Gas Barrier Laminate With Cured Adhesive for Breakage-Free Singulation
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Solution Overview
Problem
Existing gas barrier laminates fail to provide sufficient sealing properties during the dicing process, leading to breakage of the gas barrier layer when singulating sensor devices, especially those requiring transparency or sensitivity to moisture.
Innovation Solution
A gas barrier laminate comprising a base material, a gas barrier layer, and a hardenable pressure sensitive adhesion agent layer with a post-curing storage modulus of 1.0 GPa or more, allowing for enhanced rigidity and suppression of breakage during singulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a conventional pressure sensitive adhesive layer with low storage modulus is used, then bending resistance is improved, but sealing properties and rigidity during dicing process deteriorate
Solution Approach 1:
The adhesive layer transitions from a soft, flexible state during lamination to a rigid, hardened state after curing. The storage modulus dynamically changes from below 100 MPa (uncured) to 1.0 GPa or more (cured), allowing the same layer to provide both bending resistance during application and sealing strength during dicing
Solution Approach 2:
The storage modulus parameter is changed through chemical curing transformation. By controlling the curing process, the adhesive layer's mechanical properties are transformed from soft and flexible to hard and rigid, resolving the contradiction between needing softness for lamination and hardness for sealing
2Strength
If the storage modulus of the adhesive layer is increased to improve sealing properties, then sealing properties are improved, but bending resistance deteriorates
Solution Approach 1:
The adhesive layer's storage modulus is dynamically adjusted through curing. Before curing, it remains soft (storage modulus < 100 MPa) to maintain bending resistance; after curing, it becomes rigid (storage modulus ≥ 1.0 GPa) to provide sealing properties, thus resolving the contradiction through temporal separation of functions
Solution Approach 2:
The adhesive layer is applied in a soft, uncured state to ensure proper lamination and bending resistance, then curing is performed afterward to develop the rigid structure needed for sealing. This preliminary action sequence resolves the contradiction by performing functions in the optimal order
3Productivity
If a gas barrier laminate is singulated together with the adherend, then productivity is improved, but breakage of the gas barrier layer occurs
Solution Approach 1:
The storage modulus parameter is increased to 1.0 GPa or more through curing, transforming the adhesive layer from a soft matrix to a rigid support structure. This parameter change provides sufficient mechanical strength to prevent gas barrier layer breakage during singulation while maintaining integrated processing benefits
Solution Approach 2:
The cured adhesive layer forms a composite structure with enhanced mechanical properties that combines the gas barrier layer and adherend into a singulatable unit. The rigidified adhesive matrix provides the structural integrity needed for joint singulation without compromising the gas barrier layer
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The laminate effectively prevents breakage of the gas barrier layer during singulation, ensuring the integrity of the sealed product and maintaining gas barrier properties.
Implementation Method 1
a hardenable pressure sensitive adhesion agent layer having a post-curing storage modulus E1 at 23° C. of 1.0 GPa or more
Implementation Method 2
the gas barrier layer has a water vapor transmission rate of 1.0×10−2 g/m2/day or less in an atmosphere of 40° C. and 90% relative humidity
Implementation Method 3
the gas barrier layer includes a modified layer formed by ion implantation and/or a chemical vapor deposition layer
Data Source
AI summary
There is provided a gas barrier laminate capable of providing a singulated product in which occurrence of breakage of a gas barrier layer is suppressed when the gas barrier laminate is laminated on an adherend and singulated together with the adherend, the gas barrier laminate including a base material, the gas barrier layer, and a hardenable pressure sensitive adhesion agent layer in this order, wherein the hardenable pressure sensitive adhesion agent layer has a post-curing storage modulus E1 at 23° C. of 1.0 GPa or more.