CN1305657C - 热压用缓冲材料及其制造方法 - Google Patents

热压用缓冲材料及其制造方法 Download PDF

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CN1305657C
CN1305657C CNB028189450A CN02818945A CN1305657C CN 1305657 C CN1305657 C CN 1305657C CN B028189450 A CNB028189450 A CN B028189450A CN 02818945 A CN02818945 A CN 02818945A CN 1305657 C CN1305657 C CN 1305657C
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吉田晃
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Abstract

为了防止橡胶中所含的低分子量掺和剂的渗出而引起的表面膨胀的发生，热压用缓冲材料应具备橡胶片1，以及层叠于该橡胶片1的至少一面的由耐热性树脂的多孔质膜形成的表层材料2。多孔质膜的平均孔径在10μm以下，多孔质膜具有0.1cm3/cm2·sec以上的透气度。

Description

热压用缓冲材料及其制造方法
技术领域
本发明涉及热压用缓冲材料及其制造方法。本发明更具体涉及在制造铜箔叠层板、挠性印刷基板、组合多层叠层板等印刷基板，IC卡，液晶显示板，陶瓷叠层板等具有层叠结构的精密仪器部件的过程中，在对对象制品进行加压成形和热压粘合时所用的热压用缓冲材料。
背景技术
印刷基板等具有层叠结构的精密仪器部件的制造中的加压成形和热压粘合工序中，如图7所示，采用将对象物7夹在热盘8之间、施加一定的压力和热量的方法。为了获得精度良好的成形品，在热压过程中必须使施加于加压对象物7的热量和压力全面均衡。为了达到这一目的，以使平板状的缓冲材料9介于热盘8和加压对象物7之间的状态进行热压。
作为热压用缓冲材料9，可采用牛皮纸、用粘合剂粘合有机或无机纤维而形成的材料、橡胶、非织造布、橡胶和非织造布的层叠体等各种材料。除了牛皮纸以外，其它基本上都可以多次加压重复使用。其中，表面具有橡胶弹性的缓冲材料能够很好地使施加于整个平面的热量和加压均衡，而且即使在对象物7包含因电路等而造成的凹凸形状的情况下，也能够顺着对象物7的凹凸加压，所以特别适用于要求高精度的成形品的精密仪器部件的热压。
但是，橡胶的脱模性较差，在加热及加压下使用时橡胶中所含的低分子量掺和剂会渗出。因此，使用表面不具备脱模层的橡胶时，存在与加压对象物粘合、污染加压对象物的问题。因此，考虑在橡胶表面形成脱模层。
日本专利第2649899号公报(特开平8-90577号)中揭示了在橡胶层表面形成有防渗出层的成形加压用缓冲材料。防渗出层较好为兼具不透气性和脱模性的薄膜状材料，更具体为合成树脂薄膜和金属箔等。
但是，日本专利第2649899号公报中揭示的缓冲材料，由于橡胶层表面形成了不透气性的防渗出层，所以存在以下问题。即，在制造热压用缓冲材料的阶段或重复使用热压用缓冲材料时，橡胶中所含的剩余的低分子量掺和剂会渗出，这些掺和剂滞留在橡胶层和防渗出层之间，容易造成缓冲材料表面的膨胀。表面发生这种膨胀的缓冲材料的平整性差，且使热量和压力均衡化作用受损，所以已经不能够使用。此外，重复使用热压用缓冲材料时，橡胶中所含的剩余的低分子量掺和剂还会作为渗色物从缓冲材料的端部渗出到外部，产生污染加压对象物的问题。
因此，本发明的目的是提供表面不会因橡胶中所含的低分子量掺和剂而发生膨胀、不用担心橡胶中所含的低分子量掺和剂从缓冲材料端部渗出而造成污染、且表面具有橡胶弹性、脱模性也非常好的热压用缓冲材料及其制造方法。
发明的揭示
为了解决上述问题，本发明的热压用缓冲材料具备橡胶片，以及层叠于该橡胶片的至少一面的由耐热性树脂的多孔质膜形成的表层材料。
上述构成中，由于表层材料为多孔质膜，所以在制造热压用缓冲材料的阶段，可使橡胶中所含的剩余的低分子量掺和剂通过多孔质膜挥散至外部。因此，不论在缓冲材料的制造阶段，还是在使用中，橡胶中所含的低分子量掺和剂的渗出都不会引发表面的膨胀。此外，在热压用缓冲材料的制造阶段，由于橡胶中所含的剩余的低分子量掺和剂已通过多孔质膜挥散至外部，所以在缓冲材料使用过程中，不用再担心橡胶中所含的低分子量掺和剂从缓冲材料的端部渗出而污染加压对象物。另外，由于表层材料为膜，所以不会影响到缓冲材料的橡胶弹性。还有，由于表层材料由耐热性树脂形成，所以缓冲材料表面的脱模性也良好。
为使橡胶中所含的剩余的低分子量掺和剂能够通过多孔质膜有效地挥散至外部，多孔质膜最好具有0.1cm3/cm2·sec以上的透气度。此外，为了防止低分子量掺和剂过量地渗出，多孔质膜的平均孔径最好在10μm以下。另外，为了维持缓冲材料表面的良好的橡胶弹性，多孔质膜的厚度最好在100μm以下。
形成表层材料的耐热性树脂最好为含氟树脂。此外，橡胶最好为含氟橡胶。
较好的实施例中，缓冲材料的两面都具备由耐热性树脂的多孔质膜形成的表层材料。
一个实施例中，在橡胶片的另一面具备由织造布、非织造布、纸、薄膜、箔、片状物或板形成的层。另一实施例中，缓冲材料具备将中间层夹在其间而层叠的上部橡胶片和下部橡胶片，这些上部及下部橡胶片的表面层叠有表层材料。
本发明的热压用缓冲材料的制造方法具备在未硫化的橡胶片的至少一面层叠由多孔质膜形成的表层材料的步骤；施加热量及压力对未硫化的橡胶片进行一次硫化的同时，将该一次硫化橡胶片和多孔质膜结合成一体的步骤；通过对一次硫化橡胶片的二次硫化处理，使一次硫化橡胶片中所含的剩余的低分子量掺和剂通过多孔质膜挥散至外部的步骤。
利用该制造方法，由于表层材料为多孔质膜，二次硫化时橡胶中所含的剩余的低分子量掺和剂通过多孔质膜挥散至外部，所以不论在缓冲材料制造阶段，还是在使用中，都不会因橡胶中所含的低分子量掺和剂的渗出而发生膨胀。此外，在制造热压用缓冲材料的阶段，由于橡胶中所含的剩余的低分子量掺和剂已通过多孔质膜挥散至外部，所以不用再担心缓冲材料使用时橡胶中所含的低分子量掺和剂从缓冲材料的端部渗出而污染加压对象物。另外，由于表层材料为膜，所以不会影响到缓冲材料的橡胶弹性。还有，由于表层材料由耐热性树脂形成，所以缓冲材料表面的脱模性也非常好。
本发明的热压用缓冲材料的另一制造方法具备在未硫化的橡胶片的一面层叠由多孔质膜形成的表层材料的步骤；在未硫化的橡胶片的另一面层叠由织造布、非织造布、薄膜、箔、片状物或板形成的层的步骤；施加热量及压力对未硫化的橡胶片进行一次硫化的同时，将层叠于该一次硫化橡胶片的两面的层结合成一体的步骤；通过对一次硫化橡胶片的二次硫化处理，使一次硫化橡胶片中所含的剩余的低分子量掺和剂通过多孔质膜挥散至外部的步骤。
附图的简单说明
图1为表示本发明的热压用缓冲材料的一例的截面图。
图2为表示本发明的热压用缓冲材料的另一例的截面图。
图3为表示本发明的热压用缓冲材料的又一例的截面图。
图4为表示本发明的热压用缓冲材料的又一例的截面图。
图5为表示本发明的热压用缓冲材料的又一例的截面图。
图6为表示本发明的热压用缓冲材料的又一例的截面图。
图7为说明使用了缓冲材料的热压过程的简图。
实施发明的最佳方式
以下，参考附图对本发明的实施例进行说明。图1～图6表示本发明的热压用缓冲材料的代表实施例。
本发明的热压用缓冲材料具备在橡胶片1的至少一面层叠由耐热性树脂的多孔质膜形成的表层材料2并使其一体化的构造。
橡胶片1的原材料可使用具有耐热性的橡胶。具体来讲可采用含氟橡胶、EPM、EPDM、氢化丁腈橡胶、硅橡胶、丙烯酸橡胶、丁基橡胶等。这些橡胶材料可单独使用，也可混合使用，或与上述以外的有机或无机材料混合使用。其中，从耐热性良好考虑，最好使用含氟橡胶。特别好的是压缩永久变形特性良好的1，1-二氟乙烯二元系多元醇硫化含氟橡胶。1，1-二氟乙烯二元系多元醇硫化含氟橡胶可采用市售的“ダイエル”G-700系列(大金工业株式会社制)。
作为表层材料2使用的耐热性树脂的多孔质膜的平均孔径较好在10μm以下。此外，多孔质膜的透气度较好在0.1cm3/cm2·sec以上。上述透气度是按照JIS L1096定义的A法中的透气度。更好的是平均孔径在10μm以下，且透气度在0.1cm3/cm2·sec以上。这样在制造热压用缓冲材料的阶段，橡胶中所含的剩余的低分子量掺和剂就能够通过多孔质膜挥散至外部。橡胶中所含的剩余的低分子量掺和剂例如为硫化剂和增塑剂等。此外，多孔质膜的平均孔径如果超过10μm而过大，则在热压用缓冲材料的制造阶段，橡胶1会从多孔质膜2的孔渗出到表面，这样可能会破坏缓冲材料表面的平滑性及脱模性，所以不好。多孔质膜的透气度如果不足0.1cm3/cm2·sec，则橡胶中所含的剩余的低分子量掺和剂很难充分除去，所以也不好。
多孔质膜的厚度最好在100μm以下。这样就能够维持热压用缓冲材料表面的橡胶弹性。多孔质膜的厚度如果大于100μm，则有损热压用缓冲材料表面的橡胶弹性，所以不好。
此外，多孔质膜由熔点在120℃以上的耐热性树脂形成。更具体地讲，最好由聚酰亚胺树脂或含氟树脂形成。特别好的是聚四氟乙烯(PTFE)制多孔质膜。通过使用这种原材料，可使热压用缓冲材料的表面对应于热压对象物的脱模性良好。
具备上述特性的多孔质膜市售的例如有日东电工株式会社生产的“MICRO-TEX NTF”。
本发明的热压用缓冲材料可以如图1所示，在橡胶片1的两面层叠由多孔质膜形成的表层材料2并使其一体化。此外，也可以是在橡胶片1的一面层叠表层材料2而一体化，在另一面层叠1层以上由选自织造布、非织造布、纸、薄膜、箔、片状物及板的1种以上的材料形成的层而一体化的结构。在橡胶片的另一面层叠的材料可根据热压对象物和加压条件等作适当选择。
图2所示的热压用缓冲材料具备上下具有在橡胶片1的一面层叠多孔质膜形成的表层材料2的构成、且上下橡胶片的未层叠表层材料2的面对向贴合、中间用编织材料3加固的构造。编织材料3可使用玻璃编织材料、芳香族聚酰胺编织材料等耐热性编织材料。
图3所示的热压用缓冲材料具备上下具有在橡胶片1的一面层叠多孔质膜形成的表层材料2的构成，且上下橡胶片的未层叠表层材料2的面对向贴合，中间夹着编织材料3、橡胶片1和编织材料3的层叠物的构造。
图4所示的热压用缓冲材料具备在橡胶片1的一面层叠多孔质膜形成的表层材料2、在另一面层叠加固板4的构造。加固板4可采用铝、不锈钢等金属板及纤维加固树脂板等。
图5所示的热压用缓冲材料具备上下具有在橡胶片1的一面层叠多孔质膜形成的表层材料2的构成、且上下橡胶片的未层叠表层材料2的面对向贴合、中间用加固板4加固的构造。
图6所示的热压用缓冲材料具备上下具有在橡胶片1的一面层叠多孔质膜形成的表层材料2的构成，且上下橡胶片的未层叠表层材料2的面对向贴合，中间夹着粘合材料5、非织造布6和粘合材料5的层叠物的构造。粘合材料5可采用玻璃编织材料等织造布中涂布或含浸了含氟橡胶等耐热性橡胶而形成的材料。非织造布6包括聚酰胺纤维、芳香族聚酰胺纤维、聚苯并唑(PBO)纤维等，它们可单独使用，也可混合形成非织造布。
图1～图6所示的仅是本发明的代表实施例，只要符合本发明的基本要素，也可以是除此以外的变形例。
以下，对本发明的热压用缓冲材料的制造方法进行说明。
首先，层叠热压用缓冲材料的各构成材料。此时，至少一个表面形成未硫化状态的橡胶片1的表面层叠多孔质膜形成的表层材料2的构成。例如，制造图1所示的热压用缓冲材料时，在未硫化状态的橡胶片1的两面层叠由多孔质膜形成的表层材料2。
然后，施加热量和压力，在对未硫化状态的橡胶片1进行一次硫化的同时使橡胶片1和多孔质膜2结合成一体。一次硫化例如在160℃～200℃、0.098MPa～3.92MPa(1kgf/cm2～40kgf/cm2)、5分钟～10分钟的条件下进行加压硫化。
接着，通过对与多孔质膜形成的表层材料2一体化的橡胶片1的二次硫化处理，使一次硫化后的橡胶片1中所含的剩余的低分子量掺和剂通过多孔质膜2挥散至外部，获得热压用缓冲材料。二次硫化最好在橡胶片1中所含的增塑材料的沸点以上的温度、且在加压使用温度以上的温度下进行。二次硫化的温度如果过低，则低分子量的掺和剂不能够充分向外部挥散，如果过高，则橡胶会劣化。因此，较好的二次硫化温度为200℃～260℃左右。二次硫化最好进行1小时以上(更好为4～48小时)。此外，二次硫化在多孔质膜2的表面呈开放状态、且不施加压力的条件下进行。这样能够有效地使橡胶片1中所含的低分子量的掺和剂挥散。
图2～图6所示的例子中，层叠构造的至少一个表面具备未硫化状态的橡胶片1的一面层叠多孔质膜形成的表层材料2的构成。在未硫化状态的橡胶片1的一面层叠由多孔质膜形成的表层材料2的情况下，另一面可层叠1层以上由选自织造布、非织造布、纸、薄膜、箔、片状物及板的1种以上的材料形成的层。然后，对整个层叠结构施加热量和压力，在对未硫化状态的橡胶片1进行一次硫化的同时使整体粘合一体化。一次硫化的条件与图1的情况相同。然后，与图1的情况相同，通过对橡胶片1进行二次硫化，使一次硫化后的橡胶片1中所含的剩余的低分子量掺和剂通过多孔质膜2挥散至外部，即可获得热压用缓冲材料。
产业上利用的可能性
本发明适用于对铜箔叠层板、印刷基板、IC卡、液晶显示板、陶瓷叠层板等对象制品进行加压成形和热压粘合时所用的热压用缓冲材料。

Claims (2)

1.热压用缓冲材料的制造方法，其特征在于，具备在未硫化的橡胶片的至少一面层叠由多孔质膜形成的表层材料的步骤；施加热量及压力对前述未硫化的橡胶片进行一次硫化的同时，将该一次硫化橡胶片和前述多孔质膜结合成一体的步骤；通过在加热但不施加压力的条件下对前述一次硫化橡胶片的二次硫化处理，使前述一次硫化橡胶片中所含的剩余的低分子量掺和剂通过前述多孔质膜挥散至外部的步骤。
2.热压用缓冲材料的制造方法，其特征在于，具备在未硫化的橡胶片的一面层叠由多孔质膜形成的表层材料的步骤；在前述未硫化的橡胶片的另一面层叠由织造布、非织造布、薄膜、箔、片状物或板形成的层的步骤；施加热量及压力对前述未硫化的橡胶片进行一次硫化的同时，将层叠于该一次硫化橡胶片的两面的层结合成一体的步骤；通过在加热但不施加压力的条件下对前述一次硫化橡胶片的二次硫化处理，使前述一次硫化橡胶片中所含的剩余的低分子量掺和剂通过前述多孔质膜挥散至外部的步骤。
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