.3 parts by mass, more preferably less than 0.1 parts by mass, even more preferably less than 0.01 parts by mass, and even more preferably 0.00 parts by mass, when the entire resin composition for forming the unevenness-absorbing resin layer 30 is taken as 100 parts by mass. When the content of the thermal polymerization initiator contained in the resin composition for forming the unevenness-absorbing resin layer 30 is less than the above upper limit value, the moldability can be further improved when the unevenness-absorbing resin layer 30 is extrusion molded, and the unevenness-following ability of the adhesive film 50 can be further improved. The thermal polymerization initiator means the same as the thermal polymerization initiator contained in the thermosetting adhesive layer described below.

[0035] The layer that is in direct contact with the irregularity-absorbing resin layer 30 preferably contains a thermal polymerization initiator. When the layer in direct contact with the unevenness-absorbing resin layer 30 contains a thermal polymerization initiator, the vacuum resistance of the adhesive film 50 is further improved. Although the exact mechanism is unclear, the inventors consider that in the manufacturing process of an electronic device, when the temperature of the adhesive film 50 bonded to an electronic component becomes high (for example, 150°C or higher), the thermal polymerization initiator contained in the layer in direct contact with the unevenness-absorbing resin layer 30 diffuses into the unevenness-absorbing resin layer 30, hardening the resin constituting the unevenness-absorbing resin layer 30, hardening the entire adhesive film 50, and making it difficult for the adhesive film 50 bonded to the electronic component to float.

[0036] The thickness of the unevenness-absorbing resin layer 30 is preferably 20 μm or more, more preferably 30 μm or more, from the viewpoint of further improving the handleability of the adhesive film 50, and is preferably 500 μm or less, more preferably 300 μm or less, even more preferably 200 μm or less, and even more preferably 150 μm or less, from the viewpoint of further improving the performance balance between the unevenness-following ability and vacuum resistance of the adhesive film 50.

[0037] [Thermosetting adhesive layer] The thermosetting adhesive layer 40 is a layer provided for bonding the adhesive film 50 to the circuit-forming surface of the electronic component. The thermosetting adhesive layer 40 can be made of, for example, a known adhesive, and preferably contains a (meth)acrylic resin and a thermal polymerization initiator.

[0038] Examples of the resin contained in the thermosetting adhesive layer 40 include (meth)acrylic resins, silicone resins, urethane resins, olefin resins, and styrene resins. Among these, it is preferable to use a (meth)acrylic resin as the base polymer because the adhesive strength can be easily adjusted.

[0039] Examples of the (meth)acrylic resin of the present embodiment include homopolymers of (meth)acrylic acid ester compounds, copolymers of (meth)acrylic acid ester compounds and comonomers, etc. Examples of the (meth)acrylic acid ester compounds include methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, dimethylaminoethyl (meth)acrylate, and glycidyl (meth)acrylate. These (meth)acrylic acid ester compounds may be used alone or in combination of two or more. Examples of comonomers constituting the (meth)acrylic copolymer include vinyl acetate, (meth)acrylonitrile, styrene, (meth)acrylic acid, itaconic acid, (meth)acrylamide, methylol (meth)acrylamide, maleic anhydride, etc. These comonomers may be used alone or in combination of two or more.

[0040] The thermosetting adhesive layer 40 preferably contains a thermal polymerization initiator. The thermal polymerization initiator of the present embodiment is, for example, at least one selected from the group consisting of a thermal radical polymerization initiator, a thermal cationic polymerization initiator, and a thermal anionic polymerization initiator, and is preferably a thermal radical polymerization initiator.

[0041] The thermal radical polymerization initiator of the present embodiment is, for example, at least one selected from the group consisting of peroxides and azo compounds, and is preferably a peroxide. The peroxide of this embodiment is preferably 1,1-di(t-butylperoxy)-2-methylcyclohexane, 1,1-di(t-butylperoxy)-cyclohexane, 2,2-di(4,4-di-(t-butylperoxy)cyclohexyl)propane, t-butylperoxymaleic acid, t-butylperoxy-3,3,5-trimethylhexanoate, t-butylperoxylaurate, t-butylperoxyisopropyl monocarbonate, t-butylperoxy-2-ethylhexyl monocarbonate, t-hexylperoxybenzone, or the like. The at least one selected from the group consisting of butyl peroxyacetate, t-butylperoxyacetate, 2,2-di(t-butylperoxy)butane, t-butylperoxybenzoate, n-butyl-4,4-di-(t-butylperoxy)valerate, di(2-t-butylperoxyisopropyl)benzene, dicumyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, t-butylcumyl peroxide, di-t-butyl peroxide, and 2,5-dimethyl-2,5-di(t-butylperoxy)-3-hexyne.

[0042] The peroxide of the present embodiment preferably contains at least one structure selected from the group consisting of the following formula (I) and the following formula (II) in the molecule, and more preferably contains the following structure of formula (II) in the molecule.

[0043] [ka]

[0044] In formula (I), the wavy lines indicate points of attachment.

[0045] [ka]

[0046] In formula (II), the wavy line indicates the point of attachment.

[0047] The one-minute half-life temperature of the thermal radical polymerization initiator of this embodiment is preferably 140°C or higher, more preferably 145°C or higher, and even more preferably 150°C or higher, and is preferably 200°C or lower, more preferably 195°C or lower, more preferably 190°C or lower, more preferably 185°C or lower, and even more preferably 180°C or lower. When the one-minute half-life temperature of the thermal radical polymerization initiator is equal to or higher than the above lower limit, the thermal radical polymerization initiator is less likely to be thermally decomposed when forming the thermosetting adhesive layer 40 in the manufacturing process of the adhesive film 50, and the unevenness-following ability of the adhesive film 50 is further improved, which is preferable. When the one-minute half-life temperature of the thermal radical polymerization initiator is equal to or lower than the above upper limit, the thermal radical polymerization initiator is decomposed at a temperature lower than the temperature at which the resin contained in the adhesive film 50 is excessively softened, and the vacuum resistance of the adhesive film 50 is further improved, which is preferable.

[0048] The hydrogen abstraction ability of the thermal radical polymerization initiator of this embodiment is preferably 20% or more, more preferably 25% or more, and further preferably 30% or more, and the upper limit is not particularly limited, but may be 90% or less, or 80% or less. When the hydrogen abstraction ability of the thermal radical polymerization initiator of this embodiment is equal to or more than the above lower limit, the resin contained in the pressure-sensitive adhesive film 50 is more easily crosslinked, and the vacuum resistance of the pressure-sensitive adhesive film 50 is further improved, which is preferable. Here, the hydrogen abstraction ability means a value calculated by a radical trapping method using α-methylstyrene dimer as a radical trapping agent. More specifically, first, a thermal radical polymerization initiator is decomposed in the coexistence of α-methylstyrene dimer and cyclohexane. Among the radicals generated from the thermal radical polymerization initiator, those with weak hydrogen abstraction ability are captured by α-methylstyrene dimer. On the other hand, radicals with strong hydrogen abstraction ability abstract hydrogen from cyclohexane, generating cyclohexyl radicals. The cyclohexyl radicals are captured by α-methylstyrene dimer and are led to the trapping products of cyclohexyl radicals. The hydrogen abstraction ability is the ratio (molar fraction) of the amount of the trapping products of cyclohexyl radicals to the theoretical amount of radicals generated.

[0049] The content of the thermal polymerization initiator contained in the thermosetting adhesive layer 40, when the content of the (meth)acrylic resin contained in the thermosetting adhesive layer 40 is taken as 100 parts by mass, is preferably 0.1 parts by mass or more, more preferably 0.3 parts by mass or more, and even more preferably 0.5 parts by mass or more, from the viewpoint of further improving the vacuum resistance of the adhesive film 50, and is preferably 2.0 parts by mass or less, more preferably 1.8 parts by mass or less, and even more preferably 1.5 parts by mass or less, from the viewpoint of further improving the unevenness-following ability of the adhesive film 50. Here, the content of the thermal polymerization initiator contained in the thermosetting adhesive layer 40 means the content of the thermal polymerization initiator in the adhesive for forming the thermosetting adhesive layer 40. That is, the content of the thermal polymerization initiator in this specification means the amount charged when forming the thermosetting adhesive layer 40. The contents of the crosslinking agent and the polyfunctional acrylate described below also mean the amount charged, like the thermal polymerization initiator.

[0050] The thermosetting adhesive layer 40 may contain a crosslinking agent. Examples of the crosslinking agent of the present embodiment include epoxy compounds such as sorbitol polyglycidyl ether, polyglycerol polyglycidyl ether, pentaerythritol polyglycidyl ether, and diglycerol polyglycidyl ether; aziridine compounds such as tetramethylolmethane-tri-β-aziridinyl propionate, trimethylolpropane-tri-β-aziridinyl propionate, N,N'-diphenylmethane-4,4'-bis(1-aziridinecarboxamide), and N,N'-hexamethylene-1,6-bis(1-aziridinecarboxamide); and isocyanate compounds such as tetramethylene diisocyanate, hexamethylene diisocyanate, and polyisocyanate.

[0051] The content of the crosslinking agent contained in the thermosetting adhesive layer 40, when the content of the (meth)acrylic resin contained in the thermosetting adhesive layer 40 is taken as 100 parts by mass, is preferably 0.1 parts by mass or more, more preferably 0.3 parts by mass or more, even more preferably 0.5 parts by mass or more, even more preferably 1.0 parts by mass or more, even more preferably 1.5 parts by mass or more, even more preferably 2.0 parts by mass or more, and even more preferably 2.3 parts by mass or more, from the viewpoint of further improving the performance balance of the adhesive film 50's unevenness-following ability and vacuum resistance, and is preferably 10.0 parts by mass or less, more preferably 7.0 parts by mass or less, even more preferably 5.0 parts by mass or less, even more preferably 4.0 parts by mass or less, and even more preferably 3.0 parts by mass or less, from the viewpoint of further improving the performance balance of the adhesive film 50's unevenness-following ability and vacuum resistance.

[0052] The thermosetting adhesive layer 40 may further contain a polyfunctional acrylate in addition to the (meth)acrylic resin. The polyfunctional acrylate in this embodiment is an acrylate having two or more radically reactive double bonds. Examples of the polyfunctional acrylate of the present embodiment include urethane acrylate, epoxy acrylate, polyester acrylate, polyether acrylate, pentaerythritol polyacrylate, dipentaerythritol polyacrylate, ethoxylated isocyanuric acid triacrylate, trimethylolpropane triacrylate, and ditrimethylolpropane tetraacrylate.

[0053] The content of the polyfunctional acrylate contained in the thermosetting adhesive layer 40, when the content of the (meth)acrylic resin contained in the thermosetting adhesive layer 40 is taken as 100 parts by mass, is preferably 2.0 parts by mass or more, more preferably 3.0 parts by mass or more, and even more preferably 4.0 parts by mass or more, from the viewpoint of further improving the performance balance of the adhesive film 50's unevenness-following ability and vacuum resistance, and is preferably 20.0 parts by mass or less, more preferably 15.0 parts by mass or less, and even more preferably 12.0 parts by mass or less, from the viewpoint of further improving the performance balance of the adhesive film 50's unevenness-following ability and vacuum resistance.

[0054] The thickness of the thermosetting adhesive layer 40 is not particularly limited, but is preferably 1 μm or more, more preferably 5 μm or more, even more preferably 10 μm or more, even more preferably 15 μm or more, and is preferably 100 μm or less, more preferably 50 μm or less, even more preferably 30 μm or less, even more preferably 25 μm or less.

[0055] The thermosetting adhesive layer 40 can be formed, for example, by applying an adhesive coating liquid onto the irregularity-absorbing resin layer 30 . The adhesive coating liquid can be applied by a conventionally known coating method, such as a roll coater method, a reverse roll coater method, a gravure roll method, a bar coat method, a comma coater method, a die coater method, etc. There are no particular limitations on the drying conditions for the applied adhesive, but it is generally preferable to dry the adhesive at a temperature range of 80 to 200° C. for 10 seconds to 10 minutes. More preferably, the adhesive is dried at 80 to 170° C. for 15 seconds to 5 minutes.

[0056] [Other layers] An adhesive layer may be provided between each layer of the adhesive film 50. This adhesive layer can improve the adhesion between each layer.

[0057] An example of a method for producing the adhesive film 50 according to this embodiment will be described. First, the irregularity-absorbing resin layer 30 is formed by extrusion molding on one surface of the base layer 20. Next, an adhesive coating liquid is applied onto the irregularity-absorbing resin layer 30 and dried to form a thermosetting adhesive layer 40, thereby obtaining an adhesive film 50.

[0058] Next, a method for manufacturing the electronic device of this embodiment will be described. The electronic device in this embodiment includes elements, devices, final products, etc. to which electronic engineering technology is applied, such as semiconductor devices, power semiconductor devices, semiconductor chips, semiconductor elements, printed wiring boards, electric circuit display devices, information and communication terminals, light-emitting diodes, physical batteries, and chemical batteries. The electronic device of this embodiment is preferably a power semiconductor device. A power semiconductor device is a semiconductor device that controls and converts electric power, and generally has a rated current of 1 A or more.

[0059] The manufacturing method of the electronic device of this embodiment is not particularly limited, but preferably includes the steps of: (A) preparing a structure including an electronic component having a circuit formation surface and the adhesive film attached to the circuit formation surface side of the electronic component; and (B) treating the surface of the electronic component opposite the circuit formation surface side in a vacuum atmosphere. Each step of the method for manufacturing an electronic device will now be described.

[0060] [Process (A)] FIG. 2 is a cross-sectional view that illustrates the structure 100 in the step (A). In step (A), a structure 100 is prepared that includes an electronic component 10 having a circuit-formation surface 10A and an adhesive film 50 attached to the circuit-formation surface 10A side of the electronic component 10.

[0061] Such a structure 100 can be produced by attaching an adhesive film 50 to the circuit-forming surface 10A of the electronic component 10. The method of laminating the adhesive film 50 to the circuit-forming surface 10A of the electronic component 10 is not particularly limited, and the lamination can be performed by a known method. For example, the lamination may be performed manually or by a device called an automatic laminating machine to which a roll-shaped adhesive film 50 is attached.

[0062] When the circuit-forming surface 10A of the electronic device 10 is bonded, for example, the adhesive film 50 is heated. The heating temperature is appropriately set depending on the type of adhesive film 50, and is not particularly limited, but may be, for example, 40° C. or higher, 45° C. or higher, and 120° C. or lower, or 110° C. or lower.

[0063] The electronic component 10 is not particularly limited as long as it has a circuit-forming surface 10A, but examples thereof include a semiconductor wafer, a sapphire substrate, a lithium tantalate substrate, a molded wafer, a molded panel, a molded array package, a semiconductor substrate, and the like, with a semiconductor wafer being preferred. Examples of semiconductor wafers include silicon wafers, sapphire wafers, germanium wafers, germanium-arsenic wafers, gallium-phosphorus wafers, gallium-arsenic-aluminum wafers, gallium-arsenic wafers, and lithium tantalate wafers, with silicon wafers being preferred.

[0064] Circuits such as wiring, capacitors, diodes, transistors, etc. are formed on the surface of the circuit-forming surface 10A of the electronic component 10. The circuit-forming surface may be subjected to plasma treatment. Furthermore, the circuit-forming surface 10A of the electronic component 10 may be uneven due to the presence of bump electrodes or the like. Furthermore, the bump electrodes are bonded to electrodes formed on the mounting surface, for example, when mounting an electronic device on the mounting surface, to form an electrical connection between the electronic device and the mounting surface (the mounting surface of a printed circuit board, etc.). Examples of the bump electrode include ball bumps, printed bumps, stud bumps, plated bumps, and pillar bumps. That is, the bump electrode is usually a convex electrode. These bump electrodes may be used alone or in combination of two or more types. The height and diameter of the bump electrodes are not particularly limited, but are preferably 10 μm or more, more preferably 50 μm or more, and preferably 400 μm or less, more preferably 300 μm or less. The bump pitch is also not particularly limited, but is preferably 20 μm or more, more preferably 100 μm or more, and preferably 600 μm or less, more preferably 500 μm or less. The metal species constituting the bump electrode is not particularly limited, and examples thereof include solder, silver, gold, copper, tin, lead, bismuth, and alloys thereof, but the adhesive film 50 is preferably used when the bump electrode is a solder bump. These metal species may be used alone or in combination of two or more.

[0065] [Process (B)] In step (B), surface 10B of electronic component 10 opposite circuit-forming surface 10A is treated in a vacuum atmosphere. Step (B) is a step that is performed after step (A). Therefore, in step (B), surface 10B of electronic component 10 in structure 100 opposite to circuit-forming surface 10A is treated.

[0066] In step (B), the vacuum atmosphere means a low-pressure state in which the pressure is reduced below atmospheric pressure by a vacuum device, and may be, for example, 1000 Pa or less, 100 Pa or less, or 10 Pa or less.

[0067] Step (B) may be performed under high temperature conditions. When step (B) is performed under high temperature conditions, the temperature of the structure 100 in step (B) is preferably 60°C or higher, more preferably 80°C or higher, even more preferably 100°C or higher, even more preferably 120°C or higher, even more preferably 140°C or higher, and preferably 230°C or lower, more preferably 210°C or lower, even more preferably 190°C or lower, even more preferably 170°C or lower.

[0068] In step (B), the method for treating surface 10B of electronic component 10 opposite circuit-forming surface 10A is not particularly limited, and may be a step in a known method for manufacturing electronic devices. The step (B) is preferably at least one step selected from the group consisting of an ion implantation step, a metal film formation step, and an annealing treatment step.

[0069] The method for producing an electronic device of this embodiment preferably further includes a step of heating structure 100 prior to step (B). It is preferable to further include a step of heating the structure 100 as a step prior to step (B), since this thermally cures the resin contained in the adhesive film 50, thereby better preventing the adhesive film 50 from lifting off the electronic component 10 in step (B). The temperature of structure 100 in the step of heating structure 100 is preferably 60°C or higher, more preferably 80°C or higher, even more preferably 100°C or higher, even more preferably 120°C or higher, even more preferably 140°C or higher, and preferably 230°C or lower, more preferably 210°C or lower, even more preferably 190°C or lower, even more preferably 170°C or lower.

[0070] [Process (C)] The method for producing an electronic device of the present embodiment preferably further includes the step (C) of removing the adhesive film 50 from the electronic component 10. Step (C) is a step subsequent to step (B). That is, in step (C), the adhesive film 50 is removed from the electronic component 10 in the structure 100.

[0071] The method for removing the adhesive film 50 from the electronic component 10 is not particularly limited, and may be performed, for example, by a known method of peeling the adhesive film 50 from the electronic component 10. The peeling may be performed, for example, manually or by a device called an automatic peeling machine.

[0072] The adhesive film 50 may be peeled off from the electronic component 10 at room temperature (around 25°C), or if the automatic peeling machine is equipped with a heating function, the adhesive film 50 may be peeled off after the structure 100 has been heated to a predetermined temperature (for example, 40°C or higher and 90°C or lower).

[0073] The surface of the electronic component 10 after peeling off the adhesive film 50 may be washed as necessary. Examples of the washing method include wet washing such as water washing or solvent washing, and dry washing such as plasma washing. In the case of wet washing, ultrasonic washing may be used in combination. The washing method may be appropriately selected depending on the degree of contamination on the surface of the electronic component 10.

[0074] [Process (D)] The method for manufacturing an electronic device of this embodiment preferably further includes a step (D) of backgrinding surface 10B of electronic component 10 opposite circuit-forming surface 10A. Step (D) is a step carried out between steps (A) and (B). "Back grinding" means to thin the electronic component 10 to a predetermined thickness without damaging the electronic component 10. For example, the structure 100 is fixed to a chuck table or the like of a grinding machine, and the surface 10B of the electronic component 10 opposite the circuit formation surface 10A is ground.

[0075] In such a back grinding operation, electronic component 10 is ground until its thickness becomes equal to or less than a desired thickness. The thickness of electronic component 10 before grinding is appropriately determined depending on the diameter, type, etc. of electronic component 10, and the thickness of electronic component 10 after grinding is appropriately determined depending on the size of the resulting chip, type of circuit, etc. Furthermore, when the electronic component 10 is half-cut or a modified layer is formed by laser irradiation, the electronic component 10 is divided into individual chips.

[0076] The back grinding method is not particularly limited, and any known grinding method can be used. Grinding can be performed while cooling the electronic component 10 and the grindstone by pouring water on them. If necessary, a dry polishing process, which is a grinding method that does not use grinding water, can be performed at the end of the grinding process. After the back grinding is completed, chemical etching is performed as necessary. Chemical etching is performed by immersing the electronic component 10 with the adhesive film 50 attached in an etching solution selected from the group consisting of an acidic aqueous solution consisting of a single or mixed solution of hydrofluoric acid, nitric acid, sulfuric acid, acetic acid, etc., and an alkaline aqueous solution such as a potassium hydroxide aqueous solution and a sodium hydroxide aqueous solution. Etching is performed for the purpose of removing distortion generated on the back surface of the electronic component 10, further thinning the electronic component 10, removing oxide films, etc., and pretreatment when forming an electrode on the back surface. The etching solution is appropriately selected depending on the above purpose.

[0077] [Other processes] The method for manufacturing an electronic device according to the present embodiment may include other steps in addition to those described above. As the other steps, any method known in the art for manufacturing electronic devices may be used. For example, any process generally performed in the manufacturing process of electronic components, such as a resist process, a developing process, an ashing process, a sputtering process, a dicing process, a die bonding process, a wire bonding process, a flip chip connection process, a cure heating test process, a sealing process, a reflow process, etc., may be further performed.

[0078] Although the embodiments of the present invention have been described above, these are merely examples of the present invention, and various configurations other than those described above can also be adopted.

[0079] The present invention is not limited to the above-described embodiment, and modifications and improvements within the scope of the present invention that can achieve the object of the present invention are included in the present invention. EXAMPLES

[0080] The present invention will be specifically described below with reference to examples and comparative examples, but the present invention is not limited thereto. Details regarding the preparation of the adhesive film are as follows.

[0081] <Material> Base layer 1: Polyethylene naphthalate film (manufactured by Toyobo Film Solutions Co., Ltd., product name: Teonex Q81, thickness: 50 μm) Resin 1: Ethylene-vinyl acetate copolymer (manufactured by Mitsui Dow Polychemicals, product name: Evaflex EV460, melting point: 84°C, content of structural units derived from vinyl acetate: 19% by mass, MFR (190°C, 2.16 kg): 2.5 g / 10 min) Crosslinking agent 1: Isocyanate-based crosslinking agent (manufactured by Mitsui Chemicals, Inc., product name: Olestar P49-75S) Thermal polymerization initiator 1: Peroxide (manufactured by Nouryon Chemical Industries, Ltd., product name: Perkadox 12-XL25) Photopolymerization initiator 1: α-aminoketone (manufactured by IGM Resins BV, product name: Omnirad379) Multifunctional acrylate 1: ditrimethylolpropane tetraacrylate (manufactured by Shin-Nakamura Chemical Co., Ltd., product name: AD-TMP)

[0082] <Preparation of (meth)acrylic polymer solution a> n-Butyl acrylate (77 parts by mass), methyl methacrylate (16 parts by mass), 2-hydroxyethyl acrylate (7 parts by mass), and t-butylperoxy-2-ethylhexanoate (0.3 parts by mass) as a polymerization initiator were reacted in toluene (20 parts by mass) and ethyl acetate (80 parts by mass) at 85° C. for 10 hours. After the reaction was completed, the solution was cooled, and toluene (30 parts by mass), methacryloyloxyethyl isocyanate (7 parts by mass), and dibutyltin dilaurate (0.05 parts by mass) were added thereto, and the mixture was reacted at 85° C. for 12 hours while blowing in air, to obtain a (meth)acrylic polymer solution a.

[0083] <Preparation of (meth)acrylic polymer solution b> n-Butyl acrylate (72 parts by mass), methyl methacrylate (18 parts by mass), 2-hydroxyethyl methacrylate (7 parts by mass), acrylic acid (3 parts by mass), and t-butylperoxy-2-ethylhexanoate (0.3 parts by mass) as a polymerization initiator were reacted in toluene (36 parts by mass) and ethyl acetate (53 parts by mass) at 85° C. for 10 hours. After completion of the reaction, the solution was cooled and toluene (34 parts by mass) was added to obtain a (meth)acrylic polymer solution b.

[0084] [Example 1] (Preparation of adhesive coating solution for thermosetting adhesive layer) To 100 parts by mass of (meth)acrylic polymer solution a (solid content), thermal polymerization initiator 1 (0.8 parts by mass), crosslinking agent 1 (2.56 parts by mass), and multifunctional acrylate 1 (10 parts by mass) were added to obtain an adhesive coating liquid for a thermosetting adhesive layer.

[0085] (Preparation of adhesive film) Using an extrusion molding machine, resin 1 (100 parts by mass) was extrusion molded onto base layer 1. A laminated film was obtained in which a 70 μm-thick irregularity-absorbing resin layer was laminated on the base layer. Next, the adhesive coating liquid for the thermosetting adhesive layer was applied to a silicone release-treated polyethylene terephthalate film (38 μm) and dried to form a thermosetting adhesive layer with a thickness of 20 μm. The obtained thermosetting adhesive layer was then attached to the unevenness-absorbing resin layer side of the laminated film described above to obtain an adhesive film.

[0086] [Examples 2 to 4 and Comparative Example 2] (Preparation of adhesive coating solution for thermosetting adhesive layer) An adhesive coating liquid for a thermosetting adhesive layer was obtained in the same manner as in Example 1, except that the formulation of the adhesive coating liquid was as shown in Table 1. (Preparation of adhesive film) A pressure-sensitive adhesive film was obtained in the same manner as in Example 1, except that the thickness of the irregularity-absorbing resin layer was set to a thickness shown in Table 1.

[0087] [Example 5] (Preparation of adhesive coating solution for thermosetting adhesive layer) In the same manner as in Example 1, an adhesive coating liquid for a thermosetting adhesive layer was obtained.

[0088] (Preparation of Coating Solution for Irregularity-Absorbing Resin Layer) Crosslinking agent 1 (0.3 parts by mass) was added to (meth)acrylic polymer solution a (50 parts by mass) and (meth)acrylic polymer solution b (50 parts by mass) to obtain a coating liquid for an irregularity-absorbing resin layer.

[0089] (Preparation of adhesive film) The coating liquid for the irregularity-absorbing resin layer was applied onto the base layer 1 and dried to form an irregularity-absorbing resin layer having a thickness of 40 μm, thereby obtaining a laminated film. Next, the adhesive coating liquid for the thermosetting adhesive layer was applied to a silicone release-treated polyethylene terephthalate film (38 μm) and dried to form a thermosetting adhesive layer with a thickness of 20 μm. The obtained thermosetting adhesive layer was then attached to the unevenness-absorbing resin layer side of the laminated film described above to obtain an adhesive film.

[0090] [Comparative Example 1] (Preparation of Coating Solution for Thermosetting Adhesive Layer) An adhesive coating liquid for a thermosetting adhesive layer was obtained in the same manner as in Example 1, except that the formulation of the adhesive coating liquid was as shown in Table 1.

[0091] (Preparation of adhesive film) The adhesive coating liquid for the thermosetting adhesive layer was applied to a polyethylene terephthalate film (38 μm) that had been subjected to a silicone release treatment, and then dried to form a thermosetting adhesive layer having a thickness of 20 μm. Next, the obtained thermosetting adhesive layer was attached to the base layer 1 to obtain an adhesive film.

[0092] <Measurement and evaluation methods> (1) Measurement of deformation rate and deformation amount of adhesive film at 100℃ A measurement sample was prepared by laminating n sheets of adhesive film until the thickness reached 1.4±0.1 mm. Here, the measurement sample was laminated so that the base layer of the adhesive film and the thermosetting adhesive layer of the adhesive film adjacent thereto were in direct contact with each other. The number of laminated sheets of adhesive film was set to a number that made the thickness of the measurement sample close to 1.4 mm. In other words, the number of laminated sheets of adhesive film differs depending on the thickness of the adhesive film, and therefore the number of laminated sheets of adhesive film differs depending on the sample. A dynamic viscoelasticity measuring device (EPLEXOR 500N, manufactured by Netzsch-Gabo) was used to measure the deformation amount when a load of 10 N was continuously applied to a measurement sample cut to a width of 10 mm under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The measurement sample was placed so that the long axis of the indenter in the upper jig was in the same direction as the width direction of the measurement sample, and a load was continuously applied in the thickness direction of the measurement sample. The deformation rate [%] at 100° C. was calculated by the formula "(deformation amount in 600 seconds [μm] / number of layers of the measurement sample n / thickness per layer of the pressure-sensitive adhesive film [μm])×100". The deformation amount [μm] at 100° C. was calculated according to the formula "deformation amount [μm] at 600 seconds / number of layers of the measurement sample n".

[0093] (2) Measurement of deformation rate and deformation amount of adhesive film at 150℃ A measurement sample was prepared by the method described in (1). Then, the measurement sample was heat-treated at 130° C. for 30 minutes using a constant temperature dryer (manufactured by Yamato Scientific Co., Ltd., DN-63H). A dynamic viscoelasticity measuring device (EPLEXOR 500N, manufactured by Netzsch-Gabo) was used to measure the deformation amount when a load of 5N was continuously applied to a measurement sample cut to a width of 10 mm under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The measurement sample was placed so that the long axis of the indenter in the upper jig was in the same direction as the width direction of the measurement sample, and a load was continuously applied in the thickness direction of the measurement sample. The deformation rate [%] at 150° C. was calculated by the formula "(deformation amount in 600 seconds [μm] / number of layers of the measurement sample n / thickness per layer of the pressure-sensitive adhesive film [μm])×100". The deformation amount [μm] at 150° C. was calculated by the formula "deformation amount [μm] in 600 seconds / number of layers of the measurement sample n".

[0094] (3) Evaluation of unevenness-following ability An adhesive film was attached to the circuit formation surface of a wafer (8-inch power device simulation wafer, height of circuit formation surface (polyimide thickness): 10 μm, chip size: 10 mm × 10 mm, small pad size: 1 mm × 1 mm) using a bonding device (manufactured by Takatori Corporation, product name: TPL-0612W) under the conditions of SP1: 800 Pa, SP2: 300 Pa, SP3: 100 Pa, bonding pressure: 0.2 MPa, bonding temperature: 100°C. The wafer to which the adhesive film was attached was observed at any two points using a laser microscope (manufactured by Keyence Corporation, product name: VK-X1000) and evaluated according to the following criteria. A (Good): No floating is observed near the 10μm step of the polyimide B (Fail): A lift was observed near the 10 μm step of the polyimide.

[0095] (4) Vacuum resistance evaluation Using the method described in (3), an adhesive film was attached to the circuit-formed surface of the wafer, and the wafer was left for at least 1 hour, after which the wafer was prebaked at 130°C for 30 minutes using a constant temperature dryer (manufactured by Yamato Scientific Co., Ltd., DN-63H). The wafer with the adhesive film attached was then heated in a vacuum constant temperature dryer (manufactured by Shimizu Rikagaku Kikai Seisakusho Co., Ltd., VOD6-4H) under conditions of vacuum pressure: 100 to 150 Pa, temperature: 150°C, and time: 15 minutes. During the heating process under reduced pressure, the presence or absence of lifting of the film was visually observed, and evaluated according to the following criteria. A (Good): No floating with a diameter of 0.5 mm or more is visually observed B (Fail): A floating area with a diameter of 0.5 mm or more is visually confirmed.

[0096] Evaluations were carried out for each of Examples 1 to 5 and Comparative Examples 1 and 2. The results are shown in Table 1.

[0097] [Table 1]

[0098] It can be seen from Table 1 that the adhesive films of the examples were evaluated as being good in both the conformability to irregularities and the vacuum resistance. In other words, it can be seen that the adhesive film of the present embodiment has an improved balance of the conformability to irregularities and the vacuum resistance. [Explanation of symbols]

[0099] 10. Electronic Components 10A Circuit formation surface of electronic components 10B The surface opposite to the circuit formation surface of the electronic component 20 Base material layer 30 Unevenness-absorbing resin layer 40 Thermosetting adhesive layer 50 Adhesive Film 100 structures

Claims

1. An adhesive film for use in a manufacturing process of an electronic device, comprising: The deformation rate at 100° C. calculated by the following method 1 is 2.0% or more and 70.0% or less, An adhesive film having a deformation rate at 150°C of 25.0% or less, as calculated by Method 2 below. [Method 1] A measurement sample was prepared by stacking n sheets of the adhesive film until the thickness reached 1.4±0.1 mm, and the measurement sample was cut to a width of 10 mm. The measurement sample was measured for deformation amount when a load of 10 N was continuously applied using a dynamic viscoelasticity measuring device under the following conditions: temperature: 100°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is defined as the deformation rate [%] at 100°C. [Method 2] A sample in which n sheets of the adhesive film were laminated until the thickness reached 1.4±0.1 mm was prepared by heat treatment at 130° C. for 30 minutes. The measurement sample was cut to a width of 10 mm, and the deformation amount was measured using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150° C., deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen, when a load of 5 N was continuously applied. The value calculated by the formula "(deformation amount at 600 seconds [μm] / number of layers of the measurement sample n / thickness per sheet of the adhesive film [μm]) × 100" is defined as the deformation rate [%] at 150° C.

2. An adhesive film for use in a manufacturing process of an electronic device, comprising: The deformation amount at 100° C. calculated by the following method 3 is 1.0 μm or more and 100.0 μm or less, An adhesive film having a deformation amount at 150°C of 35.0 µm or less, as calculated by the following method 4. [Method 3] A measurement sample is prepared by stacking n sheets of the pressure-sensitive adhesive film until the thickness reaches 1.4±0.1 mm, and the measurement sample is cut to a width of 10 mm. The measurement sample is subjected to a continuous load of 10 N under the following conditions: temperature: 100° C., deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen, and the deformation amount at 100° C. is measured using a dynamic viscoelasticity measuring device. The value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers of the measurement sample n" is defined as the deformation amount at 100° C. [μm]. [Method 4] A sample in which n sheets of the adhesive film were laminated until the thickness reached 1.4±0.1 mm was prepared by heat treatment at 130°C for 30 minutes to prepare a measurement sample. The measurement sample was cut to a width of 10 mm, and the deformation amount was measured using a dynamic viscoelasticity measuring device under the following conditions: temperature: 150°C, deformation mode: compression, upper jig: three-point bending (indenter tip: 2.5R), lower jig: parallel plate, measurement time: 1000 seconds, atmosphere: nitrogen, when a load of 5 N was continuously applied. The value calculated by the formula "deformation amount at 600 seconds [μm] / number of layers n of the measurement sample" was defined as the deformation amount at 150°C [μm].

3. The adhesive film according to claim 1 or 2, comprising a base layer, an irregularity-absorbing resin layer, and a thermosetting adhesive layer in this order.

4. The adhesive film according to claim 3 , wherein the irregularity-absorbing resin layer and the thermosetting adhesive layer are provided so as to be in direct contact with each other.

5. The adhesive film according to claim 3 , wherein the thermosetting adhesive layer contains a (meth)acrylic resin and a thermal polymerization initiator.

6. The adhesive film according to claim 3, wherein the resin constituting the unevenness-absorbing resin layer comprises at least one selected from the group consisting of ethylene-vinyl acetate copolymer, (meth)acrylic resin, ethylene-α-olefin copolymer, and low-density polyethylene.

7. The pressure-sensitive adhesive film according to claim 3 , wherein the thickness of the irregularity-absorbing resin layer is 20 μm or more and 500 μm or less.

8. The pressure-sensitive adhesive film according to claim 3 , wherein the resin constituting the base layer comprises at least one selected from the group consisting of polyethylene naphthalate, polyethylene terephthalate, and polyimide.

9. The manufacturing process of the electronic device includes a step (A) of preparing a structure comprising an electronic component having a circuit formation surface and the adhesive film attached to the circuit formation surface side of the electronic component, and a step (B) of treating the surface of the electronic component opposite the circuit formation surface side under a vacuum atmosphere.

10. The adhesive film according to claim 1 or 2, wherein the electronic device is a power semiconductor device.