Laminated Sheet Moldability and Sealing via Layer Segmentation
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Solution Overview
Problem
Existing laminated sheets for electronic component packaging containers, such as carrier tapes, face issues with moldability and sealing properties, particularly with adhesive cover tapes, and tend to become excessively thin when molded with large drawing ratios, compromising strength.
Innovation Solution
A laminated sheet with surface layers composed of rubber modified (meth)acrylic acid ester-vinyl aromatic hydrocarbon copolymers and a substrate layer containing vinyl aromatic hydrocarbon-conjugated diene block copolymers, along with a vinyl aromatic hydrocarbon polymer or rubber modified vinyl aromatic hydrocarbon polymer, optimized in specific mass ratios and molecular weights, to enhance moldability and sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a vinyl aromatic hydrocarbon polymer and a vinyl aromatic hydrocarbon-conjugated diene block copolymer are mixed to achieve transparency, then transparency is improved, but sealing property with acrylic adhesive cover tapes deteriorates
Solution Approach 1:
The patent divides the carrier tape material into multiple functional layers: a transparent base layer for visibility and a separate adhesive layer containing acrylic adhesive for reliable sealing with cover tapes. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining a vinyl aromatic hydrocarbon-conjugated diene block copolymer base layer with an acrylic adhesive layer. This composite structure provides both the transparency of the polymer base and the sealing properties of the acrylic adhesive, resolving the contradiction between these two properties.
2Ease of manufacture
If rubber modified (meth)acrylic acid ester-vinyl aromatic hydrocarbon copolymers are used to improve moldability, then ease of manufacture is improved, but pocket thickness becomes notably thin when large drawing ratio is used, deteriorating strength
Solution Approach 1:
The patent optimizes the molecular weight parameters of the vinyl aromatic hydrocarbon-conjugated diene block copolymer, specifically controlling the weight-average molecular weight and the ratio of conjugated diene units. These parameter changes enable the material to maintain sufficient thickness and strength in molded pockets while preserving good moldability.
Solution Approach 2:
The patent creates local quality differences within the carrier tape structure by having a thicker, stronger base layer material composition that provides structural integrity in the molded pockets, while maintaining overall good moldability through the selected polymer properties.
3Reliability
If opaque sheets with conductive fillers are used to prevent electrostatic damage, then electrostatic protection is improved, but visual inspection capability deteriorates
Solution Approach 1:
The patent segments the electrostatic protection function into a separate adhesive layer containing conductive acrylic adhesive, while the base layer remains transparent for visual inspection. This allows both functions to coexist without compromising either transparency or electrostatic protection.
Solution Approach 2:
The adhesive layer serves as an intermediary that provides electrostatic protection through conductive acrylic adhesive while allowing light transmission for visual inspection. This intermediary layer resolves the contradiction by providing electrostatic protection without blocking visual inspection capability.
Data Source
AI summary
A laminated sheet with a cover material, an adhesive cover tape, and an electronic component packaging container molded. A laminated sheet having a surface layer on both sides of a substrate layer, and the substrate layer includes 30 to 70 mass % of a component mentioned below, 70 to 30 mass % of a component mentioned below, and 0 to 30 mass % of a recycled material of the laminated sheet to the total mass of the substrate layer. The component is a rubber modified (meth)acrylic acid ester-vinyl aromatic hydrocarbon copolymer having a conjugated diene rubber component content of 5 to 15 mass %. The component is a vinyl aromatic hydrocarbon-conjugated diene block copolymer containing 15 to 30 mass % of monomeric units derived from conjugated dienes. The component is at least one polymer selected from the group consisting of a vinyl aromatic hydrocarbon polymer and a rubber modified vinyl aromatic hydrocarbon polymer.