Flush Adhesive Sheet Structure to Prevent Air Entrapment
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Solution Overview
Problem
The entrapment of air at the interface of adhesive sheets used in semiconductor modules, particularly when a different material sheet is incorporated, leads to voids and reduced insulation reliability, posing a challenge in forming electrically insulating layers.
Innovation Solution
An adhesive sheet with a first adhesive surface having both adhesive resin composition and a different material sheet, where the different material sheet is embedded and flush with the resin composition, and a method involving a double-layer structure production process to ensure seamless integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a different material sheet is incorporated into the adhesive sheet to provide additional functions, then the adhesive sheet can be utilized in various applications, but air is likely to be entrapped at the step formed by the protruding different material sheet
Solution Approach 1:
The different material sheet is embedded within the adhesive resin composition, with its outer peripheral edge positioned within the adhesive sheet rather than protruding. This nesting approach allows the different material sheet to provide additional functions while preventing air entrapment at steps, as the adhesive resin composition covers the edges to create a flush surface.
Solution Approach 2:
The different material sheet is positioned specifically at the center portion of the adhesive sheet, with its area being smaller than the adhesive sheet. This localized placement provides the additional function where needed while maintaining the adhesive sheet's overall integrity and preventing air entrapment at the boundaries.
2Reliability
If two or more adhesive sheets are laminated to form a highly-reliable electrically insulating layer, then electrical insulation reliability is improved, but the complexity of the structure increases
Solution Approach 1:
The adhesive sheet is designed as a composite structure combining adhesive resin composition with an embedded different material sheet. This single-layer composite provides both adhesive functionality and the additional function (such as electrical insulation), eliminating the need to laminate multiple separate adhesive sheets and thereby reducing structural complexity while maintaining reliability.
3Ease of operation
If the different material sheet is made to have a smaller area than the sheet body and is layered on the surface, then the adhesive sheet exhibits adhesiveness from the adhesive resin composition, but a step is formed at the outer peripheral edge causing air entrapment
Solution Approach 1:
The different material sheet is embedded within the adhesive resin composition with its edges positioned inside the adhesive sheet boundaries. This nesting ensures the adhesive resin composition covers the different material sheet's peripheral edge, creating a flush surface that prevents air entrapment while maintaining the adhesive sheet's adhesiveness through the exposed adhesive resin composition areas.
Data Source
AI summary
An adhesive sheet according to the present invention is an adhesive sheet including a different material sheet configured to be flush with the rest of the adhesive sheet.