Adhesive Sheet Island Pattern Tearing Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the pre-cut processing of adhesive sheets for semiconductor devices, the adhesive layer becomes fragile and prone to tearing during peeling, making it difficult to successfully remove the unnecessary adhesive layer from the peeling base material.
Innovation Solution
A method is developed to manufacture adhesive sheets with an adhesive layer on a long peeling base material in the form of an island, where the width of the narrowest portion of the unnecessary adhesive layer is adjusted to have a breaking strength of 200 g or more, preventing tearing during peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the adhesive layer is made thin or fragile to achieve precise positioning and reduce waste, then the manufacturing precision and productivity improve, but the adhesive layer becomes prone to tearing during peeling
Solution Approach 1:
The patent applies different properties to different parts of the adhesive layer. The necessary adhesive layer maintains its original thin and precise properties for positioning accuracy, while the unnecessary adhesive layer is made with increased breaking strength through controlled tearing lines to prevent damage during peeling. This local differentiation resolves the contradiction between precision and strength.
Solution Approach 2:
The adhesive layer is segmented into two functional zones: a necessary adhesive layer that remains intact for precise positioning, and an unnecessary adhesive layer that is divided by tearing lines into removable segments. This segmentation allows the thin adhesive layer to maintain precision while the segmented unnecessary portions can be peeled off without tearing the critical adhesive areas.
2Manufacturing precision
If a special assembling apparatus is used to cut and bond the film-shaped adhesive, then the manufacturing precision and reliability improve, but the device complexity and production cost increase
Solution Approach 1:
The adhesive sheet is prepared in advance with pre-formed island patterns and tearing lines during the manufacturing process. This preliminary action eliminates the need for complex special apparatus during assembly, as the adhesive is already configured for precise positioning and easy peeling. The precision is achieved through pre-manufacturing rather than complex assembly equipment.
Solution Approach 2:
The unnecessary adhesive portions are extracted from the adhesive sheet during manufacturing, leaving only the necessary adhesive islands. This extraction simplifies the assembly process by eliminating the need for complex cutting and bonding apparatus, while maintaining high precision through the pre-formed island structure.
3Reliability
If multiple attachment steps are used to attach film-shaped adhesive and dicing tape separately, then the reliability of each step can be optimized, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the adhesive layer and dicing tape into a single integrated adhesive sheet structure. The unnecessary adhesive layer serves dual purposes: it provides the peeling function and also acts as the dicing tape. This merging reduces the number of attachment steps from two separate processes to one integrated process, maintaining reliability while simplifying the manufacturing process.
Solution Approach 2:
The unnecessary adhesive layer is designed to serve multiple functions: it provides the peeling interface for removing excess adhesive, acts as the dicing tape for cutting the substrate, and maintains structural integrity during processing. This multi-functionality eliminates the need for separate dicing tape attachment steps, reducing process complexity while maintaining reliability.
Data Source
AI summary
A method for manufacturing an adhesive sheet according to the present invention is a method for manufacturing an adhesive sheet including a long peeling base material 1 and an adhesive layer 2 provided on the peeling base material 1 in the form of an island, the method including a peeling step of, after laminating a long adhesive layer 2 on the peeling base material 1, peeling off an unnecessary portion 6 of the adhesive layer 2 so that a predetermined portion of the adhesive layer is left on the peeling base material 1 in the form of an island, wherein, in the peeling step, the width W of a narrow portion 8, which is the narrowest in width in a short direction of the unnecessary portion 6 of the adhesive layer 2, is adjusted so that the breaking strength in the narrow portion 8 is 200 g or more.