WO2016163537A1 - グラファイト複合フィルム及びその製造方法並びに放熱部品 - Google Patents
グラファイト複合フィルム及びその製造方法並びに放熱部品 Download PDFInfo
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- WO2016163537A1 WO2016163537A1 PCT/JP2016/061607 JP2016061607W WO2016163537A1 WO 2016163537 A1 WO2016163537 A1 WO 2016163537A1 JP 2016061607 W JP2016061607 W JP 2016061607W WO 2016163537 A1 WO2016163537 A1 WO 2016163537A1
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- Prior art keywords
- graphite
- adhesive layer
- film
- composite film
- graphite composite
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Classifications
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- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
- C09J2301/312—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier parameters being the characterizing feature
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2400/00—Presence of inorganic and organic materials
- C09J2400/10—Presence of inorganic materials
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
Definitions
- the present invention relates to a graphite composite film, a method for producing the same, and a heat dissipation component.
- graphite film Since graphite film has excellent heat dissipation properties, it is used as a heat dissipation component for semiconductor elements and other heat generating components mounted on various electronic devices such as computers or electrical devices.
- the graphite film in order to exhibit the excellent thermal conductivity of the graphite film, is bonded to the casing of the heat generating component using an adhesive or an adhesive such as an epoxy resin or an acrylic resin. ing.
- An adhesive or an adhesive such as an epoxy resin or an acrylic resin.
- a general graphite composite film with adhesive applied to the entire surface is excellent in heat dissipation due to good adhesion between the graphite composite film and the adherend (heat generating component), but when bonded to a heat generating component
- heat generating component heat generating component
- the thermal problem of electronic devices in recent years has become serious, the size of graphite composite films used in electronic devices has increased, and in the pasting of such large sheets, there is a problem of bubble generation. It has become apparent.
- the present invention relates to a graphite composite film in which bubble generation between the adherend and the graphite composite film when bonded to the adherend is reduced without impairing heat dissipation, a method for producing the same, and such a graphite composite
- An object is to provide a heat dissipation component using a film.
- the present inventors have found that in a graphite composite film having a graphite film and an adhesive layer in contact with the graphite film, the graphite film covered with an adhesive with respect to the entire area of the graphite film The area ratio of 35% or more and 100% or less was bonded to the adherend without impairing heat dissipation by forming an uneven structure on the surface of the adhesive layer opposite to the surface in contact with the graphite film. It has been found that the generation of bubbles between the adherend and the graphite composite film can be reduced, and the present invention has been completed. That is, the present invention includes the following inventions.
- the graphite composite film according to the present invention has a graphite film and an adhesive layer in contact with the graphite film, and the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more.
- the pressure-sensitive adhesive layer has an uneven structure on the surface opposite to the surface in contact with the graphite film.
- a method for producing a graphite composite film according to the present invention is a method for producing a graphite composite film having a graphite film and an adhesive layer in contact with the graphite film, and is covered with an adhesive for the entire area of the graphite film.
- the ratio of the area of the graphite film is 35% or more and 100% or less, and at least one side of the pressure-sensitive adhesive layer having the concavo-convex structure, the concavo-convex structure is disposed on the side opposite to the surface in contact with the graphite film.
- the method includes a step of laminating the adhesive layer and the graphite film.
- another method for producing a graphite composite film according to the present invention is a method for producing a graphite composite film having a graphite film and an adhesive layer in contact with the graphite film, wherein the unevenness of the separator having an uneven structure on the surface thereof.
- the step of producing a pressure-sensitive adhesive layer having a concavo-convex structure on at least one side and the surface of the pressure-sensitive adhesive layer having a concavo-convex structure on at least one side are in contact with the graphite film.
- a further method for producing a graphite composite film according to the present invention is a method for producing a graphite composite film having a graphite film and an adhesive layer in contact with the graphite film, wherein the graphite composite film has an uneven structure on the surface.
- the uneven structure is formed on the surface of the adhesive layer.
- the heat dissipation component according to the present invention is a heat dissipation component including a graphite composite film, the graphite composite film having a graphite film and an adhesive layer in contact with the graphite film,
- the ratio of the area of the graphite film covered with the agent is 35% or more and 100% or less
- the adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film.
- the graphite composite film according to the present invention can reduce the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend without impairing heat dissipation.
- the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend is reduced without impairing heat dissipation. Can be manufactured.
- the graphite composite film can reduce the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend without impairing the heat dissipation.
- it looks bad (ii) irregularities due to air bubbles cause physical obstacles to other parts, (iii) poor adhesion to the adherend, (iv) Generation
- FIG. 1 Two modes of a cross-sectional view when cut, or a cross-sectional view when a striped groove shown in FIG. It is a figure which shows the result of having observed the thermal radiation component from the protective layer side of the graphite film in the Example of this invention. It is a figure which shows the cross section of the graphite composite film which has the adhesion layer of the three-layer structure of this invention.
- a to B representing a numerical range means “A or more (including A and greater than A) and B or less (including B and less than B)”.
- Graphite Composite Film As described above, a general graphite composite film coated with an adhesive on the entire surface has excellent heat dissipation because of good adhesion between the graphite composite film and the adherend (heat-generating component). However, there is a problem in that air bubbles are generated between the adherend and the graphite composite film when the heat generating component is joined.
- a method for solving the problem of bubble generation a method of reducing the adhesion frequency and adhesion between the adherend and the graphite composite film can be considered. As such a method, specifically, a method using a point-like pressure sensitive adhesive or a pressure sensitive adhesive (peel strength) weak may be considered. The heat dissipation which is the main purpose of this is sacrificed.
- the present inventors have intensively studied to realize a graphite composite film capable of suppressing air entrapment without impairing heat dissipation, and as a result, have a graphite film and an adhesive layer in contact with the graphite film,
- the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and 100% or less, and the uneven structure is formed on the surface opposite to the surface where the adhesive layer is in contact with the graphite film.
- the graphite composite film according to the present invention has a graphite film and an adhesive layer in contact with the graphite film, and the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35.
- the pressure-sensitive adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film.
- the adhesive layer is a layer that is laminated on a graphite film and joins an adherend and a graphite bonded film.
- the area of the graphite film covered with the pressure-sensitive adhesive is 35% to 100% of the total area of the graphite film, and the pressure-sensitive adhesive layer is opposite to the surface in contact with the graphite film. It is only necessary to have a concavo-convex structure on the surface. Thereby, the bubble generation between the adherend and the graphite composite film when bonded to the adherend can be reduced without impairing the heat dissipation of the graphite composite film.
- the present inventors are estimating as follows.
- the graphite composite film when an uneven structure is formed on the surface of the adhesive layer in contact with the adherend, even if bubbles are generated between the graphite composite film and the adherend when they are bonded together
- the bubbles can be easily removed by the fine gap generated by the concavo-convex structure (so-called “ease of air”).
- 35% to 100% of the total area of the graphite film is covered with the pressure-sensitive adhesive. It is considered that the graphite composite film is bonded to the adherend by the pressure-sensitive adhesive that exists also in at least a part of the portion where the gap has occurred. Therefore, since the adhesion between the graphite composite film and the adherend (for example, SUS casing, plastic casing, etc.) is good, heat transfer from the graphite composite film to the adherend is smooth. There is no loss of sex.
- the area of the graphite film covered with the adhesive means the area of the graphite film covered with the adhesive in the layer containing the adhesive for bonding to the adherend. To do. Therefore, when the pressure-sensitive adhesive layer has a multilayer structure, the “area of the graphite film covered with the pressure-sensitive adhesive” means that the pressure-sensitive adhesive layer is bonded to the adherend opposite to the surface in contact with the graphite film. The area of the graphite film covered with the pressure-sensitive adhesive in the layer containing the pressure-sensitive adhesive, that is, the outermost layer.
- the pressure-sensitive adhesive in the outermost layer is not in direct contact with the graphite film, but the area of the graphite film corresponding to the area covered by the pressure-sensitive adhesive is expressed as “graphite covered with pressure-sensitive adhesive”. "Area of film”.
- the area of the graphite film covered with the adhesive is 35% or more and 100% or less of the total area of the graphite film. That is, the present invention includes a case where the ratio of the area of the graphite film covered with the pressure-sensitive adhesive to the total area of the graphite film is 100% and a case where the ratio is 35% or more and less than 100%.
- the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 100%, for example, as shown in FIG.
- the area is covered with an adhesive, and the adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film.
- the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and less than 100%, for example, as shown in FIG.
- the graphite film has an exposed portion that is not covered with the adhesive, and the adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film.
- the ratio of the area of the graphite film covered with the pressure-sensitive adhesive to the total area of the graphite film is more preferably 35% or more and 90% or less, and further preferably 50% or more and 85% or less.
- the contact with the adherend is good and the heat conduction is excellent, and the heat dissipation of the graphite composite film is impaired.
- it is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be reduced.
- the contact with a to-be-adhered body is good, it is excellent also in adhesive force.
- the adhesive layer only needs to have an uneven structure on the surface opposite to the surface in contact with the graphite film, and the structure of the surface in contact with the graphite film of the adhesive layer is any structure. May be. That is, the surface of the adhesive layer in contact with the graphite film may or may not have an uneven structure.
- Concave and convex structure having a concavo-convex structure is not particularly flat as long as it has irregularities, and other configurations are not particularly limited.
- the surface roughness of the surface having the uneven structure of the adhesive layer is preferably Ra 0.19 ⁇ m or more and 10 ⁇ m or less, Rz 1.6 ⁇ m or more and 100 ⁇ m or less, Ra 0.19 ⁇ m or more and 1.0 ⁇ m or less, and Rz is 1.6 ⁇ m or more and 10.0 ⁇ m or less, more preferably Ra is 0.35 ⁇ m or more and 0.70 ⁇ m or less, and Rz is 2.5 ⁇ m or more and 6.0 ⁇ m or less.
- the surface roughness of the adhesive layer having a concavo-convex structure is such that Ra is preferably 0.19 ⁇ m or more and 10 ⁇ m or less, more preferably 0.19 ⁇ m or more and 1.0 ⁇ m or less, and further preferably 0.35 ⁇ m. It is above 0.70 ⁇ m.
- the surface roughness of the surface having the concavo-convex structure of the adhesive layer is preferably such that Rz is 1.6 ⁇ m or more and 100 ⁇ m or less, more preferably 1.6 ⁇ m or more and 10.0 ⁇ m or less, and particularly preferably Rz2. It is 5 ⁇ m or more and 6.0 ⁇ m or less.
- the surface roughness of the surface having the concavo-convex structure is within the above range, bubbles between the adherend and the graphite composite film when bonded to the adherend without impairing the heat dissipation of the graphite composite film Since generation
- the surface roughness means a value measured by the measuring method described in the examples.
- the specific shape of the uneven structure is not particularly limited, and may be any shape.
- the concavo-convex structure may not be constant in shape, and may be a mixture of at least one of concave and convex portions having various shapes.
- the concavo-convex structure is more preferably composed of at least one of a concave portion and a convex portion having a certain shape from the viewpoint of appearance and productivity. If it has a certain shape, it looks beautiful, and if it has a certain pattern, it is suitable for mass production of films.
- the specific shape when the concavo-convex structure is composed of at least one of a concave portion and a convex portion having a certain shape is not particularly limited, but for example, a lattice-like or striped groove, or A plurality of independent island-shaped protrusions can be mentioned.
- FIG. 1 shows a specific example of the uneven structure.
- FIG. 1A is a plan view of a plurality of independent island-like protrusions as viewed from above.
- hatched portions are island-shaped protrusions.
- the shape of the island-shaped protrusions is circular in the figure, but is not limited to a circular shape, and may be any shape, such as an ellipse, a polygon, a rod, a band, an indeterminate shape, etc. It may be.
- Polygons include triangles, squares such as squares, rectangles, and rhombuses, pentagons, hexagons, and the like.
- the adhesive may or may not exist on the bottom surface portion of the recess.
- the cross-sectional view may be a mixture of the configuration shown in FIG. 9A and the configuration shown in FIG. 9B.
- the island-shaped projections are convex portions of the concavo-convex structure, and portions other than the island-shaped projections are concave portions of the concavo-convex structure.
- FIG. 9 is an example in which the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and less than 100%.
- FIG. 9A in this example, there is a portion where the graphite film 41 is not covered with the adhesive 42 and is exposed.
- the exposed portion of the graphite film 41 that is not covered with the adhesive 42 corresponds to the bottom surface 39 of the recess.
- the height h of the island-shaped protrusion is the same as the thickness of the pressure-sensitive adhesive layer (the second pressure-sensitive adhesive layer in the pressure-sensitive adhesive layer having a three-layer structure described later), and no adhesive is present in the concave portion of the pressure-sensitive adhesive layer.
- the graphite film 41 (a base material having a three-layer structure in an adhesive layer having a three-layer structure described later) is exposed.
- the pressure-sensitive adhesive layer includes a plurality of pressure-sensitive adhesive portions disposed on the graphite film 41, and the uneven structure on the surface of the pressure-sensitive adhesive layer has a convex portion made of the pressure-sensitive adhesive portion, and no adhesive is present in the concave portion. It can also be said that the film 41 is exposed.
- Such a configuration is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced.
- FIG. 9B is an example in which the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 100%.
- the entire area of the graphite film 41 is covered with the adhesive 42, and the uneven structure is formed on the surface opposite to the surface in contact with the graphite film 41. have.
- the height h of the island-shaped protrusions is smaller than the thickness of the adhesive layer (the second adhesive layer in the adhesive layer having a three-layer structure described later), and between the bottom 39 of the concave portion of the adhesive layer and the graphite film 41. Adhesive is present.
- the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced, and thereafter, the bottom 39 of the concave portion of the adhesive layer and the graphite This is preferable because the adherend and the graphite composite film are bonded to each other by the adhesive existing between the film 41 and the film 41.
- the upper surface 38 of each island-like protrusion is more preferably on the same surface. Further, from the same viewpoint, it is more preferable that the upper surface 38 of each island-shaped protrusion is a flat surface.
- the island-like protrusions are regularly arranged, but may be irregularly arranged. Further, in FIGS. 1A and 9A and 9B, the island-shaped protrusions have the same shape, but may include a plurality of different shapes.
- the bottom surface 39 of the recess is not particularly limited to this, but is preferably on the same plane. The bottom surface 39 is more preferably a flat surface.
- the side surface 40 of the island-shaped protrusion may be substantially perpendicular to the bottom surface 39 or the top surface 38 or may have an angle.
- the angle ⁇ formed by the side surface 40 of the island-shaped protrusion and the bottom surface 39 is preferably 60 ° or more and 150 ° or less, more preferably 90 ° or more and 120 ° or less.
- this embodiment also includes a form in which the side surface 40 of the island-shaped protrusion is connected to the bottom surface 39 or the top surface 38 in a rounded manner without necessarily clearly forming an angle ⁇ .
- the height h of the island-shaped projections that is, the distance between the bottom surface 39 and the top surface 38 is preferably 0.1 ⁇ m or more and 20 ⁇ m or less, more preferably 0.5 ⁇ m or more and 5 ⁇ m or less, and further preferably 1.0 ⁇ m or more and 3 or less. 0.0 ⁇ m or less. If the height h of the island-shaped protrusions is within the above range, bubbles are generated between the adherend and the graphite composite film when bonded to the adherend without impairing the heat dissipation of the graphite composite film. Since it can reduce more suitably, it is preferable.
- a distance between one side of the island-shaped protrusion and one side of an adjacent island-shaped protrusion facing the side is preferably 0.01 mm or more, and more preferably 0.1 mm or more.
- the upper limit is preferably 2.0 mm or less, more preferably 0.88 mm or less, and still more preferably 0.5 mm or less.
- the interval between one side of the island-shaped protrusion quadrilateral and one side of the quadrangle of the adjacent island-shaped protrusion facing the side is preferably within the above range. If the distance is within the above range, it is possible to reduce bubble generation between the adherend and the graphite composite film when bonded to the adherend without impairing the heat dissipation of the graphite composite film. preferable.
- FIG. 1B is a plan view of the lattice-shaped grooves as viewed from above.
- the unhatched part is a lattice-like groove.
- the grid-like groove is a square grid in the figure, but is not limited to a square grid, and may be any grid, for example, a triangular grid, a rectangular grid, a rhombus grid, a polygonal grid. Or may include a plurality of types of lattices.
- the groove is not limited to a straight groove, and may be a curved groove.
- the cross-sectional view when the grid-like groove shown in FIG. 1B is cut along the broken line B is the same as that of FIG.
- the configuration shown in FIG. 9B may be used, or these configurations may be mixed.
- the lattice-shaped groove is a concave portion of the concavo-convex structure, and the portion other than the lattice-shaped groove is a convex portion of the concavo-convex structure.
- the depth h of the lattice-shaped groove is the thickness of the adhesive layer (the second adhesive layer in the case of an adhesive layer having a three-layer structure described later).
- the graphite film 41 (a base material in a pressure-sensitive adhesive layer having a three-layer structure described later) is exposed without an adhesive in the recess.
- Such a configuration is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced.
- the depth h of the lattice-shaped groove is the thickness of the adhesive layer (the second adhesive layer in the case of an adhesive layer having a three-layer structure described later).
- An adhesive is present between the bottom 39 of the recess and the graphite film 41. According to such a configuration, the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced, and thereafter, the bottom 39 of the concave portion of the adhesive layer and the graphite This is preferable because the adherend and the graphite composite film are bonded to each other by the adhesive existing between the film 41 and the film 41.
- the upper surfaces of the portions other than the groove portions which are convex portions are on the same surface.
- the upper surface is more preferably a flat surface.
- the pitch of the grid-like grooves is preferably 0.05 mm or more and 2.0 mm or less, more preferably 0.1 mm or more and 1.0 mm or less, and further preferably 0.15 mm or more and 0.40 mm or less.
- the pitch of the lattice-shaped grooves refers to the interval between the intersection of the grooves constituting the lattice and the intersection adjacent to the intersection.
- the said intersection means the intersection of the lines which pass through the center of a groove
- the pitch is the length of one side of the square and the rhombus formed by a line passing through the center of the groove, respectively.
- the depth of the groove is preferably 0.1 ⁇ m or more and 20 ⁇ m or less, more preferably 0.3 ⁇ m or more and 5 ⁇ m or less, and further preferably 0.5 ⁇ m or more and 1.9 ⁇ m or less.
- the width of the groove is not particularly limited, but is preferably 0.001 mm to 2 mm, more preferably 0.01 mm to 0.05 mm. If the depth and width of the lattice-shaped grooves are within the above range, bubbles are generated between the adherend and the graphite composite film when bonded to the adherend without impairing the heat dissipation of the graphite composite film. Can be reduced more preferably.
- the shape of the groove is not particularly limited, and the cross section is, for example, a V shape, a U shape, a quadrangle, or the like. Further, the cross section of the groove is not strictly V-shaped, U-shaped, or square, but may be an irregular shape obtained by deforming these. Note that the plurality of independent island-shaped protrusions and the lattice-shaped grooves may exhibit the same uneven shape.
- FIG. 1C is a plan view of the striped groove as viewed from above.
- stripe means a stripe-like stripe and is the meaning except a lattice stripe.
- the non-hatched part is a striped groove.
- the striped groove is a straight groove in the figure, but the shape of the groove is not limited to this, and may be a curved groove.
- the interval between the grooves is constant, but it is not necessarily constant.
- the cross-sectional view when the striped groove shown in FIG. 1C is cut by the broken line C is the same as the configuration of FIG.
- the configuration shown in FIG. 9B may be used, or these configurations may be mixed.
- the striped groove is a concave portion of the concavo-convex structure, and the portion other than the striped groove is a convex portion of the concavo-convex structure.
- the stripe-shaped groove depth h is the thickness of the pressure-sensitive adhesive layer (the second pressure-sensitive adhesive layer in a pressure-sensitive adhesive layer having a three-layer structure described later).
- the graphite film 41 (a base material in a pressure-sensitive adhesive layer having a three-layer structure described later) is exposed without an adhesive in the recess. Such a configuration is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced.
- the depth h of the stripe-like groove is the thickness of the adhesive layer (the second adhesive layer in the adhesive layer having a three-layer structure described later).
- An adhesive is present between the bottom 39 of the recess and the graphite film 41 (a base material in the case of an adhesive layer having a three-layer structure described later).
- the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced, and thereafter, the bottom 39 of the concave portion of the adhesive layer and the graphite This is preferable because the adherend and the graphite composite film are bonded to each other by the adhesive existing between the film 41 and the film 41.
- the upper surfaces of the portions other than the groove portions which are convex portions are on the same surface.
- the upper surface is more preferably a flat surface.
- the pitch of the striped grooves is preferably 0.1 mm or more and 2.0 mm or less, and more preferably 0.5 mm or more and 1.0 mm or less.
- the pitch of the striped grooves refers to the interval between the grooves.
- interval means the space
- the depth, width and shape of the groove are the same as those of the lattice-like groove.
- the thickness of the adhesive layer is preferably 1.00 ⁇ m or more and 20.00 ⁇ m or less, more preferably 2.00 ⁇ m or more and 10.00 ⁇ m or less, and further preferably 3.00 ⁇ m or more and 7.00 ⁇ m or less. If the thickness of the said adhesion layer is 1.00 micrometers or more, since connection with a to-be-adhered body can fully be performed, it is preferable. Moreover, if the thickness of the said adhesion layer is 20.00 micrometers or less, it is preferable at a viewpoint which can suppress the thermal resistance at the time of tell
- the “thickness of the pressure-sensitive adhesive layer” means the thickness of the layer containing the pressure-sensitive adhesive for bonding to the adherend. Therefore, when the pressure-sensitive adhesive layer has a multilayer structure, the “thickness of the pressure-sensitive adhesive layer” means a layer containing a pressure-sensitive adhesive for bonding to the adherend opposite to the surface in contact with the graphite film of the pressure-sensitive adhesive layer, that is, Refers to the thickness of the outermost layer. For example, when the adhesive layer has a three-layer structure as described later, the thickness of the adhesive layer refers to the thickness of the second adhesive layer described later.
- the thickness of the adhesive layer refers to a value obtained by measurement based on the method described in Examples described later. Further, in the present specification, when the graphite film (GS), the adhesive layer and the adhesive layer have a three-layer structure, the thicknesses of the respective layers, the graphite composite film, the application layer, the protective layer, and the like are also described later. The value obtained by measurement based on the method described in 1. *
- the adhesive layer has a surface in contact with the graphite film in which the area of the graphite film covered with the adhesive is 35% to 100% of the total area of the graphite film.
- the structure is not particularly limited as long as it has a concavo-convex structure on the surface on the opposite side, and may be a single layer structure or a multilayer structure. More preferably, the adhesive layer has a three-layer structure including a first adhesive layer, a base material, and a second adhesive layer. By including the base material in the adhesive layer, the stiffness of the graphite composite film increases.
- FIG. 11 schematically shows a cross section of an example of a graphite composite film having an adhesive layer having a three-layer structure.
- (A) of FIG. 11 is an example in which the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and less than 100%, and (b) of FIG. This is an example in which the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 100%.
- the first adhesive layer 45, the substrate 44, and the second adhesive layer 43 are formed on the graphite film 41 from the graphite film 41 side.
- the adhesive layer 45, the base material 44, and the second adhesive layer 43 are laminated in this order. Therefore, the adhesive layer only needs to have the uneven structure on the surface of the second adhesive layer 43 that is not in contact with the base material 44.
- the concavo-convex structure in the case where the adhesive layer has a three-layer structure is as described in the above “(1-1-1) concavo-convex structure”, and the description thereof is omitted here.
- graphite film 41 is read as “base material”
- “adhesive layer” is read as “second adhesive layer”.
- the area of the graphite film covered with the adhesive may be 35% or more and 100% or less of the total area of the graphite film.
- the area of the graphite film covered with the adhesive is an adhesive for bonding to the adherend on the side opposite to the surface in contact with the graphite film of the adhesive layer.
- the area of the graphite film covered with the adhesive in the containing layer that is, the second adhesive layer.
- the area of the graphite film and the area of the base material are preferably the same.
- the area of the graphite film covered with the adhesive in the second adhesive layer is the adhesive of the second adhesive layer. It can also be said that it is the area of the base material covered with.
- the area of the base material covered with the adhesive is preferably 35% to 100% of the total area of the base material.
- the area of the base material covered with the adhesive may be 100% of the total area of the base material, or may be 35% or more and less than 100%.
- the configuration is the graphite film and the adhesive shown in the example of FIG. 9B.
- the graphite film is replaced with a base material, and the description is omitted here.
- the second adhesive layer 43 the entire area of the base material 44 is covered with the adhesive, and the second adhesive layer 43 is the base material 44.
- the configuration is the graphite shown in the example of FIG. Since the structure of the film and the pressure-sensitive adhesive is such that the graphite film is replaced with a base material, the description thereof is omitted here.
- the second adhesive layer 43 there is an exposed portion where the base material 44 is not covered with the adhesive, and the second adhesive layer 43 is The surface opposite to the surface in contact with the substrate has an uneven structure.
- the ratio of the area of the base material covered with the pressure-sensitive adhesive to the total area of the graphite film is more preferably 35% or more and 90% or less, and further preferably 50% or more and 85% or less. If the ratio of the area of the base material covered with the adhesive to the total area of the base material is within the above range, the contact with the adherend is good and the heat conduction is excellent, and the heat dissipation of the graphite composite film is improved. Without loss, it is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be reduced. Moreover, since the contact with a to-be-adhered body is good, it is excellent also in adhesive force.
- the adhesive layer has a three-layer structure
- the adhesive may or may not exist on the bottom surface of the concave portion of the concavo-convex structure of the second adhesive layer.
- the base material is exposed in the concave portion of the concave-convex structure. That is, in the second adhesive layer, the area of the base material covered with the adhesive is more preferably 35% or more and less than 100% of the total area of the base material.
- the second pressure-sensitive adhesive layer is a plurality of pressure-sensitive adhesive portions arranged on the substrate, and the uneven structure on the surface of the pressure-sensitive adhesive layer has a convex portion made of the pressure-sensitive adhesive portion and an adhesive in the concave portion.
- the base material is exposed without.
- Such a configuration is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be more efficiently reduced.
- the distance between one side of the island-shaped protrusion and one side of the adjacent island-shaped protrusion facing the side is: Preferably it is 0.01 mm or more, More preferably, it is 0.1 mm or more.
- the upper limit is preferably 2.0 mm or less, more preferably 0.88 mm or less, and still more preferably 0.5 mm or less. It is preferable that the distance between one side of the island-shaped protrusion which is the adhesive portion and one side of the adjacent island-shaped protrusion facing the side is 0.01 mm or more in order to reduce bubble generation more efficiently.
- the distance is within the above range, the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend can be reduced without impairing the heat dissipation of the graphite composite film. This is preferable because it is possible.
- the ratio of the area of the adhesive portion to the entire area of the adhesive layer is preferably 35% or more and 90% or less, more preferably 50% or more and 85% or less. If the ratio of the area of the adhesive portion to the entire area of the adhesive layer is within the above range, the contact with the adherend is good and excellent in heat conduction, without impairing the heat dissipation of the graphite composite film. This is preferable because the generation of bubbles between the adherend and the graphite composite film when bonded can be reduced. Moreover, since the contact with a to-be-adhered body is good, it is excellent also in adhesive force.
- the ratio of the area of the graphite film covered with the adhesive of the first adhesive layer in contact with the graphite film to the total area of the graphite film may be 100% or 35% or more and less than 100%. However, it is more preferably 100%. Thereby, it can be set as the composite film which does not impair the heat dissipation of a graphite composite film.
- each layer in the adhesive layer including the first adhesive layer, the base material, and the second adhesive layer is not particularly limited, but the first adhesive layer is preferably 0.1 ⁇ m or more and 20 ⁇ m or less, and more. Preferably they are 0.5 micrometer or more and 5 micrometers or less, More preferably, they are 1 micrometer or more and 3 micrometers or less.
- the substrate is preferably 0.5 ⁇ m or more and 10 ⁇ m or less, more preferably 1 ⁇ m or more and 5 ⁇ m or less.
- the second adhesive layer is preferably 0.1 ⁇ m or more and 20 ⁇ m or less, more preferably 0.5 ⁇ m or more and 5 ⁇ m or less, and further preferably 1 ⁇ m or more and 3 ⁇ m or less.
- the adhesive material used for the adhesive layer examples include acrylic adhesives, silicone adhesives, rubber adhesives, and the like. These materials have excellent heat resistance, and sufficient long-term reliability can be obtained even when used in combination with heat-generating components and / or heat-dissipating components. In addition, these materials can be used repeatedly and are excellent in long-term reliability, and thus are excellent in reusability and removability.
- the adhesive layer has a three-layer structure
- the materials of the first adhesive layer and the second adhesive layer may be the same or different.
- the present technology can also be applied to adhesives that are used by applying heat such as polyimide or epoxy.
- the base material is preferably a polymer film.
- PET polyethylene terephthalate
- PPS polyphenylene sulfide
- PEN polyethylene naphthalate
- polyester resins polyester resins.
- a film etc. are mentioned.
- polyimide and polyethylene terephthalate are excellent in heat resistance, strength and dimensional stability, and when made into a graphite composite film, obtain a graphite composite film with excellent peelability and scratch resistance without reducing thermal conductivity. Can do.
- the second adhesive layer only needs to have a concavo-convex structure on the surface opposite to the surface in contact with the substrate, and the structure of the surface of the second adhesive layer in contact with the substrate is any structure. It may be. That is, the surface of the second adhesive layer in contact with the base material may or may not have an uneven structure.
- the structure of the surface of the first adhesive layer in contact with the substrate or the graphite film may be any structure. That is, the surface of the first adhesive layer in contact with the substrate or the graphite film may or may not have an uneven structure.
- the graphite film used in the present invention is not particularly limited as long as it is a graphite film that can be used as a heat dissipation component.
- a graphite film obtained by sheeting graphite powder such as natural graphite or artificial graphite, or a graphite film obtained by heat treating a polymer film can be suitably used.
- a graphite film obtained by sheeting graphite powder is produced by pressing and solidifying graphite powder into a sheet.
- the powder In order for the graphite powder to be formed into a film, the powder needs to be in the form of flakes or flakes.
- the most common method for producing such graphite powder is a method called an expanded (expanded graphite) method.
- graphite is immersed in an acid such as sulfuric acid to produce a graphite intercalation compound, which is then heat treated and foamed to separate the graphite layers. After peeling, the graphite powder is washed to remove the acid to obtain a thin film graphite powder.
- the graphite powder obtained by such a method is further subjected to rolling roll molding to obtain film-like graphite.
- the graphite film produced using expanded graphite obtained by such a method is rich in flexibility and has high thermal conductivity in the film surface direction, and therefore is preferably used for the purpose of the present invention.
- Graphite films obtained by heat treatment of polymer films are polyimide, polyamide, polyoxadiazole, polybenzothiazole, polybenzobisthiazole, polybenzoxazole, polybenzobisoxazole, polyparaphenylene vinylene, polybenzimidazole, poly It is produced by heat-treating at least one polymer film selected from benzobisimidazole and polythiazole.
- the raw material film for the graphite film used in the present invention is more preferably a polyimide film.
- Polyimide film is prone to carbonization and graphitization of the film, so the thermal diffusivity, thermal conductivity, and electrical conductivity of the film tend to increase uniformly at low temperatures, and the thermal diffusivity, thermal conductivity, and electrical conductivity.
- the point that it itself is likely to be high the point that it becomes graphite with high thermal conductivity even when the thickness is thick, the crystallinity of the resulting graphite is excellent, heat resistance, bendability, and when bonded to a protective film, from the surface It is more preferable in that a graphite film in which graphite is difficult to fall off is easily obtained.
- the polymer film as a starting material is carbonized by preheating treatment, and then the obtained carbonized film is graphitized at a high temperature.
- Carbonization is more preferably performed under reduced pressure or in an inert gas.
- Carbonization is usually performed at a temperature of about 1000 ° C.
- the heat treatment temperature needs to be 2000 ° C. or higher, and finally 2400 ° C.
- the temperature in each heating space 3 is in a plurality of stages between 500 ° C. and 900 ° C. so as to be uniform in each heating space 3. adjust.
- the polymer film 2 is set in a rewinding device and continuously supplied to the heat treatment device 1. At this time, it is preferable to convey the heated film at a line speed of 100 cm / min or more and 1000 cm / min or less while applying a tension with a tensile strength of 5 kgf / cm 2 or more and 500 kgf / cm 2 or less.
- each heating space 3 as shown in FIG. 3, it is preferable that the film 2 is sandwiched from above and below by a graphite jig 4 and conveyed so as to slide between the jigs 4.
- the pressure applied in the thickness direction of the film 2 is preferably adjusted to 0.5 g / cm 2 or more and 10 g / cm 2 or less.
- the carbonized film 5 wound in a roll is put into a graphitization furnace 6 and graphitized as shown in FIG. Note that the dotted line in FIG. 4 indicates the position of the winding core.
- the TD direction of the carbonized film coincides with the gravity direction 7.
- the graphite film used in the present invention preferably has a thermal conductivity in the plane direction of the film of 200 W / mK or more and a thermal conductivity in the direction perpendicular to the film plane of 20 W / mK or less.
- the thermal conductivity in the surface direction of the film is 200 W / m ⁇ K or more
- the thermal conductivity of the graphite composite film is increased even as a composite product in which an adhesive layer or a protective film layer is formed.
- the thermal conductivity in the thickness direction of the graphite film needs to be sufficiently small.
- the thermal conductivity in the direction perpendicular to the film surface is 20 W / mK or less, it becomes possible to preferentially diffuse the heat from the heat generating part of the adherend in the surface direction, thereby suppressing heat spots. .
- the thermal conductivity in the plane direction of the film is preferably 800 W / m ⁇ K or more.
- the thickness of the graphite film is preferably 5 ⁇ m or more and 250 ⁇ m or less, More preferably, they are 5 micrometers or more and 120 micrometers or less, More preferably, they are 7 micrometers or more and 50 micrometers or less, Most preferably, they are 10 micrometers or more and 40 micrometers or less. If the thickness of the graphite film is 5 ⁇ m or more, it is preferable because it has a heat dissipating capability necessary for cooling the electronic equipment. Moreover, if the thickness of the graphite film is 250 ⁇ m or less, it can be put into a thin electronic device, which is preferable.
- the graphite film used in the present invention may be a single-layer sheet obtained by forming a sheet of graphite powder or heat-treating a polymer film.
- the graphite film includes a graphite film.
- a graphite laminate in which sheets and adhesive layers are alternately laminated is also included.
- the said adhesive layer is not limited to this, For example, at least 1 resin of a thermoplastic resin and a thermosetting resin is included.
- the thickness of the adhesive layer is not limited to this, but is preferably 0.1 ⁇ m or more and less than 15 ⁇ m.
- the number of laminated graphite sheets contained in the graphite laminate is not limited to this, but is, for example, 3 layers or more, more preferably 5 layers or more, and further preferably 10 layers or more, Particularly preferred is 15 layers or more, and most preferred is 20 layers or more.
- the upper limit of the number of layers is not limited to this, but is, for example, 1000 layers or less, more preferably 500 layers or less, further preferably 200 layers or less, and even more preferably 100 layers. Or less, particularly preferably 80 layers or less, and most preferably 50 layers or less. It is preferable that the number of laminated layers is three or more because a graphite laminated body having high heat transport capability and excellent mechanical strength can be obtained.
- the number of adhesion layers included in the graphite laminate is not particularly limited, and can be appropriately set according to the number of graphite sheets.
- two or more adhesive layers as well as one adhesive layer may be disposed between adjacent graphite sheets.
- It may be disposed only on the top surface of the body, only on the bottom surface of the graphite laminate, or may be disposed on both the top surface and the bottom surface of the graphite laminate. It may be disposed only on the uppermost surface, disposed only on the lowermost surface of the graphite laminate, or may be disposed on both the uppermost surface and the lowermost surface of the graphite laminate.
- graphite sheets and adhesive layers are alternately laminated includes (a) a case where one adhesive layer is disposed between adjacent graphite sheets, and (b) adjacent graphite sheets. Both are included when two or more adhesive layers are disposed between them. That is, the adhesive layer may be a laminate of a plurality of adhesive layers.
- Such a graphite laminate can be produced by a method in which graphite sheets and adhesive layers are alternately laminated, and the laminate is heated and pressurized.
- the graphite adhesive sheet can be produced by forming an adhesive layer on at least one surface of the graphite sheet and then laminating the graphite adhesive sheet.
- the graphite laminate may be obtained by further compressing a laminate in which the graphite sheet and the adhesive layer are alternately laminated.
- “obtained by compression” intends that the total thickness of the material after compression is thinner than the total thickness of the material before compression. At this time, those in which the components of the adhesive layer are infiltrated into the surface of the graphite sheet are also included in “obtained by compression”.
- Whether or not the graphite laminate is obtained by compression is determined by i) comparing the thickness of the graphite laminate before and after the compression treatment, or ii) the graphite laminate by SEM (scanning electron microscope). This can be confirmed by observing the interface between the layers.
- another structure may be inserted
- the thickness of the graphite film, that is, the graphite laminate is not limited to this, but is preferably 0.05 mm or more. More preferably, it is 0.09 mm or more, More preferably, it is 0.10 mm or more. If the thickness of the graphite laminate is 0.05 mm or more, the amount of heat that can be transported increases, and the present invention can also be applied to electronic devices that generate a large amount of heat.
- the upper limit of the thickness of the graphite film, that is, the graphite laminate is not limited to this, but is preferably 10 mm or less, more preferably 7.5 mm or less from the viewpoint of thinning the electronic device. More preferably, it is 5 mm or less, particularly preferably 2.5 mm or less, and most preferably 1 mm or less.
- Each graphite sheet constituting the graphite laminate can be produced by the above-described method of forming a graphite powder such as natural graphite or artificial graphite, or the method of heat-treating a polymer film.
- each graphite sheet constituting the graphite laminate is not limited to this, but is preferably 10 ⁇ m or more and 200 ⁇ m or less, more preferably 12 ⁇ m or more and 150 ⁇ m or less, and further preferably 15 ⁇ m or more and 100 ⁇ m or less. It is particularly preferably 20 ⁇ m or more and 80 ⁇ m or less. If the thickness of each graphite sheet is 10 ⁇ m or more, the number of graphite sheets contained in the graphite laminate can be reduced, and the number of adhesion layers having low thermal conductivity can be reduced. Moreover, if the thickness of each said graphite sheet is 200 micrometers or less, the high thermal conductivity of a graphite laminated body is realizable.
- a film-like material can be used, and a varnish-like material can also be used.
- thermosetting resin PU (polyurethane), phenol resin, urea resin, melamine resin, guanamine resin, vinyl ester resin, unsaturated polyester, oligoester acrylate, diallyl phthalate, DKF resin (a kind of resorcinol resin) , Xylene resin, epoxy resin, furan resin, PI (polyimide series) resin, PEI (polyetherimide) resin, PAI (polyamideimide) resin, PPE (polyphenylene ether), and the like.
- an epoxy resin, a urethane resin, and PPE (polyphenylene ether) are preferable because of a wide range of material selection and excellent adhesion to the graphite sheet.
- thermoplastic resin examples include acrylic, ionomer, isobutylene maleic anhydride copolymer, AAS (acrylonitrile-acrylic-styrene copolymer), AES (acrylonitrile-ethylene-styrene copolymer), AS (acrylonitrile-styrene copolymer).
- ABS acrylonitrile-butadiene-styrene copolymer
- ACS acrylonitrile-chlorinated polyethylene-styrene copolymer
- MBS methyl methacrylate-butadiene-styrene copolymer
- ethylene-vinyl chloride copolymer EVA (ethylene-vinyl acetate copolymer), EVA (ethylene-vinyl acetate copolymer system), EVOH (ethylene vinyl alcohol copolymer), polyvinyl acetate, chlorinated vinyl chloride, chlorinated polyethylene, chlorinated poly Pyrene, carboxyvinyl polymer, ketone resin, norbornene resin, vinyl propionate, PE (polyethylene), PP (polypropylene), TPX (polymethylpentene), polybutadiene, PS (polystyrene), styrene maleic anhydride copolymer, methacrylic, EMAA (ethylene-me
- an aromatic material for example, polyester adhesive, polyethylene terephthalate, etc.
- the adhesive layer is aligned substantially in parallel with the plane of the graphite sheet, and the graphite sheet layer is hardly disturbed during lamination, and has a thermal conductivity close to the theoretical value. Can be obtained.
- the volume of the graphite film used in the present invention is more preferably 50 mm 3 or more.
- the stiffness of the graphite film becomes stronger, the followability to the adherend to be bonded becomes worse, and air bubbles easily enter between the graphite film and the adherend. Is difficult to solve.
- a graphite film using a graphite laminate in which the number of graphite sheets laminated is two or more it is important to solve this problem.
- the pressure-sensitive adhesive layer of the present invention is used, such a problem can be solved even when the volume of the graphite film is 50 mm 3 or more.
- the volume tends to increase, so that it is particularly effective to use the adhesive layer of the present invention.
- the graphite composite film according to the present invention may have the graphite film and the adhesive layer, but may further have a separator, a protective layer, an application layer, and the like. .
- separator is a sheet in which a release material is formed on a base film, and is laminated on the adhesive surface of the adhesive layer.
- the separator is usually intended to cover the adhesive surface of the adhesive layer until the use of the graphite composite film, and is peeled off when the graphite composite film is used.
- the separator may be used as a mold for transferring the concavo-convex structure to the pressure-sensitive adhesive layer in the production process of the graphite composite film.
- the separator used as such a mold is peeled off after transfer, and a new flat separator is laminated.
- the separator used as a mold is not peeled off and can be used as it is to cover the adhesive surface until the use of the graphite composite film.
- the thickness of the separator is not particularly limited, but is preferably 2 ⁇ m to 200 ⁇ m, more preferably 6 ⁇ m to 100 ⁇ m, and still more preferably 10 ⁇ m to 80 ⁇ m.
- the thickness of the separator is 200 ⁇ m or less, the graphite composite film is not damaged when the separator is peeled off.
- the thickness is 2 ⁇ m or more, the handling properties of the separator are sufficient.
- the material for the base film is not particularly limited, and examples thereof include PET film, polypropylene film, polyethylene film, polystyrene film, polyimide film, and the like.
- the release agent is not particularly limited, and examples thereof include silicone and fluorine.
- the protective layer is laminated on the surface of the graphite film opposite to the surface in contact with the adhesive layer to protect the graphite film, to provide electrical insulation, and to generate graphite powder. It is used for the purpose of suppressing and reinforcing the graphite film.
- the thickness of the protective layer is not particularly limited, but is preferably 2 ⁇ m to 200 ⁇ m, more preferably 6 ⁇ m to 100 ⁇ m, and particularly preferably 10 ⁇ m to 30 ⁇ m. If the thickness of the protective layer is 200 ⁇ m or less, the heat dissipation characteristics of the graphite film will not be impaired. On the other hand, if the thickness is 2 ⁇ m or more, the function of the protective layer can be sufficiently exhibited.
- the material of the protective layer is not particularly limited, and for example, a polymer film such as a PET film, a polypropylene film, a polyethylene film, a polystyrene film, or a polyimide film can be used.
- a polymer film such as a PET film, a polypropylene film, a polyethylene film, a polystyrene film, or a polyimide film can be used.
- the application layer is a sheet in which a slightly adhesive material that can be re-peeled is formed on the base film.
- the application layer is opposite to the side of the protective layer that contacts the graphite film. Laminated on the surface and peeled off when using the graphite composite film.
- the graphite composite film according to the present invention preferably has a peel strength with SUS of 4.0 N / 25 mm or more and 12.0 N / 25 mm or less, more preferably 5.0 N / 25 mm or more and 8 0.0 N / 25 mm or less, more preferably 6.0 N / 25 mm or more and 7.0 N / 25 mm or less.
- the peel strength refers to a value measured by the method described in the examples. If the peel strength between the graphite composite film and SUS is 4.0 N / 25 mm or more, it is preferable because the adhesion to the adherend is high and the heat diffused by the graphite film is easily transmitted to the adherend. Further, if the peel strength is 12.0 N / 25 mm or less, it is preferable from the viewpoint that it is difficult to bite air between the adherend and the graphite composite film at the time of bonding to the adherend.
- the graphite composite film according to the present invention preferably has an area of 3 cm 2 or more. If it is 3 cm 2 or more, the heat dissipation effect is high, and it is suitable for cooling high-power electronic devices in recent years.
- the graphite composite film according to the present invention preferably has an area of 5 cm 2 or more, more preferably 10 cm 2 or more. Further, when the area of the conventional film is increased, there is a problem that air is entrained and air bubbles are generated between the adherend and the graphite composite film when the film is joined to the heat generating component. However, according to the present invention, it is possible to reduce the generation of bubbles even when the area is as large as 25 cm 2 or more. Therefore, the present invention is particularly effective when a graphite composite film having a large area of 25 cm 2 or more is used.
- the method for producing a graphite composite film according to the present invention is not particularly limited as long as it is a method capable of producing the above-described graphite composite film according to the present invention.
- a method of laminating a pressure-sensitive adhesive layer having a concavo-convex structure and a graphite film (manufacturing method 1), and forming a pressure-sensitive adhesive layer on a graphite film having a concavo-convex structure on the surface to form the concavo-convex structure of the graphite film
- the method (manufacturing method 2) etc. which appear on the adhesive layer surface can be mentioned.
- the method for producing a graphite composite film according to this embodiment includes the pressure-sensitive adhesive layer and the pressure-sensitive adhesive layer so that the concave-convex structure of the pressure-sensitive adhesive layer having a concavo-convex structure on at least one side is disposed on the opposite side of the surface in contact with the graphite film. A step of laminating the graphite film.
- an adhesive layer provided with a concavo-convex structure on at least one surface is prepared in advance, and the concavo-convex structure is disposed on the side opposite to the surface in contact with the graphite film.
- Laminate with graphite film Any method may be used for laminating the adhesive layer and the graphite film, and for example, a laminator device can be used.
- the method for producing an adhesive layer having an uneven structure on at least one side is not particularly limited, and examples thereof include the following methods.
- the pressure-sensitive adhesive layer provided with a concavo-convex structure on at least one surface can be produced by a method of applying or printing a pressure-sensitive adhesive solution so as to have a desired concavo-convex structure.
- a known method can be appropriately selected and used, and is not particularly limited.
- the above-mentioned adhesive layer including the first adhesive layer, the base material, and the second adhesive layer can be produced by the method shown in FIG. 5 as an example.
- a gravure coater machine in which the squeegee 11 is installed an adhesive solution film is formed on the base material 16 (first adhesive layer 15), and after drying, the separator 14 is bonded to the first adhesive layer side and laminated product 13 Is made.
- the adhesive solution 9 is dot-printed on the separator 8 so that a desired plurality of island-shaped protrusions 17 are separately formed.
- the laminated product 12 obtained by dot printing is dried, and then laminated with the previously produced laminated product 13 such that the dot-printed surface (second adhesive layer 17) is in contact with the substrate 16 of the laminated product 13.
- the first adhesive layer 15 obtained by forming the adhesive solution on the substrate 16 and drying, the substrate 16, and the second adhesive layer 17 obtained by dot printing and drying the adhesive solution in order A laminated adhesive layer is obtained.
- the desired unevenness is formed on at least one side by the method of applying or printing the adhesive solution in the same manner.
- An adhesive layer having a structure can be produced.
- the method for producing a graphite composite film according to the present embodiment further includes a step of producing a pressure-sensitive adhesive layer having a concavo-convex structure on at least one side by applying or printing the pressure-sensitive adhesive solution so as to have a desired concavo-convex structure. May further be included.
- a pressure-sensitive adhesive layer having a concavo-convex structure on at least one surface is prepared by applying or printing a pressure-sensitive adhesive solution so as to have a desired concavo-convex structure; Including a step of laminating the adhesive layer and the graphite film so that the uneven structure of the adhesive layer having an uneven structure on at least one side is disposed on the opposite side of the surface in contact with the graphite film. Good.
- the pressure-sensitive adhesive layer provided with a concavo-convex structure on at least one surface can be produced by a method of transferring the concavo-convex structure of a separator having a concavo-convex structure complementary to a desired concavo-convex structure onto the surface of the pressure-sensitive adhesive layer. According to this method, it is possible to easily form a concavo-convex structure on the adhesive layer surface of the graphite film.
- the method for producing a graphite composite film according to the present embodiment further includes a pressure-sensitive adhesive layer provided with a concavo-convex structure on at least one side by transferring the concavo-convex structure of a separator having a concavo-convex structure on the surface to the surface of the pressure-sensitive adhesive layer.
- the process of producing may be further included.
- the method for producing a graphite composite film according to the present embodiment produces an adhesive layer having a concavo-convex structure on at least one side by transferring the concavo-convex structure of a separator having a concavo-convex structure on the surface to the surface of the adhesive layer. And a step of laminating the adhesive layer and the graphite film such that the uneven structure of the adhesive layer having an uneven structure on at least one side is disposed on the opposite side of the surface in contact with the graphite film. May be included.
- a known method can be appropriately selected and used, and is not particularly limited.
- a method of transferring a concavo-convex structure by forming a pressure-sensitive adhesive solution on the surface of a separator having a concavo-convex structure (transfer method 1), contacting the surface having the concavo-convex structure of a separator having a concavo-convex structure on the surface with an adhesive layer
- a method of transferring the concavo-convex structure (transfer method 2) can be mentioned.
- the surface roughness of the separator having the concavo-convex structure is preferably Ra 0.06 ⁇ m to 1.00 ⁇ m, Rz 0.3 ⁇ m to 10.0 ⁇ m, and more preferably Ra 0.30 ⁇ m to 0.00. 70 ⁇ m or less, and Rz 2.90 ⁇ m or more and 5.10 ⁇ m or less. If the surface roughness of the surface having the concavo-convex structure of the separator is within the above range, the loss between the heat dissipation of the graphite composite film and the adhesion between the adherend and the graphite composite film when adhered to the adherend Since bubble generation can be reduced more suitably, it is preferable.
- Transfer method 1 As a method of forming a pressure-sensitive adhesive solution on the surface of the separator having a concavo-convex structure on the surface and transferring the concavo-convex structure, a known method can be appropriately selected and used, and is not particularly limited.
- the above-mentioned pressure-sensitive adhesive layer including the first pressure-sensitive adhesive layer, the base material, and the second pressure-sensitive adhesive layer can be produced by the method shown in FIG. 6 as an example.
- a pressure-sensitive adhesive solution is formed on the base material 23 (first pressure-sensitive adhesive layer 24), and after drying, the separator 25 is bonded to the first pressure-sensitive adhesive layer side and laminated product 13 Is made.
- the pressure-sensitive adhesive solution 20 is formed into a desired thickness using the squeegee 21 on the separator 19 that has been embossed so as to have a concavo-convex structure complementary to the desired concavo-convex structure. .
- the liquid film becomes the second adhesive layer 22.
- the laminated product 13 is laminated so that the surface of the second adhesive layer 22 opposite to the surface in contact with the separator 19 is in contact with the base material 23 of the laminated product 13.
- the first pressure-sensitive adhesive layer 24 obtained by forming and drying the pressure-sensitive adhesive solution on the base material 23, the base material 23, and the concavo-convex structure of the separator obtained by drying the pressure-sensitive adhesive solution on the separator 19
- a pressure-sensitive adhesive layer in which the second pressure-sensitive adhesive layer 22 to which is transferred is sequentially laminated is obtained.
- the separator 19 is peeled off and the surface in contact with the second adhesive layer 22 is newly flat in order to cover the adhesive surface of the second adhesive layer 22 until the use of the graphite composite film.
- the separator may be laminated.
- one adhesive layer other than the three-layered adhesive layer including the first adhesive layer, the base material, and the second adhesive layer is similarly embossed so as to have a concavo-convex structure complementary to the desired concavo-convex structure. It can be produced by a method in which a pressure-sensitive adhesive solution is formed on a treated separator and the concavo-convex structure is transferred.
- the pressure-sensitive adhesive layer in contact with the separator means a pressure-sensitive adhesive layer after drying
- the pressure-sensitive adhesive layer after drying means a pressure-sensitive adhesive layer having a solvent residual ratio of 5% by weight or less.
- the solvent remaining rate can be measured by the following calculation formula by drying only the pressure-sensitive adhesive part at a temperature equal to or higher than the boiling point of the solvent in an oven or the like, measuring the weight before and after the drying.
- Residual ratio of solvent (%) (weight before drying ⁇ weight after drying) / weight before drying ⁇ 100
- a known method can be appropriately selected and used.
- a method of laminating a separator having a concavo-convex structure on the surface to the adhesive layer can be mentioned.
- an adhesive layer having a concavo-convex structure on at least one surface can be produced using conventional equipment and products only by changing the specifications of the separator.
- the above-mentioned pressure-sensitive adhesive layer including the first pressure-sensitive adhesive layer, the base material, and the second pressure-sensitive adhesive layer can be produced by the method shown in FIG. 7 as an example.
- one separator 26 of the three-layer structure adhesive layer including the first adhesive layer 29, the base material 28, and the adhesive layer 27 not having the uneven structure is peeled off, and the adhesive not having the exposed uneven structure.
- a separator 31 that has been embossed so as to have a concavo-convex structure complementary to a desired concavo-convex structure is laminated on the layer 27 so that the embossed surface is in contact with the layer 27 to obtain an adhesive layer.
- a single-layer adhesive layer other than the adhesive layer having a three-layer structure including the first adhesive layer, the base material, and the second adhesive layer can also be produced by the same method.
- the concavo-convex can be easily formed on the adhesive layer surface of the graphite composite film.
- the method for forming the adhesive layer on the graphite film having a concavo-convex structure on the surface is not particularly limited, and any method may be used.
- the adhesive layer is laminated on the graphite film using a laminator device. And a method of forming a pressure-sensitive adhesive solution on a graphite film and drying.
- the method for producing a graphite film having a concavo-convex structure on the surface is not particularly limited.
- a graphite film is rolled using a rolling roll whose surface is embossed in the production process of the graphite film.
- the graphite sheet having the concavo-convex structure on the surface is manufactured on the lowermost surface or the uppermost surface of the laminate so that the surface of the laminate has the concavo-convex structure.
- a lamination method or the like can be used.
- the surface roughness of the surface of the graphite film having an uneven structure on the surface is preferably Ra 0.55 ⁇ m to 1.70 ⁇ m, Rz 2.3 ⁇ m to 6.00 ⁇ m, more preferably Ra 0.80 ⁇ m to 1 .30 ⁇ m or less and Rz 3.20 ⁇ m or more and 4.70 ⁇ m or less. If the surface roughness of the surface having the concavo-convex structure of the graphite film having the concavo-convex structure on the surface is in the above range, even the surface roughness of a normal pressure-sensitive adhesive layer having no concavo-convex surface can be easily formed.
- the thickness of the graphite film having an uneven structure on the surface is preferably 5 ⁇ m or more and 250 ⁇ m or less, more preferably 5 ⁇ m or more and 120 ⁇ m or less, and still more preferably when the graphite film used in the present invention is a single layer sheet as described above. They are 7 micrometers or more and 50 micrometers or less, Especially preferably, they are 10 micrometers or more and 40 micrometers or less. If the thickness of the graphite film is within the above range, it is preferable because the adhesive layer is easily uneven.
- the thickness of the graphite film, that is, the graphite laminate is not limited to this, but is preferably 0.05 mm or more, more Preferably it is 0.09 mm or more, More preferably, it is 0.10 mm or more.
- the upper limit of the thickness of the graphite film, that is, the graphite laminate is not limited to this, but is preferably 10 mm or less, more preferably 7.5 mm or less from the viewpoint of thinning the electronic device. More preferably, it is 5 mm or less, particularly preferably 2.5 mm or less, and most preferably 1 mm or less.
- the surface roughness of the surface having the concavo-convex structure of the pressure-sensitive adhesive layer having the concavo-convex structure formed by the above method is preferably Ra 0.19 ⁇ m or more and 10 ⁇ m or less, and Rz 1.6 ⁇ m or more and 100 ⁇ m or less, more preferably Ra is 0.19 ⁇ m or more and 0.80 ⁇ m or less, Rz is 2.0 ⁇ m or more and 5.00 ⁇ m or less, more preferably Ra is 0.25 ⁇ m or more and 0.60 ⁇ m or less, and Rz is 2.5 ⁇ m or more and 4.00 ⁇ m or less.
- the surface roughness is preferably Ra 0.19 ⁇ m to 10 ⁇ m, more preferably Ra 0.19 ⁇ m to 0.80 ⁇ m, and still more preferably Ra 0.25 ⁇ m to 0.60 ⁇ m.
- the surface roughness is preferably Rz 1.6 ⁇ m or more and 100 ⁇ m or less, more preferably Rz 2.0 ⁇ m or more and 5.00 ⁇ m or less, and further preferably Rz 2.5 ⁇ m or more and 4.00 ⁇ m or less. If the surface roughness of the adhesive layer is in the above range, the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend is reduced without impairing the heat dissipation of the graphite composite film. Is preferable.
- the thickness of the pressure-sensitive adhesive layer having a concavo-convex structure formed on the surface by the above method is preferably 1.00 ⁇ m to 20.00 ⁇ m, more preferably 2.00 ⁇ m to 10.00 ⁇ m, and still more preferably 3. It is 00 ⁇ m or more and 7.00 ⁇ m or less. If the thickness of the said adhesion layer is 1.00 micrometers or more, since connection with a to-be-adhered body can fully be performed, it is preferable. Moreover, if the thickness of the said adhesion layer is 20.00 micrometers or less, since an unevenness
- the above-described graphite composite film manufacturing method may include at least one of a step of laminating a protective layer and a step of laminating an application layer in addition to the above steps.
- the graphite composite film according to the present invention can reduce the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend without impairing heat dissipation. It can be suitably used for heat dissipation components. Therefore, the heat dissipation component including the graphite composite film according to the present invention is also included in the present invention.
- the heat dissipating part according to the present invention is a heat dissipating part including a graphite composite film
- the graphite composite film includes a graphite film and an adhesive layer in contact with the graphite film, and the total area of the graphite film is If the ratio of the area of the graphite film covered with the adhesive is 35% or more and 100% or less, and the adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film Good. Since the graphite composite film is as described in “[1] Graphite composite film”, the description thereof is omitted here.
- the configuration of the heat dissipation component according to the present invention is not particularly limited as long as it includes the graphite composite film of the present invention.
- the adherend is, for example, a radiator.
- the material of the radiator is a metal such as SUS, a resin, or the like.
- examples of the heat radiating body include a casing of a heat generating component.
- the graphite film When the thickness of the graphite film is 90 ⁇ m or less, more preferably 60 ⁇ m or less, or when the graphite film is preferably composed of a single-layer graphite sheet, the graphite film is opposite to the surface in contact with the adherend. A concavo-convex structure resulting from the concavo-convex structure of the adhesive layer appears on the surface. Further, when a protective layer is laminated on the surface of the graphite film opposite to the adhesive layer, that is, the surface opposite to the surface of the graphite film in contact with the adherend, or the protective layer and the application layer are laminated. In the case where it is formed, an uneven structure due to the uneven structure of the adhesive layer appears on the surface of the protective layer or application layer, respectively.
- Ra is preferably 0.15 ⁇ m or more and 10 ⁇ m or less, more preferably 0.17 ⁇ m or more and 1.0 ⁇ m or less, Preferably they are 0.18 micrometer or more and 0.25 micrometer or less.
- Rz is preferably 1.0 ⁇ m or more and 100 ⁇ m or less, more preferably 1.0 ⁇ m or more and 10 ⁇ m or less, and further preferably 1.50 ⁇ m or more and 2.00 ⁇ m or less.
- Ra and Rz is preferably Ra 0.15 ⁇ m to 10 ⁇ m, Rz 1.0 ⁇ m to 100 ⁇ m, more preferably Ra 0.17 ⁇ m to 1.0 ⁇ m, and Rz 1.0 ⁇ m to 10 ⁇ m. More preferably, Ra is 0.18 ⁇ m or more and 0.25 ⁇ m or less, and Rz is 1.50 ⁇ m or more and 2.00 ⁇ m or less.
- the adherend of the graphite film is made because the graphite film is thick.
- the uneven structure resulting from the uneven structure of the adhesive layer cannot be visually observed on the surface opposite to the surface in contact with the surface.
- the adhesive layer has an uneven structure, and an adhesive for the entire area of the graphite film. It can be confirmed that the area ratio of the covered graphite film is 35% or more and 100% or less.
- the present invention has the following configuration. (1) It has a graphite film and an adhesive layer in contact with the graphite film, and the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and 100% or less, The adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film. (2) The graphite composite film according to (1), wherein the surface roughness of the surface having the uneven structure of the adhesive layer is Ra 0.19 ⁇ m or more and 10 ⁇ m or less. (3) The graphite composite film according to (1) or (2), wherein the surface roughness of the surface having the uneven structure of the adhesive layer is Rz 1.6 ⁇ m or more and 100 ⁇ m or less.
- the uneven structure on the surface of the adhesive layer is a lattice-shaped or striped groove, or a plurality of independent island-shaped protrusions.
- the adhesive layer includes a first adhesive layer, a base material, and a second adhesive layer, and the adhesive layer is formed on the graphite film from the graphite film side, the first adhesive layer, The ratio of the area of the graphite film that is laminated in the order of the base material and the second adhesive layer and is covered with the adhesive of the second adhesive layer to the total area of the graphite film is 35% or more and 100% or less.
- the adhesive layer has the concavo-convex structure on the surface opposite to the surface in contact with the base material of the second adhesive layer.
- the second adhesive layer is a plurality of adhesive portions arranged on the base material,
- the uneven structure on the surface of the pressure-sensitive adhesive layer is characterized in that a convex portion is composed of the pressure-sensitive adhesive portion, and no adhesive is present in the concave portion, and the base material is exposed.
- (9) The graphite composite film according to (8), wherein the ratio of the area of the adhesive portion to the entire area of the adhesive layer is 35% or more.
- the adhesive part is a regularly arranged polygonal, rod-like, or strip-like island-shaped protrusion, between one side of the island-shaped protrusion and one side of an adjacent island-shaped protrusion facing the side
- (11) The graphite composite film according to any one of claims 1 to 10, wherein a peel strength between the graphite composite film and SUS is 4.0 N / 25 mm or more and 12.0 N / 25 mm or less.
- the graphite film is a graphite laminate in which graphite sheets and adhesive layers are alternately laminated, and the number of the graphite sheets contained in the graphite laminate is three or more.
- the pressure-sensitive adhesive layer and the graphite film are laminated so that the concave-convex structure of the pressure-sensitive adhesive layer having a concavo-convex structure on at least one surface is disposed on the opposite side of the surface in contact with the graphite film.
- a process for producing a graphite composite film comprising the step of: (17) A method for producing a graphite composite film having a graphite film and an adhesive layer in contact with the graphite film, wherein the concavo-convex structure of a separator having a concavo-convex structure on the surface is transferred to the surface of the adhesive layer, A step of producing an adhesive layer having a concavo-convex structure on one side, and the adhesive layer so that the concavo-convex structure of the adhesive layer having the concavo-convex structure on at least one side is disposed on the side opposite to the surface in contact with the graphite film And a step of laminating the graphite film and a method for producing a graphite composite film.
- a method for producing a graphite composite film (22) The graphite according to (21), wherein the surface roughness of the surface of the graphite film having a concavo-convex structure is Ra 0.55 ⁇ m to 1.70 ⁇ m and Rz 2.3 ⁇ m to 6.00 ⁇ m.
- a method for producing a composite film (23) The method for producing a graphite composite film according to (21) or (22), wherein the graphite film has a thickness of 5 ⁇ m or more and 120 ⁇ m or less. (24) The graphite composite according to any one of (21) to (23), wherein the surface roughness of the surface having the uneven structure of the adhesive layer is Ra 0.8 ⁇ m or less and Rz 4.5 ⁇ m or less.
- a method for producing a film (25) A heat dissipation component including a graphite composite film, wherein the graphite composite film has a graphite film and an adhesive layer in contact with the graphite film, and is covered with an adhesive for the entire area of the graphite film.
- the area ratio of the graphite film is 35% or more and 100% or less, and the adhesive layer has a concavo-convex structure on the surface opposite to the surface in contact with the graphite film.
- a protective layer is laminated on the surface of the graphite composite film opposite to the surface in contact with the adherend, and the surface roughness of the surface of the protective layer is Ra 0.15 ⁇ m or more and 10 ⁇ m or less, and Rz is 1.0 ⁇ m or more and 100 ⁇ m or less, and the heat dissipating component according to (26).
- the pressure-sensitive adhesive layer, graphite film (GS), protective layer, application layer thickness and surface roughness used in the examples, the distance between the island-shaped protrusions of the concavo-convex structure of the pressure-sensitive adhesive layer, the pitch, the depth and the area of the groove are It was measured by the following measurement method.
- ⁇ Surface roughness of the protective layer surface of the graphite composite film of the graphite film (GS), separator, and heat dissipation component The surface roughness of the protective layer surface of the graphite film (GS), the separator and the graphite composite film of the heat dissipation component was measured using a surface roughness measuring instrument (model number: SE-3500) (main body model number: DR-200X51). The measurement was performed under the following measurement conditions in an environment of room temperature 23 ° C. and humidity 50%.
- the measurement was carried out at 10 locations on the same sample, and the average value was determined for Ra and Rz.
- Evaluation length Arbitrary Arbitrary: 0.8mm Vertical magnification: 2000 Horizontal magnification: 100 Cut off value 0.8mm Feeding speed: 0.5mm / s ⁇ Surface roughness of adhesive layer>
- the surface roughness of the pressure-sensitive adhesive layer was measured by the same method as that for the graphite film (GS) and the separator, except that arbitrary: 8.0 mm.
- ⁇ Thickness> The thickness of the application layer, protective layer, graphite film (GS), adhesive layer, graphite composite film, etc. was measured using a thickness gauge (HEIDENHAIN-CERTO) available from HEIDENHAIN CO., LTD. The center part of the sample before lamination was measured in a% environment. In addition, the thickness of the layer which has an uneven structure measured the maximum thickness of the said center part.
- a thickness gauge HEIDENHAIN-CERTO
- the temperature was adjusted to 550 ° C., 600 ° C., 650 ° C., 700 ° C., 750 ° C., 800 ° C., and 850 ° C. in this order from the film supply side.
- the film was conveyed at a line speed of 50 cm / min while applying tension to the film at a tensile strength of 30 kgf / cm 2 .
- the film was sandwiched from above and below with a graphite jig, and the film was conveyed so as to slide between the jigs.
- the pressure applied in the thickness direction of the film was adjusted to 2 g / cm 2 .
- the carbonized film wound in a roll shape is put into a graphitization furnace so that the TD direction of the carbonized film and the direction of gravity coincide with each other as shown in FIG.
- Heat treatment was performed at a temperature rate.
- the obtained graphitized film was rolled with two rolls having a diameter of 300 mm and a width of 300 mm while applying a force of 3 tons to obtain a graphite film 1 (GS1).
- GS2> A graphite film 2 (GS2) was obtained in the same manner as GS1 except that the temperature raising rate up to 2900 ° C was set to 5 ° C / min.
- GS3> A graphite film 3 (GS3) was obtained in the same manner as GS1 except that the rate of temperature increase up to 2900 ° C was 3 ° C / min.
- GS4> A graphite film 4 (GS4) was obtained in the same manner as GS1 except that the rate of temperature increase up to 2900 ° C was 4 ° C / min.
- GS5> A graphite film 5 (GS5) was obtained in the same manner as GS1 except that the rate of temperature increase to 2900 ° C was 7.5 ° C / min.
- GS6> A graphite film 6 (GS6) was obtained in the same manner as GS1 except that the temperature rising rate up to 2900 ° C was 10 ° C / min.
- GS7> Except that the surface of the roll of the rolling roll has been embossed, and the surface roughness Ra is 1.30 ⁇ m and Rz is 5.0 ⁇ m, a graphite film 7 (GS7) is obtained in the same manner as GS1.
- ⁇ GS8> Polyimide film Apical AH manufactured by Kaneka Corporation with birefringence of 0.12, thickness of 62 ⁇ m, width of 250 mm, and length of 50 m was cut into 250 mm length, and 100 sheets of natural graphite sheets having a thickness of 200 ⁇ m were alternately laminated to 5 g / A graphite weight plate was placed so that a load of cm 2 was applied to the film.
- the polyimide film / graphite sheet laminate on which this weight plate was placed was set in a carbonization furnace and carbonized to a temperature of 1400 ° C. at a rate of 2 ° C./min.
- the carbonized film / graphite sheet laminate on which the carbonized barite plate was placed was put into a graphitization furnace as it was, and graphitized at a temperature increase rate of 5 ° C./min up to 2900 ° C.
- the obtained post-graphitized film was sandwiched between two 125 ⁇ m-thick polyimide films and pressed at a pressure of 10 MPa to obtain graphite film 8 (GS8).
- This laminated body was thermocompression bonded to obtain a graphite laminated body (thickness: 550 ⁇ m) having 15 laminated graphite sheets.
- This graphite laminate was designated as graphite film 11 (GS11).
- An adhesive layer was prepared by the method shown in FIG. Using a gravure coater, an acrylic pressure-sensitive adhesive solution diluted with toluene is formed on a PET substrate having a thickness of 2 ⁇ m and dried to have a thickness of 2 ⁇ m. The silicon-treated surface of the separator was bonded to the side on which the acrylic pressure-sensitive adhesive solution was formed to produce a laminate A. Next, separately using a gravure coater machine, after drying, 1.3 mm ⁇ 1.3 mm square island-shaped protrusions are regularly arranged as shown in FIG.
- the distance between one side of the square of adjacent island-shaped protrusions facing the side is 0.19 mm, and the ratio of the area of the adhesive portion to the total area of the adhesive layer (Table 2)
- the acrylic pressure-sensitive adhesive solution was added to one side of 75 ⁇ m in thickness so that the “area of adhesive part” was 76.1% and the thickness after drying was 2 ⁇ m.
- Dots were printed on the silicon-treated surface of a silicon-treated PET separator (in Table 2, described as “island-like protrusions” as the configuration of the second adhesive layer).
- PSA1-1 is a second adhesive obtained by dot-printing and drying the first adhesive layer, the base material, and the acrylic adhesive solution obtained by forming and drying the acrylic adhesive solution in the laminate A. It is the adhesion layer which the layer laminated
- the plurality of independent island-shaped protrusions that are the concavo-convex structure on the surface of the second adhesive layer have a square lattice shape with a pitch of 1.5 mm, a groove width of 0.19 mm, and a groove depth of 2 ⁇ m. It can also be said that this is a groove.
- PSA1-3 was the same as PSA1-1 except that the gravure roll was adjusted to have 1.3 mm square island-shaped protrusions, an interval between the island-shaped protrusions of 0.50 mm, and an adhesive area of 52.2%. Got.
- PSA1-4 was the same as PSA1-1 except that the gravure roll was adjusted to have a 2.25 mm square island-shaped protrusion, an interval between the island-shaped protrusions of 0.88 mm, and an adhesive area of 85.0%. Got.
- PSA1-5 was the same as PSA1-1 except that the gravure roll was adjusted to have a 3.5 mm square island-shaped protrusion, an interval between the island-shaped protrusions of 0.19 mm, and an adhesive area of 90.0%. Got.
- PSA1-6 was the same as PSA1-1 except that the gravure roll was adjusted to have 0.7 mm square island-shaped protrusions, an interval between the island-shaped protrusions of 0.1 mm, and an adhesive area of 76.6%. Got.
- PSA1-7 was the same as PSA1-1 except that the gravure roll was adjusted to have 0.07 mm square island-shaped projections, an interval between island-shaped projections of 0.01 mm, and an adhesive area of 76.6%. Got.
- An adhesive layer was prepared by the method shown in FIG. Using a gravure coater, an acrylic pressure-sensitive adhesive solution diluted with toluene is formed on a PET substrate having a thickness of 2 ⁇ m and dried to have a thickness of 2 ⁇ m. The silicon-treated surface of the separator was bonded to the side on which the acrylic pressure-sensitive adhesive solution was formed to produce a laminate A.
- the formed acrylic pressure-sensitive adhesive solution After drying the formed acrylic pressure-sensitive adhesive solution, it is laminated with the previously prepared laminated product A so that the surface on which the acrylic pressure-sensitive adhesive solution is formed contacts the base material of the laminated product A, and PSA2-1 Got. Thereafter, the embossed PET separator is peeled off, and the exposed surface of the layer obtained by forming an acrylic pressure-sensitive adhesive solution and drying it is transferred to the surface to which the shape of the embossed surface has been transferred. The silicon-treated surface of the flat PET separator was bonded. PSA2-1 is obtained by forming a film of an acrylic pressure-sensitive adhesive solution in laminate A and drying the first pressure-sensitive adhesive layer, base material, and acrylic pressure-sensitive adhesive solution obtained on an embossed PET separator. The second adhesive layer is an adhesive layer laminated in order, and both surfaces are obtained in a state of being covered with a PET separator.
- PSA2-2 was obtained in the same manner as PSA2-1 except that an embossed PET separator (thickness 75 ⁇ m) subjected to embossing with a pitch of 0.2 ⁇ 0.3 mm and an average peak height of 0.3 ⁇ m was used.
- PSA2-3 was obtained in the same manner as PSA2-1, except that an embossed PET separator (thickness 75 ⁇ m) that had been embossed with a pitch of 0.2 ⁇ 0.3 mm and an average peak height of 0.5 ⁇ m was used.
- PSA2-4 was obtained in the same manner as PSA2-1 except that an embossed PET separator (thickness 75 ⁇ m) subjected to embossing with a pitch of 0.1 ⁇ 0.1 mm and an average peak height of 1.0 ⁇ m was used.
- PSA2-5 was obtained in the same manner as PSA2-1 except that an embossed PET separator (thickness 75 ⁇ m) subjected to embossing with a pitch of 2.0 ⁇ 2.0 mm and an average peak height of 1.0 ⁇ m was used.
- PSA2-6> An acrylic adhesive solution diluted with toluene to a thickness of 8 ⁇ m was formed on a PET substrate having a thickness of 4 ⁇ m, and an acrylic adhesive solution was formed to an thickness of 8 ⁇ m on an embossed PET separator. Except for this, PSA2-6 was obtained in the same manner as PSA2-1.
- Neofix 5S2 is a double-sided tape having a total thickness of 5 ⁇ m that is available from Nichiei Kako Co., Ltd. When the surface roughness of the second pressure-sensitive adhesive layer was measured, it was a pressure-sensitive adhesive having a Ra of 0.10 ⁇ m and a Rz of 1.20 ⁇ m and little unevenness.
- PSA3-1 An adhesive layer was prepared by the method shown in FIG. One separator of Neofix 5S2 available from NEIEI KAKO Co., Ltd. is peeled off, and an embossed PET separator having a thickness of 75 ⁇ m, surface roughness Ra of 0.55 ⁇ m, and Rz of 3.41 ⁇ m is newly applied to the adhesive surface. PSA3-1 was obtained by laminating so that the surfaces having roughness were in contact (in Table 2, described as “embossed separator” as the configuration of the second adhesive layer).
- PSA3-1 is a pressure-sensitive adhesive layer in which a first pressure-sensitive adhesive layer in contact with the non-peeled separator of Neofix 5S2, a base material, and a second pressure-sensitive adhesive layer of Neofix 5S2 laminated with an embossed PET separator are laminated in order. The surface of is obtained in a state covered with a PET separator.
- PSA3-2 was obtained in the same manner as PSA3-1 except that an embossed PET separator having a surface roughness Ra of 0.06 ⁇ m and Rz of 0.30 ⁇ m was used.
- PSA3-3 was obtained in the same manner as PSA3-1 except that an embossed PET separator having a surface roughness Ra of 0.30 ⁇ m and Rz of 2.90 ⁇ m was used.
- PSA3-4 was obtained in the same manner as PSA3-1 except that an embossed PET separator having a surface roughness Ra of 0.70 ⁇ m and Rz of 5.10 ⁇ m was used.
- PSA3-5 was obtained in the same manner as PSA3-1 except that an embossed PET separator having a surface roughness of Ra1.00 ⁇ m and Rz10.00 ⁇ m was used.
- the pressure-sensitive adhesive mainly composed of an acrylic polymer is formed into a round granular shape having an outer diameter of 0.5 mm, and the upper surface of the pressure-sensitive adhesive is flattened at intervals of 0.25 mm and a graphite film 1 (GS1 having a thickness of 32 ⁇ m). ) was printed by pressing with a squeegee so as to have a thickness of 6 ⁇ m (described as “spot-like” as the configuration of the second adhesive layer in Table 3).
- Each granular pressure-sensitive adhesive constitutes a pressure-sensitive adhesive portion.
- the “interval of 0.25 mm” refers to an interval between adjacent round adhesive parts (in Table 3, “interval between adhesive parts”).
- the ratio of the area of the adhesive part in PSA4 to the area of the entire adhesive layer was 34.9%.
- PSA4 refers to the part of the adhesive material formed on the resulting graphite film.
- normal PSA means a pressure-sensitive adhesive having a three-layer structure including a first pressure-sensitive adhesive layer and a second pressure-sensitive adhesive layer that do not have an uneven structure.
- Tables 2 to 3 also show the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film (in Tables 2 to 3, “the ratio of the area covered with the adhesive ( %) ").
- the graphite composite film has a size of 100 mm x 120 mm, and the adhesive layer / graphite film (GS) / protective layer / application layer, both surfaces of which are covered with a PET separator, are layered in this order from the adhesive layer.
- GS graphite film
- protective layer / application layer both surfaces of which are covered with a PET separator
- it was manufactured by laminating so that no air was involved.
- the PET separator on the first adhesive layer side of the adhesive layer was peeled off, and the adhesive layer and the graphite film were laminated so that the exposed adhesive surface of the first adhesive layer was in contact with the graphite film. That is, lamination was performed so that the second adhesive layer was disposed on the surface opposite to the surface in contact with the graphite film.
- a protective layer and an application layer were laminated in this order on the surface of the graphite film opposite to the surface in contact with the adhesive layer to obtain a laminated product.
- the obtained laminates were respectively sized according to Tables 4 to 5 (Examples 1 to 28 and Comparative Example 1: 70 mm ⁇ 90 mm; Examples 29, 32 and 34 to 36: 50 mm ⁇ 50 mm, Example 30, 31 and 33: 15 mm ⁇ 40 mm) to obtain a graphite composite film.
- a pressure-sensitive adhesive mainly composed of an acrylic polymer is formed into a round granular shape having an outer diameter of 0.5 mm, and the pressure-sensitive adhesive has a flat top surface.
- the graphite film has a spacing of 0.25 mm and a thickness of 32 ⁇ m.
- a graphite composite film was prepared in the same manner as in Example 1 except that the film was printed by pressurizing with a squeegee so as to have a thickness of 6 ⁇ m, and then a 75 ⁇ m PET separator was bonded.
- Comparative Example 3 the pressure-sensitive adhesive mainly composed of an acrylic polymer has a round granular shape with an outer diameter of 0.5 mm, and the pressure-sensitive adhesive has a flat top surface.
- the graphite film has a spacing of 1.5 mm and a thickness of 32 ⁇ m.
- a graphite composite film was prepared in the same manner as in Example 1 except that the film was printed by pressurizing with a squeegee so as to have a thickness of 6 ⁇ m, and then a 75 ⁇ m PET separator was bonded.
- Example 2 A graphite composite film was produced in the same manner as in Example 29 except that the size was cut to 15 mm ⁇ 15 mm.
- the peel strength was determined according to “Testing method of adhesive strength by peeling 180 degrees against test plate” in Method 1 described in JIS-Z0237.
- An SUS plate described in JIS-Z0237 having a width of 50 mm, a length of 125 mm, a thickness of 1.1 mm, and a surface roughness Ra of 50 nm was washed with methanol.
- Substrate SUS plate of size 80mm x 100mm, thickness 0.2mm (washed with methanol) Environment: Environment temperature 23 ° C., humidity 50% Number of measurements: N10 (N10 times of the following evaluations are adopted as the result) Procedure: The PET composite film separator was peeled off. On the flat base, the graphite composite film was held with the adhesive surface of the exposed second adhesive layer facing up. The adherend was placed on the adhesive surface of the graphite composite film so that the surface to which the adherend was attached was in contact at a stretch, and a weight of 5 kg (size: 80 mm ⁇ 100 mm) was placed thereon and held for 10 seconds.
- the air was removed from the adherend by three reciprocations with a rubber roller having a weight of 10 kg. Thereafter, remaining air pockets were counted and evaluated according to the following criteria. In addition, since air pockets appear as bumps on the adherend surface, the size and presence of the air pockets are apparently raised, and the maximum length of the maximum air pocket is measured. The longest distance measured)), and the measurement length can be evaluated according to the following criteria.
- FIG. 8 shows an apparatus configuration diagram of the heat dissipation test of the graphite composite film.
- the graphite composite film PET separator was peeled off, and using a laminator, the SUS plate 33 and the graphite film 35 having a size of 80 mm ⁇ 100 mm and a thickness of 0.2 mm were combined with the SUS plate and the exposed adhesive layer 34. Lamination was performed so that the adhesive surface was in contact with the surface at once.
- the application layer is also peeled off, and then a ceramic heater (a black body spray with an emissivity of 0.94 is applied to the heater surface) as a heat generating component 37 of 10 mm ⁇ 10 mm ⁇ 1 mm is applied from the protective layer 36 side.
- the heat dissipation test was carried out by installing a windshield around the environment so that the temperature did not change by convection under the conditions of an environmental temperature of 23 ° C. and a humidity of 50%. The temperature was measured by measuring the temperature on the heater using a thermo viewer. The measurement was carried out N5 times, and the average value of the five measurements was taken as the measurement value, and the following evaluation was made.
- ⁇ Cost of adhesive layer The cost of the adhesive layer was evaluated by the cost per unit area obtained by dividing the material cost of the adhesive layer required for producing one piece of the graphite composite film by the area (cm 2 ) of the graphite composite film. As a standard, the cost of the adhesive layer per unit area of the conventional graphite composite film of Comparative Example 1 was normalized to 1, and the costs of other Examples, Comparative Examples, and Reference Examples were calculated.
- the adhesion stability was evaluated according to the following criteria. The measurement was carried out three times, and the largest number of the following evaluations was adopted as a result.
- Graphite composite film of the present invention (Examples 19 to 25) having an adhesive layer provided with a concavo-convex structure by the method to be disclosed, a method of laminating an adhesive layer having a concavo-convex structure and a graphite film, and a graphite having a concavo-convex structure on the surface
- the size of the graphite composite film is smaller than the result of Reference Example 1 in which a graphite composite film was prepared in the same manner as Comparative Example 1 except that the size was 40 mm ⁇ 60 mm, the adherend and graphite were It turns out that the problem of bubble generation between the composite films does not occur in the first place.
- the graphite composite film of the present invention functions effectively for the problem of bubble generation, particularly when the size of the graphite composite film is 25 cm 2 or more.
- the graphite composite films obtained in Examples 1, 3, 4, and 6 are particularly excellent in that both the bubble evaluation and the heat dissipation test are high. From these results, the ratio of the area of the adhesive part to the area of the entire adhesive layer is 50% or more and 85% or less, the “interval between island-shaped protrusions” is 0.1 mm or more, or It can be seen that the groove pitch of 0.1 mm or more is more preferable for achieving both higher heat dissipation and a large reduction in bubble generation.
- the graphite composite films obtained in Examples 8 and 10 are particularly excellent in that both the bubble evaluation and the evaluation of the heat dissipation test are high. From these results, it is confirmed that the groove depth is 0.5 ⁇ m or more, the groove pitch is 0.15 ⁇ m or more, or the thickness of the adhesive layer is 10 ⁇ m or less. It can be seen that it is more preferable in order to achieve both large reductions.
- the graphite composite films obtained in Examples 14, 16, and 17 are particularly excellent in that both the bubble evaluation and the heat dissipation test are high.
- the surface roughness of the surface having the concavo-convex structure of the separator used for transferring the concavo-convex structure to the adhesive layer is Ra 0.30 ⁇ m to 0.70 ⁇ m and Rz 2.90 ⁇ m to 5.10 ⁇ m. It is understood that this is more preferable for achieving both higher heat dissipation and a large reduction in bubble generation.
- the graphite composite films obtained in Examples 19, 21, and 22 are particularly excellent in that the bubble evaluation and the evaluation of the heat dissipation test are both high.
- the surface roughness of the surface having the concavo-convex structure of the graphite film used for forming the concavo-convex structure on the surface of the adhesive layer by causing the concavo-convex structure of the graphite film to appear on the surface of the adhesive layer is Ra 0.80 ⁇ m. It can be seen that it is more preferably 1.30 ⁇ m or less and Rz 3.20 ⁇ m or more and 4.70 ⁇ m or less in order to achieve both higher heat dissipation and a large reduction in bubble generation.
- Examples 29 to 33 and 36 have an adhesive layer provided with a concavo-convex structure by a method of forming an adhesive solution on a separator having a concavo-convex structure on the surface and transferring the concavo-convex structure, as in Examples 8 to 13. It is a graphite composite film of the present invention.
- Examples 29 to 33 differ from Examples 8 to 13 in which a graphite film composed of a single layer graphite sheet is used in that a graphite laminate is used as the graphite film. In comparison with a graphite film composed of a single-layer graphite sheet having a smaller thickness, a graphite film using a graphite laminate often has a thickness of 90 ⁇ m or more.
- Example 36 is the same as a graphite film in terms of a single layer, but in the point that a graphite film having a thickness of 90 ⁇ m or more is used, a graphite film having a smaller thickness is used. 13 and different.
- the thickness of the graphite film is 90 ⁇ m or more, the stiffness of the graphite film is particularly strong, the followability to the adherend to be bonded is deteriorated, and bubbles are formed between the graphite film and the adherend. There is a problem that it becomes easy to enter. However, it was shown that the generation of bubbles can be suppressed by using the adhesive layer of the present invention.
- Example 34 is a graphite composite film of the present invention having an adhesive layer provided with an uneven structure by a method of applying or printing an adhesive solution as in Examples 1 to 7.
- Example 34 is different from Examples 1 to 7 in which a graphite film made of a single-layer graphite sheet is used in that a graphite laminate is used as the graphite film. Also in Example 34, it is shown that the generation of bubbles can be suppressed, and the same results as in Examples 29 to 33 and 36 can be said.
- Example 35 similarly to Examples 14 to 18, an adhesive layer provided with a concavo-convex structure by a method of transferring the concavo-convex structure by bringing the surface having the concavo-convex structure of a separator having a concavo-convex structure into contact with the adhesive layer
- the graphite composite film of the present invention is different from Examples 14 to 18 in which a graphite film made of a single-layer graphite sheet is used in that a graphite laminate is used as the graphite film. Also in Example 35, it is shown that the generation of bubbles can be suppressed, and the same result as in Examples 29 to 33 and 36 can be said.
- the volume of the graphite film is 50 mm 3 or more
- the stiffness of the graphite film becomes stronger
- the followability to the adherend to be bonded becomes worse
- a graphite film using a graphite laminate in which the number of graphite sheets laminated is two or more
- the problems can be solved in Examples 1 to 35 in which the volume of the graphite film is 50 mm 3 or more by using the adhesive layer of the present invention.
- the volume tends to increase, so that it is particularly effective to use the adhesive layer of the present invention.
- the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 100%.
- Examples 8 to 25 27-33, 35, and 36 show that the adhesion stability of the graphite composite film to the adherend is superior.
- Examples 1 to 7 in which the ratio of the area of the graphite film covered with the adhesive to the total area of the graphite film is 35% or more and less than 100%, the ratio is less than 35%. Compared to Examples 2 and 3, it was shown that adhesion stability was superior.
- Example 37 A heat radiating component was prepared using the graphite composite film obtained in Example 1. Specifically, the PET separator of the graphite composite film is peeled off, and using a laminator, an SUS plate having a size of 70 mm ⁇ 100 mm and a thickness of 0.2 mm and the graphite composite film are bonded to the SUS plate and the adhesive surface of the exposed adhesive layer. The heat-radiating parts were manufactured by pasting them together so that they touched at once. At this time, a protective layer and an application layer are laminated on the surface of the graphite film opposite to the surface in contact with the SUS plate of the composite graphite film.
- FIG. 10 shows the result of peeling the application layer from the obtained heat dissipation component and observing it from the protective layer side. As shown in FIG. 10, it was confirmed that a concavo-convex structure due to the concavo-convex structure of the adhesive layer appeared on the surface of the graphite film on the side opposite to the surface in contact with the SUS plate of the heat dissipation component.
- Example 38 A heat radiating part was prepared using the graphite composite film obtained in Example 29. Specifically, the PET separator of the graphite composite film is peeled off, and using a laminator, an SUS plate having a size of 70 mm ⁇ 100 mm and a thickness of 0.2 mm and the graphite composite film are bonded to the SUS plate and the adhesive surface of the exposed adhesive layer. The heat-radiating parts were manufactured by pasting them together so that they touched at once. At this time, a protective layer and an application layer are laminated on the surface of the graphite film opposite to the surface in contact with the SUS plate of the composite graphite film.
- the heat dissipation component was cut in a direction perpendicular to the surface of the graphite composite film, and the cut surface was observed. On the cut surface, it was observed that the adhesive layer existing between the SUS plate and the graphite film of the heat dissipation component had an uneven structure on the SUS side.
- the graphite composite film according to the present invention it is possible to reduce the generation of bubbles between the adherend and the graphite composite film when bonded to the adherend without impairing heat dissipation.
- the graphite composite film according to the present invention can be suitably used in the fields of electronic equipment, precision equipment and the like as heat radiating parts such as heat radiating films and heat spreader materials.
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Abstract
Description
上述したように、粘着剤が全面に塗布されている一般的なグラファイト複合フィルムは、グラファイト複合フィルムと被着体(発熱部品)との密着性が良いので放熱性に優れるが、発熱部品に接合させたときに、空気を巻き込み被着体とグラファイト複合フィルムとの間に気泡が発生するという問題がある。気泡発生の問題を解決する方法としては、被着体とグラファイト複合フィルムの密着頻度や密着性を落とす方法が考えられる。かかる方法としては、具体的には、点状の粘着剤を使用したり、粘着力(ピール強度)の弱い粘着剤を使用したりする方法などが考えられるが、これらの方法では、グラファイト複合フィルムの主目的である放熱性を犠牲にしてしまうこととなる。そこで、本発明者らは、放熱性を損なうことなく空気の噛みこみを抑制できるグラファイト複合フィルムを実現すべく鋭意検討した結果、グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層が前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有するグラファイト複合フィルムによれば、放熱性を損なうことなく空気の噛みこみを抑制できることを見出し本発明を完成させるに至った。即ち、本発明に係るグラファイト複合フィルムは、グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層は、前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有するものである。
粘着層とは、グラファイトフィルム上に積層され、被着体とグラファイト結合フィルムとを接合する層である。本発明に係るグラファイト複合フィルムは、粘着剤により覆われているグラファイトフィルムの面積が、グラファイトフィルムの全面積の35%以上100%以下であり、粘着層は、グラファイトフィルムと接した面と反対側の表面に凹凸構造を有していればよい。これにより、グラファイト複合フィルムの放熱性を損なうことなく、被着体に貼り合わせた際の被着体とグラファイト複合フィルムとの間の気泡発生を低減することができる。本発明の効果について、本発明者らは次のように推測している。まず、グラファイト複合フィルムにおいて、被着体と接する粘着層の表面に凹凸構造が形成されている場合、グラファイト複合フィルムと被着体とを貼り合せた際に両者の間に気泡が生じたとしても、当該凹凸構造によって生じる微細な間隙により、容易に気泡を除去することができる(いわゆる“エア抜け”の容易性)。そして、本発明に係るグラファイト複合フィルムでは、グラファイトフィルムの全面積の35%~100%が粘着剤で覆われているので、凹凸構造によって微細な間隙が生じて気泡が除去された後に、微細な間隙が生じていた部分の少なくとも一部においても存在する粘着剤によりグラファイト複合フィルムが被着体に接合されると考えられる。そのため、グラファイト複合フィルムと被着体(例えば、SUSの筐体、プラスチックの筐体など)との密着性が良いことから、グラファイト複合フィルムから被着体への熱移動がスムーズであるので、放熱性を損なうことがない。
本発明において、凹凸構造を有しているとは、平坦でなく凹凸を有していればよく、その他の構成は特に限定されない。例えば、前記粘着層の凹凸構造を有する表面の表面粗さは、Ra0.19μm以上10μm以下、且つ、Rz1.6μm以上100μm以下であることがより好ましく、Ra0.19μm以上1.0μm以下、且つ、Rz1.6μm以上10.0μm以下であることがさらに好ましく、Ra0.35μm以上0.70μm以下、且つ、Rz2.5μm以上6.0μm以下であることが特に好ましい。或いは、前記粘着層の凹凸構造を有する表面の表面粗さは、Raが好ましくは0.19μm以上10μm以下であり、より好ましくは0.19μm以上1.0μm以下であり、さらに好ましくは0.35μm以上0.70μm以下である。また、前記粘着層の凹凸構造を有する表面の表面粗さは、Rzがより好ましくは1.6μm以上100μm以下であり、さらに好ましくは1.6μm以上10.0μm以下であり、特に好ましくはRz2.5μm以上6.0μm以下である。前記凹凸構造を有する表面の表面粗さが前記範囲内であれば、グラファイト複合フィルムの放熱性を損なうことなく、被着体に貼り合わせた際の被着体とグラファイト複合フィルムとの間の気泡発生を低減することができるため好ましい。なお、ここで、表面粗さとは、実施例に記載の測定方法によって測定された値を言う。
図1に前記凹凸構造の具体例を示す。図1中(a)は、独立した複数の島状突起を上から見た平面図である。図中、ハッチング部分が島状突起である。ここで、島状突起の形状は、図では円形であるが、円形に限定されるものではなくどのような形状であってもよく、例えば、楕円形、多角形、棒状、帯状、不定形等であってもよい。多角形には、三角形、正方形・長方形・ひし形等の四角形、五角形、六角形等が含まれる。
図1中(b)は、格子状の溝を上から見た平面図である。図中、ハッチングされていない部分が格子状の溝である。ここで、格子状の溝は、図では正方形格子であるが、正方形格子に限定されるものではなくどのような格子であってもよく、例えば、三角形格子、長方形格子、ひし形格子、多角形格子等であってもよいし、複数種類の格子を含むものであってもよい。また、溝は直線の溝に限定されるものではなく曲線の溝であってもよい。
図1中(c)は、縞状の溝を上から見た平面図である。なお、本発明において、縞状とは、図1の(c)に示すように、筋状の縞をいい、格子縞を除く趣旨である。図中、ハッチングされていない部分が縞状の溝である。ここで、縞状の溝は、図では直線の溝であるが、溝の形状はこれに限定されるものではなく、曲線の溝であってもよい。また、図では、溝と溝との間隔は一定であるが、必ずしも一定でなくてもよい。
前記粘着層の厚みは、好ましくは1.00μm以上20.00μm以下であり、より好ましくは2.00μm以上10.00μm以下であり、更に好ましくは、3.00μm以上7.00μm以下である。前記粘着層の厚みが1.00μm以上であれば被着体との接続が十分に行えるため好ましい。また、前記粘着層の厚みが20.00μm以下であればグラファイトフィルムで拡散した熱を、粘着剤を介して被着体に伝える場合の熱抵抗を抑制できる観点で好ましい。なお、ここで、「粘着層の厚み」とは、被着体と貼り合わせるための粘着剤を含む層の厚みを意味する。したがって、粘着層が多層構造である場合は、「粘着層の厚み」とは、粘着層の前記グラファイトフィルムと接した面と反対側の被着体と貼り合わせるための粘着剤を含む層、即ち最外層の厚みを指す。例えば、粘着層が後述するように三層構造を有する場合は、粘着層の厚みとは、後述する第2粘着層の厚みを指す。
前記粘着層は、粘着剤により覆われているグラファイトフィルムの面積が、グラファイトフィルムの全面積の35%以上100%以下であり、グラファイトフィルムと接した面と反対側の表面に凹凸構造を有していればその構成は特に限定されるものではなく単層構造であっても多層構造であってもよい。前記粘着層は、第1粘着層、基材、及び第2粘着層を含む三層構造を有することがより好ましい。前記粘着層が基材を含むことにより、グラファイト複合フィルムのコシが増える。またグラファイトフィルムの破断を抑制できるため、一度取り付けたグラファイトフィルムを再剥離する際に、グラファイトフィルムが層間剥離する事を抑制することができる。それゆえ、一旦グラファイトフィルムを剥がし再度貼りつける作業を容易に行うことができる。
本発明に用いられるグラファイトフィルムは、放熱部品として用いることができるグラファイトフィルムであれば特に限定されるものではない。
本発明に係るグラファイト複合フィルムは、上記グラファイトフィルムと粘着層とを有していればよいが、さらに、セパレーター、保護層、アプリケーション層等を有していてもよい。
セパレーターは、基材フィルムに離形材が形成されたシートであり、粘着層の粘着面に積層される。セパレーターは、通常粘着層の粘着面をグラファイト複合フィルムの使用時までカバーすることを目的とするものであり、グラファイト複合フィルムの使用時に剥離される。なお、本発明では、グラファイト複合フィルムの製造工程において、セパレーターを、凹凸構造を粘着層に転写するための型としても用いる場合がある。このような型として用いられるセパレーターは、転写後剥離して、新たに平坦なセパレーターが積層される。しかし、型として用いられるセパレーターを剥離せず、そのまま、グラファイト複合フィルムの使用時まで、粘着面をカバーするために使用することもできる。
保護層は、グラファイトフィルムの粘着層と接する面と反対側の面に積層され、グラファイトフィルムを保護する目的、電気絶縁性を付与する目的、黒鉛粉の発生を抑制する目的、グラファイトフィルムを補強する目的等で用いられる。
アプリケーション層は、基材フィルムに再剥離が可能な程度の微粘着材が形成されているシートであり、例えば、前記保護層のグラファイトフィルムと接する側と反対の面に積層され、グラファイト複合フィルムの使用時に剥離される。
本発明に係るグラファイト複合フィルムは、SUSとのピール強度が好ましくは4.0N/25mm以上12.0N/25mm以下であり、より好ましくは5.0N/25mm以上8.0N/25mm以下、更に好ましくは6.0N/25mm以上7.0N/25mm以下である。ここで、ピール強度とは、実施例において記載する方法により測定した値をいう。グラファイト複合フィルムとSUSとのピール強度が4.0N/25mm以上であれば、被着体との密着性が高く、グラファイトフィルムで拡散した熱を被着体に伝えやすいため好ましい。また、前記ピール強度が12.0N/25mm以下であれば、被着体への貼り合わせの際に、被着体とグラファイト複合フィルムの間で空気を噛みにくい点で好ましい。
本発明に係るグラファイト複合フィルムの製造方法は、上述した本発明に係るグラファイト複合フィルムを製造できる方法であれば特に限定されるものではない。例えば、大きく分けて、凹凸構造を有する粘着層とグラファイトフィルムとを積層する方法(製造方法1)と、表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成してグラファイトフィルムの当該凹凸構造を粘着層表面に出現させる方法(製造方法2)等を挙げることができる。
本実施形態に係るグラファイト複合フィルムの製造方法は、少なくとも片面に凹凸構造を有する粘着層の、当該凹凸構造が、グラファイトフィルムと接した面と反対側に配置されるように、当該粘着層と当該グラファイトフィルムとを積層する工程を含んでいる。
少なくとも片面に凹凸構造を設けた粘着層は、粘着剤溶液を所望の凹凸構造となるように塗布又は印刷する方法により作製することができる。所望の凹凸構造となるように塗布又は印刷する方法としては、公知の方法を適宜選択して用いることができ、特に限定されるものではない。
或いは、少なくとも片面に凹凸構造を設けた粘着層は、所望の凹凸構造と相補的関係にある凹凸構造を有するセパレーターの前記凹凸構造を粘着層の表面に転写する方法により作製することができる。かかる方法によれば、グラファイトフィルムの粘着層表面に、容易に凹凸構造を形成することができる。
表面に凹凸構造を有するセパレーターの当該表面に粘着剤溶液を製膜して凹凸構造を転写する方法としては、公知の方法を適宜選択して用いることができ、特に限定されるものではない。
以下に、表面に凹凸構造を有するセパレーターの前記凹凸構造を有する面を粘着層に接触させて凹凸構造を転写する方法について説明する。なお、ここで、セパレーターを接触させる粘着層は乾燥後の粘着層を意味し、乾燥後の粘着層とは、溶媒残存率が5重量%以下の粘着層をいう。溶媒残存率は、粘着剤部のみをオーブンなどで溶剤の沸点以上の温度で、十分に乾燥させ、その前後の重量を測定し、以下の計算式で測定することができる。
溶媒残存率(%)=(乾燥前の重量-乾燥後の重量)/乾燥前の重量×100
表面に凹凸構造を有するセパレーターの前記凹凸構造を有する面を粘着層に接触させて、凹凸構造を転写する方法としては、公知の方法を適宜選択して用いることができ、特に限定されるものではないが、例えば、表面に凹凸構造を有するセパレーターを粘着層にラミネートする方法等を挙げることができる。かかる方法によれば、セパレーターの仕様を変更するのみで、従来の設備や製品を利用して少なくとも片面に凹凸構造を有する粘着層を作製することができる。
本実施形態に係るグラファイト複合フィルムの製造方法は、表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成して、グラファイトフィルムの当該凹凸構造を当該粘着層表面に出現させることによって、当該粘着層の表面に凹凸構造を形成する。
本発明に係るグラファイト複合フィルムは、放熱性を損なうことなく、被着体に貼り合わせた際の被着体とグラファイト複合フィルムとの間の気泡発生を低減させることができるので、放熱部品に好適に利用することができる。したがって、本発明にかかるグラファイト複合フィルムを含む放熱部品も本発明に含まれる。
(1)グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層は、前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有するものであることを特徴とするグラファイト複合フィルム。
(2)前記粘着層の凹凸構造を有する表面の表面粗さが、Ra0.19μm以上10μm以下であることを特徴とする(1)に記載のグラファイト複合フィルム。
(3)前記粘着層の凹凸構造を有する表面の表面粗さが、Rz1.6μm以上100μm以下であることを特徴とする(1)又は(2)に記載のグラファイト複合フィルム。
(4)前記粘着層の厚みが1.00μm以上20.00μm以下であることを特徴とする(1)から(3)のいずれかに記載のグラファイト複合フィルム。
(5)前記粘着層の表面の凹凸構造は、格子状又は縞状の溝、或いは、独立した複数の島状突起であることを特徴とする(1)から(4)のいずれか1項に記載のグラファイト複合フィルム。
(6)前記格子状又は縞状の溝のピッチが0.05mm以上2.0mm以下であることを特徴とする(5)に記載のグラファイト複合フィルム。
(7)前記粘着層は、第1粘着層、基材、及び第2粘着層を含むものであり、前記粘着層は、前記グラファイトフィルム上に、前記グラファイトフィルム側から、前記第1粘着層、前記基材、前記第2粘着層の順に積層されており、前記グラファイトフィルムの全面積に対する、第2粘着層の粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層は、前記第2粘着層の基材と接した面と反対側の表面に前記凹凸構造を有するものであることを特徴とする(1)から(6)の何れか1項に記載のグラファイト複合フィルム。
(8)前記第2粘着層は、前記基材上に配置された複数の粘着部であり、
前記粘着層の表面の凹凸構造は、凸部が前記粘着部からなり、凹部には接着剤が存在せず前記基材が露出していることを特徴とする(7)に記載のグラファイト複合フィルム。
(9)前記粘着部の面積の粘着層全体の面積に占める割合が35%以上であることを特徴とする(8)に記載のグラファイト複合フィルム。
(10)前記粘着部が、規則的に配置された、多角形、棒状、帯状の島状突起である場合、島状突起の一辺と、当該辺と向かい合う隣接する島状突起の一辺との間の間隔は、0.01mm以上であることを特徴とする(8)又は(9)に記載のグラファイト複合フィルム。
(11)前記グラファイト複合フィルムとSUSとのピール強度が4.0N/25mm以上12.0N/25mm以下であることを特徴とする請求項1から10のいずれか1項に記載のグラファイト複合フィルム。
(12)前記グラファイト複合フィルムの面積が3cm2以上であることを特徴とする(1)から(11)のいずれかに記載のグラファイト複合フィルム。
(13)前記グラファイトフィルムの厚みが90μm以上であることを特徴とする(1)から(12)のいずれかに記載のグラファイト複合フィルム。
(14)前記グラファイトフィルムは、グラファイトシートと接着層とが交互に積層されてなるグラファイト積層体であって、前記グラファイト積層体に含まれる前記グラファイトシートの積層数は3層以上であることを特徴とする(1)から(13)のいずれかに記載のグラファイト複合フィルム。
(15)前記グラファイトフィルムの体積は、50mm3以上であることを特徴とする(1)から(14)のいずれか1項に記載のグラファイト複合フィルム。
(16)グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であるとともに、少なくとも片面に凹凸構造を有する粘着層の、当該凹凸構造が、グラファイトフィルムと接した面と反対側に配置されるように、当該粘着層と当該グラファイトフィルムとを積層する工程を含むことを特徴とするグラファイト複合フィルムの製造方法。
(17)グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、表面に凹凸構造を有するセパレーターの前記凹凸構造を前記粘着層の表面に転写することによって、少なくとも片面に凹凸構造を設けた粘着層を作製する工程と、少なくとも片面に凹凸構造を有する粘着層の、当該凹凸構造が、グラファイトフィルムと接した面と反対側に配置されるように、当該粘着層と当該グラファイトフィルムとを積層する工程とを含むことを特徴とするグラファイト複合フィルムの製造方法。
(18)前記セパレーターの凹凸構造を有する表面の粗さがRa0.06μm以上1.00μm以下、且つ、Rz0.3μm以上10.0μm以下であることを特徴とする(17)に記載のグラファイト複合フィルムの製造方法。
(19)前記セパレーターの凹凸構造を有する表面に粘着剤溶液を製膜して、凹凸構造を転写することを特徴とする(17)又は(18)に記載のグラファイト複合フィルムの製造方法。
(20)前記セパレーターを、溶媒残存率5%以下の前記粘着層に接触させて、前記粘着層の表面に前記凹凸構造を転写することを特徴とする(17)又は(18)に記載のグラファイト複合フィルムの製造方法。
(21)グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、
表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成して、グラファイトフィルムの当該凹凸構造を当該粘着層表面に出現させることによって、当該粘着層の表面に凹凸構造を形成することを特徴とするグラファイト複合フィルムの製造方法。
(22)前記グラファイトフィルムの凹凸構造を有する表面の表面粗さがRa0.55μm以上1.70μm以下、且つ、Rz2.3μm以上6.00μm以下であることを特徴とする(21)に記載のグラファイト複合フィルムの製造方法。
(23)前記グラファイトフィルムの厚みが5μm以上120μm以下であることを特徴とする(21)又は(22)に記載のグラファイト複合フィルムの製造方法。
(24)前記粘着層の凹凸構造を有する表面の表面粗さがRa0.8μm以下、Rz4.5μm以下であることを特徴とする請求項(21)から(23)のいずれかに記載のグラファイト複合フィルムの製造方法。
(25)グラファイト複合フィルムを含む放熱部品であって、前記グラファイト複合フィルムは、グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層は、前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有することを特徴とする放熱部品。
(26)前記グラファイト複合フィルムを被着体に貼り合わせてなることを特徴とする(25)に記載の放熱部品。
(27)前記グラファイト複合フィルムの前記被着体と接した面と反対側の表面に保護層が積層されており、当該保護層の表面の表面粗さが、Ra0.15μm以上10μm以下、且つ、Rz1.0μm以上100μm以下であることを特徴とする(26)に記載の放熱部品。
第2粘着層の凹凸構造の島状突起相互間の間隔、ピッチ、溝の深さ及び面積は、株式会社ミツトヨから入手できるクイックスコープ(型番:QS-L1020Z/AF)を用いて測定した。画像が観察可能な条件を調整して計測を行った。PSA1-1~PSA1-7は、倍率:0.50、照明:落射0、透過0、リング50の条件で画像を観察し、島状突起相互間の間隔及び面積を計測した。また、PSA2-1~PSA2-6は、倍率:0.50、照明:落射20、透過0、リング0で画像を観察しピッチ、溝の深さ及び面積を計測した。他の粘着層についても、画像が観察可能な条件を調整して計測を行った。
グラファイトフィルム(GS)、セパレーター及び放熱部品のグラファイト複合フィルムの保護層表面の表面粗さの測定は、表面粗さ測定器(型番:SE-3500)(本体型番:DR-200X51)を用いて、室温23℃湿度50%の環境下、以下の測定条件で実施した。
任意:0.8mm
縦倍率:2000
横倍率:100
カットオフ値0.8mm
送り速さ:0.5mm/s
<粘着層の表面粗さ>
粘着層の表面粗さの測定は、任意:8.0mmとしたこと以外は、グラファイトフィルム(GS)及びセパレーターと同様の方法で測定した。
厚みの評価は、アプリケーション層、保護層、グラファイトフィルム(GS)、粘着層、グラファイト複合フィルムなどの厚みをハイデンハイン株式会社から入手可能な厚みゲージ(HEIDENHAIN-CERTO)を用い、室温23℃湿度50%の環境で、ラミネート前のサンプルの中央部を測定した。なお、凹凸構造を有する層の厚みは、前記中央部の最大厚みを測定した。
<GS1>
図2に示すように、複屈折0.15、厚み62μm、幅250mm、長さ50mの株式会社カネカ製ポリイミドフィルム アピカルNPIの巻き物を巻き替え装置にセットし、7つの加熱空間を含む加熱処理装置に連続的に供給しながら連続炭化工程を実施した。各加熱空間のMD方向(Machine Direction:流れ方向)の長さは50cm、TD方向(Transverse Direction:幅方向)の長さは300mmとし、各加熱空間内の温度を、各加熱空間内で均一になるように、フィルムの供給側から順にそれぞれ550℃、600℃、650℃、700℃、750℃、800℃、850℃に調整した。フィルムに対して引張り強さ30kgf/cm2で張力を加えながら、50cm/minのライン速度でフィルムを搬送した。各加熱空間内では図3に示すように黒鉛製の冶具でフィルムを上下から挟みこみ、フィルムを冶具の間を滑らせるように搬送した。フィルムの厚み方向に加わる圧力は2g/cm2に調整した。次に、ロール状に巻かれた炭化フィルムを、図4に示すように炭化フィルムのTD方向と、重力方向とが一致するように黒鉛化炉に投入し、2900℃まで2℃/minの昇温速度で熱処理した。得られた黒鉛化後フィルムをφ300、幅300mmの2本のロールで、3トンの力を加えながら圧延しグラファイトフィルム1(GS1)を得た。
2900℃までの昇温速度を5℃/minとしたこと以外は、GS1と同様にグラファイトフィルム2(GS2)を得た。
2900℃までの昇温速度を3℃/minとしたこと以外は、GS1と同様にグラファイトフィルム3(GS3)を得た。
2900℃までの昇温速度を4℃/minとしたこと以外は、GS1と同様にグラファイトフィルム4(GS4)を得た。
2900℃までの昇温速度を7.5℃/minとしたこと以外は、GS1と同様にグラファイトフィルム5(GS5)を得た。
2900℃までの昇温速度を10℃/minとしたこと以外は、GS1と同様にグラファイトフィルム6(GS6)を得た。
圧延ロールのロールの表面にエンボス処理が施されており、その表面粗さRaが1.30μm、Rzが5.0μmであること以外は、GS1と同様にグラファイトフィルム7(GS7)を得た。
複屈折0.12、厚み62μm、幅250mm、長さ50mの株式会社カネカ製ポリイミドフィルム アピカルAHを、250mm長さにカットし、厚み200μmの天然黒鉛シートと交互に100枚積層して、5g/cm2の荷重がフィルムにかかるように黒鉛製の重石板を載せた。この重石板を載せたポリイミドフィルム/黒鉛シート積層品を炭化炉にセットし、1400℃まで2℃/minの昇温速度で炭化した。次に炭化後の重石板を載せた炭化フィルム/黒鉛シート積層品をそのまま黒鉛化炉に投入し、2900℃まで5℃/minの昇温速度で黒鉛化した。得られた黒鉛化後フィルムを厚み125μmのポリイミドフィルム2枚で挟み、10MPaの圧力でプレス処理を実施し、グラファイトフィルム8(GS8)を得た。
厚み32μmのグラファイトシート3枚と厚み5μmの接着フィルム2枚とを、最外層がグラファイトシートとなるように交互に積層した。この積層体を熱圧着して、グラファイトシートの積層数が3層のグラファイト積層体(厚み106μm)を得た。このグラファイト積層体をグラファイトフィルム9(GS9)とした。
厚み32μmのグラファイトシート5枚と厚み5μmの接着フィルム4枚とを、最外層がグラファイトシートとなるように交互に積層した。この積層体を熱圧着して、グラファイトシートの積層数が5層のグラファイト積層体(厚み180μm)を得た。このグラファイト積層体をグラファイトフィルム10(GS10)とした。
厚み32μmのグラファイトシート15枚と厚み5μmの接着フィルム14枚とを、最外層がグラファイトシートとなるように交互に積層した。この積層体を熱圧着して、グラファイトシートの積層数が15層のグラファイト積層体(厚み550μm)を得た。このグラファイト積層体をグラファイトフィルム11(GS11)とした。
厚み32μmのグラファイトシート4枚と厚み5μmの接着フィルム3枚とを、最外層がグラファイトシートとなるように交互に積層した。この積層体を熱圧着して、グラファイトシートの積層数が4層のグラファイト積層体(厚み143μm)を得た。このグラファイト積層体をグラファイトフィルム12(GS12)とした。
厚み32μmのグラファイトシート10枚と厚み5μmの接着フィルム9枚とを、最外層がグラファイトシートとなるように交互に積層した。この積層体を熱圧着して、グラファイトシートの積層数が10層のグラファイト積層体(厚み365μm)を得た。このグラファイト積層体をグラファイトフィルム13(GS13)とした。
ポリイミドフィルムを加熱して、厚み200μmのグラファイトシートを得た。このグラファイトシートをグラファイトフィルム14(GS14)とした。
<PSA1-1>
図5に示す方法により粘着層を作製した。グラビアコーター機を用いて、厚み2μmのPET基材に、乾燥後の厚みが2μmとなるようにトルエンで希釈したアクリル系粘着剤溶液を製膜し、乾燥後、厚み75μmの片面シリコン処理のPETセパレーターのシリコン処理面を、アクリル系粘着剤溶液を製膜した側に貼り合わせ積層品Aを作製した。次に、別途、グラビアコーター機を用いて、乾燥後に1.3mm×1.3mmの正方形の島状突起が図1の(b)のように規則的に配置され、島状突起の正方形の一辺と、当該辺と向かい合う隣接する島状突起の正方形の一辺との間の間隔(島状突起相互間の間隔)が0.19mm、粘着部の面積の粘着層全体の面積に占める割合(表2及び以下のPSA1-2からPSA1-7の製造において、「粘着部面積」と表示)が76.1%、乾燥後の厚みが2μmとなるように、アクリル系粘着剤溶液を、厚み75μmの片面シリコン処理のPETセパレーターのシリコン処理面にドット印刷した(表2中、第2粘着層の構成として「島状突起」と記載)。ドット印刷により得られた積層品を乾燥後、ドット印刷した面が、積層品Aの基材と接するように、先に作製した積層品Aとラミネートし、PSA1-1を得た。PSA1-1は、積層品Aにおいてアクリル系粘着剤溶液を製膜し乾燥して得られた第1粘着層、基材、アクリル系粘着剤溶液をドット印刷し乾燥して得られた第2粘着層が順に積層した粘着層であり、両方の表面はPETセパレーターで覆われた状態で得られる。なお、本粘着層において第2粘着層の表面の凹凸構造である独立した複数の島状突起は、ピッチが1.5mm、溝の幅が0.19mm、溝の深さが2μmの正方形格子状の溝であるとも言うこともできる。
グラビアロールを1.3mm角の島状突起、島状突起相互間の間隔が0.88mm、粘着部面積35.6%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-2を得た。
グラビアロールを1.3mm角の島状突起、島状突起相互間の間隔0.50mm、粘着部面積52.2%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-3を得た。
グラビアロールを2.25mm角の島状突起、島状突起相互間の間隔0.88mm、粘着部面積85.0%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-4を得た。
グラビアロールを3.5mm角の島状突起、島状突起相互間の間隔0.19mm、粘着部面積90.0%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-5を得た。
グラビアロールを0.7mm角の島状突起、島状突起相互間の間隔0.1mm、粘着部面積76.6%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-6を得た。
グラビアロールを0.07mm角の島状突起、島状突起相互間の間隔0.01mm、粘着部面積76.6%となるように調整したこと以外は、PSA1-1と同様にしてPSA1-7を得た。
図6に示す方法により粘着層を作製した。グラビアコーター機を用いて、厚み2μmのPET基材に、乾燥後の厚みが2μmとなるようにトルエンで希釈したアクリル系粘着剤溶液を製膜し、乾燥後、厚み75μmの片面シリコン処理のPETセパレーターのシリコン処理面を、アクリル系粘着剤溶液を製膜した側に貼り合わせ積層品Aを作製した。次に、0.2mm×0.3mmの長方形格子状の線状突起であって、線状突起の高さが平均1.0μm(以下のPSA2-2からPSA2-5の製造において、「ピッチ0.2×0.3mm、山高さ平均1.0μm」のように記載、なお、凹凸構造が転写されるため、表2では、「ピッチ0.2×0.3mm、溝の深さ平均1.0μm」のように記載)のエンボス処理が施され、エンボス面に片面シリコン処理がされたエンボスPETセパレーター(厚み75μm)のエンボス面に、アクリル系粘着剤溶液を乾燥後の厚みが2μmとなるように製膜した(表2中、第2粘着層の構成として「格子状の溝」と記載)。成膜したアクリル系粘着剤溶液を乾燥後、そのアクリル系粘着剤溶液を製膜した面が、積層品Aの基材と接するように、先に作製した積層品AとラミネートしてPSA2-1を得た。その後、前記エンボスPETセパレーターを剥離し、露出した、アクリル系粘着剤溶液を製膜し乾燥して得られた層の、エンボス面の形状が転写された面に、新たに厚み75μmの片面シリコン処理の平坦なPETセパレーターのシリコン処理面を貼り合わせた。PSA2-1は、積層品Aにおいてアクリル系粘着剤溶液を製膜し乾燥して得られた第1粘着層、基材、アクリル系粘着剤溶液をエンボスPETセパレーターに成膜し乾燥して得られた第2粘着層が順に積層した粘着層であり、両方の表面はPETセパレーターで覆われた状態で得られる。
ピッチ0.2×0.3mm、山高さ平均0.3μmのエンボス処理が施されたエンボスPETセパレーター(厚み75μm)を用いたこと以外は、PSA2-1と同様にしてPSA2-2を得た。
ピッチ0.2×0.3mm、山高さ平均0.5μmのエンボス処理が施されたエンボスPETセパレーター(厚み75μm)を用いたこと以外は、PSA2-1と同様にしてPSA2-3を得た。
ピッチ0.1×0.1mm、山高さ平均1.0μmのエンボス処理が施されたエンボスPETセパレーター(厚み75μm)を用いたこと以外は、PSA2-1と同様にしてPSA2-4を得た。
ピッチ2.0×2.0mm、山高さ平均1.0μmのエンボス処理が施されたエンボスPETセパレーター(厚み75μm)を用いたこと以外は、PSA2-1と同様にしてPSA2-5を得た。
厚み4μmのPET基材に、厚み8μmとなるようにトルエンで希釈したアクリル系粘着剤溶液を製膜したこと、エンボスPETセパレーターに、アクリル系粘着剤溶液を厚み8μmとなるように製膜したこと以外は、PSA2-1と同様にしてPSA2-6を得た。
Neofix5S2は、日栄化工株式会社から入手可能な総厚み5μmの両面テープである。第2粘着層の表面粗さを測定すると、Ra0.10μmRz1.20μmと凹凸の少ない粘着剤であった。
図7に示す方法により粘着層を作製した。日栄化工株式会社から入手可能なNeofix5S2の一方のセパレーターを剥離し、露出した粘着面に新たに、厚み75μm、表面粗さRa0.55μm、Rz3.41μmのエンボスPETセパレーターを、前記粘着面に前記表面粗さを有する面が接するようにラミネートしてPSA3-1を得た(表2中、第2粘着層の構成として「エンボスセパ」と記載)。その後、前記エンボスPETセパレーターを剥離し、露出した、前記エンボスPETセパレーターのエンボス面の形状が転写された粘着面に、新たに厚み75μmの片面シリコン処理の平坦なPETセパレーターのシリコン処理面を貼り合わせた。なお、用いたNeofix5S2は乾燥されており、溶媒残存率は0.3%であった。PSA3-1は、Neofix5S2の剥離しなかった方のセパレーターに接する第1粘着層、基材、エンボスPETセパレーターをラミネートしたNeofix5S2の粘着層である第2粘着層が順に積層した粘着層であり、両方の表面はPETセパレーターで覆われた状態で得られる。
表面粗さRa0.06μm、Rz0.30μmのエンボスPETセパレーターを用いたこと以外は、PSA3-1と同様にしてPSA3-2を得た。
表面粗さRa0.30μm、Rz2.90μmのエンボスPETセパレーターを用いたこと以外は、PSA3-1と同様にしてPSA3-3を得た。
表面粗さRa0.70μm、Rz5.10μmのエンボスPETセパレーターを用いたこと以外は、PSA3-1と同様にしてPSA3-4を得た。
表面粗さRa1.00μm、Rz10.00μmのエンボスPETセパレーターを用いたこと以外は、PSA3-1と同様にしてPSA3-5を得た。
アクリル系重合体を主成分とする粘着剤を外径0.5mmの丸形の粒状とし、この粘着剤の上面を平坦とした形で0.25mmの間隔で、厚み32μmのグラファイトフィルム1(GS1)に厚み6μmとなるように、スキージで加圧して印刷し形成した(表3中、第2粘着層の構成として「点状」と記載)。前記粒状の各粘着剤は粘着部を構成する。なお、ここで、「0.25mmの間隔」とは、隣り合う丸形の粘着部相互間の間隔をいう(表3中、「粘着部相互間の間隔」と記載)。PSA4における粘着部の面積の粘着層全体の面積に占める割合は34.9%であった。PSA4は、得られたグラファイトフィルム上に形成された、粘着材の部分を指す。
アクリル系重合体を主成分とする粘着剤を外径0.5mmの丸形の粒状とし、この粘着剤の上面を平坦とした形で1.5mmの間隔で、印刷したこと以外は、PSA4と同様にしてPSA5を得た。PSA5における粘着部の面積の粘着層全体の面積に占める割合は4.9%であった。PSA5は、得られたグラファイトフィルム上に形成された、粘着材の部分を指す。
<実施例1~36、比較例1>
表1に記載のグラファイトフィルム(GS)、保護層、及びアプリケーション層、並びに、両方の表面がPETセパレーターで覆われた表2~3に記載の粘着層をそれぞれ用いてグラファイト複合フィルムを製造した。得られたグラファイト複合フィルムの粘着層のグラファイトフィルムと接した面と反対側の表面には、表4~5に記載のセパレーターがそれぞれ積層されている。なお、表2~3中「フラット」とは凹凸構造を有しないことを意味する。具体的には、Raが0.13μm以下で、且つ、Rzが1.30μm以下である場合は、凹凸が十分に少ないので、「フラット」とする。また、表2中「通常PSA」とは、凹凸構造を有しない第1粘着層と第2粘着層とを含む三層構造の粘着剤を意味する。表2~3中に、グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合を併せて示す(表2~3中、「粘着剤で覆われている面積の割合(%)」と表示)。
比較例2では、アクリル系重合体を主成分とする粘着剤を外径0.5mmの丸形の粒状としこの粘着剤の上面を平坦とした形で0.25mmの間隔、厚み32μmのグラファイトフィルム1に厚み6μmとなるように、スキージで加圧して印刷し形成したあと、75μmのPETセパレーターを貼り合わせたこと以外は、実施例1と同様にグラファイト複合フィルムを作製した。
比較例3では、アクリル系重合体を主成分とする粘着剤を外径0.5mmの丸形の粒状としこの粘着剤の上面を平坦とした形で1.5mmの間隔、厚み32μmのグラファイトフィルム1に厚み6μmとなるように、スキージで加圧して印刷し形成したあと、75μmのPETセパレーターを貼り合わせたこと以外は、実施例1と同様にグラファイト複合フィルムを作製した。
サイズ40mm×60mmとなるようにカットしたこと以外は、比較例1と同様にグラファイト複合フィルムを作製した。
サイズ15mm×15mmとなるようにカットしたこと以外は、実施例29と同様にグラファイト複合フィルムを作製した。
各実施例、比較例及び参考例で得られたグラファイト複合フィルムについて以下の評価を行った。その結果を、表4及び表5に示す。
グラファイト複合フィルムの粘着力を示す物性として、ピール強度を、JIS-Z0237記載の方法1の「試験板に対する180度引きはがし粘着力の試験方法」に準じて求めた。JIS-Z0237に記載の幅50mm×長さ125mm×厚み1.1mm、表面粗さRa:50nmのSUS板をメタノールで洗浄した。25mm×120mmにカットした、グラファイト複合フィルムのセパレーター、即ち第2粘着層に接するセパレーターを剥離し、環境温度23℃、湿度50%の条件下において、洗浄後のSUS板に、グラファイト複合フィルムを、第2粘着層とSUS板とが接するようにして、空気が入らないように2kgのローラーで2往復加圧貼付した。1時間放置後、SIMAZU製のオートグラフ(型番:AG-10TB)及び50Nのロードセル(型番:SBL-50N)を用い、同一の温度湿度条件下で300mm/minの速度で引っ張って、180度引きはがし粘着力を測定した。異なる試験片を用い同様の測定を3回実施し、結果は、3回測定の平均値の小数点以下第3位を四捨五入することにより、小数点以下第2位までの値として求め、ピール強度(単位:N/25mm)とした。
グラファイト複合フィルムを被着体に貼り合わせたときの、被着体とグラファイト複合フィルムとの間の気泡発生の低減を以下の方法により評価した。
環境:環境温度23℃、湿度50%の条件下
測定回数:N10(N10回の測定で以下の評価の内最も多いものを結果として採用する。)
手順:グラファイト複合フィルムのPETセパレーターを剥離した。フラットな台の上に、露出した第2粘着層の粘着面を上にしてグラファイト複合フィルムを保持した。グラファイト複合フィルムの粘着面に被着体を、被着体の貼付けられる面が一気に接触するように載せ、重さ5kg(サイズ80mm×100mm)の重石を載せて10秒間保持した。その後、被着体の上から重さ10kgのゴムローラで3往復して空気溜りを除去した。その後、残った空気溜りをカウントし、以下の基準により評価した。なお、空気溜りは被着体表面に***として現れるので、空気溜りの大きさと有無は、見た目に***があるもので、最大の空気溜りの最大長さを測定し(楕円形であれば、***した一番長い距離を測定する。)、その測定長を以下基準で評価することができる。
評価2…2.5mm以上6.0mm未満の空気溜りがある場合
評価3…1.5mm以上2.5mm未満の空気溜りがある場合
評価4…1.5mm未満の空気溜りがある場合
評価5…空気溜りがない場合
<密着性評価>
グラファイト複合フィルムの密着性を評価した。グラファイト複合フィルムのピール強度の試験結果を以下のように分類した。
評価2…4.0N/25mm以上5.0N/25mm未満
評価3…5.0N/25mm以上6.0N/25mm未満
評価4…6.0N/25mm以上6.5N/25mm未満
評価5…6.5N/25mm以上
<放熱試験>
グラファイト複合フィルムの放熱性を以下の放熱試験により評価した。図8にグラファイト複合フィルムの放熱試験の装置構成図を示す。バブル評価とは別に、グラファイト複合フィルムのPETセパレーターを剥離し、ラミネーターを用いて、サイズ80mm×100mm、厚み0.2mmのSUS板33とグラファイトフィルム35とを、SUS板と露出した粘着層34の粘着面とが一気に接触するように貼り合わせた。アプリケーション層も剥離し、その後、10mm×10mm×1mmの発熱部品37としてのセラミックヒーター(ヒーター面には、放射率0.94の黒体スプレーを塗布しておく。)を、保護層36側からグラファイト複合フィルムの中央に取り付け、出力2Wで加熱し、温度上昇が飽和するまで待機した。放熱試験は、環境温度23℃、湿度50%の条件下、対流で温度が変化しないように、周囲に風除けを設置して実施した。温度の測定は、サーモビューワーを用いヒーター上の温度を測定することにより行った。測定はN5回で実施し、5回測定の平均値を測定値とし、以下基準で評価した。
評価2…ヒーター上の温度が51.0℃以上51.5℃未満の場合
評価3…ヒーター上の温度が50.5℃以上51.0℃未満の場合
評価4…ヒーター上の温度が50℃以上50.5℃未満の場合
評価5…ヒーター上の温度が50℃未満の場合
<リワーク性評価>
グラファイト複合フィルムのリワーク性(再剥離性)評価を実施した。放熱試験と同様にして、グラファイト複合フィルムとSUS板を貼り合わせた。貼り合わせてから10分、室温23℃湿度50%の環境におき、続いて、同環境にて引き剥がしのテスト(リワーク作業)を行った。以下の基準に従ってリワーク性を評価した。なお測定は10回実施し、以下の評価の内最も多いものを結果として採用した。
粘着層のコストの評価は、グラファイト複合フィルムを1ピース製造するのに必要な粘着層の材料費をグラファイト複合フィルムの面積(cm2)で割った、単位面積当たりのコストで評価した。基準として、比較例1の従来のグラファイト複合フィルムの単位面積当たりの粘着層のコストを1に規格化し、その他の実施例、比較例及び参考例のコストを算出した。
評価2…コストが1.2より大きく1.3以下の場合
評価3…コストが1.1より大きく1.2以下の場合
評価4…コストが1より大きく1.1以下の場合
評価5…コストが1以下の場合
<密着安定性>
グラファイト複合フィルムの密着安定性評価を実施した。グラファイト複合フィルムのPETセパレーターを剥離し、ラミネーターを用いて、サイズ100mm×100mm、厚み2mmのSUS板とグラファイト複合フィルムとを、SUS板と露出した粘着層の粘着面とが一気に接触するように貼り合わせた。貼り合わせてから一日間、室温23℃湿度50%の環境におき、続いて、貼り合わせたものを、カッターで、すべての層が切断されるように切って、1cmの長さの切れ目を入れ、浮きの発生を観察した。具体的には、浮きの発生の有無を観察し、浮きが発生する場合は、浮きの最大長さを測定した(楕円形であれば、***した一番長い距離を測定する。)。
評価2…最大長さが0.5mm以上1mm以下の浮きがある場合
評価3…最大長さが0.5mm以下の浮きがある場合
評価4…浮きがない場合
<まとめ>
表4及び表5に示すグラファイト複合フィルムの評価結果から、粘着剤溶液を塗布又は印刷する方法により凹凸構造を設けた粘着層を有する本発明のグラファイト複合フィルム(実施例1~7、34)、表面に凹凸構造を有するセパレーターに粘着剤溶液を製膜して凹凸構造を転写する方法により凹凸構造を設けた粘着層を有する本発明のグラファイト複合フィルム(実施例8~13、29-33、36)、凹凸構造を有するセパレーターの前記凹凸構造を有する面を粘着層に接触させて凹凸構造を転写する方法により凹凸構造を設けた粘着層を有する本発明のグラファイト複合フィルム(実施例14~18、35)、表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成してグラファイトフィルムの当該凹凸構造を粘着層表面に出現させる方法により凹凸構造を設けた粘着層を有する本発明のグラファイト複合フィルム(実施例19~25)、凹凸構造を有する粘着層とグラファイトフィルムとを積層する方法と、表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成してグラファイトフィルムの当該凹凸構造を粘着層表面に出現させる方法とを組み合わせた方法により凹凸構造を設けた粘着層を有する本発明のグラファイト複合フィルム(実施例26~28)では、放熱性を損なうことなく、被着体に貼り合わせた際の被着体とグラファイト複合フィルムとの間の気泡発生を低減させることができるとともに、密着性やリワーク性に優れることが判る。
<実施例37>
実施例1で得られたグラファイト複合フィルムを用いて放熱部品を作成した。具体的には、グラファイト複合フィルムのPETセパレーターを剥離し、ラミネーターを用いて、サイズ70mm×100mm、厚み0.2mmのSUS板とグラファイト複合フィルムとを、SUS板と露出した粘着層の粘着面とが一気に接触するように貼り合わせて放熱部品を製造した。このとき、複合グラファイトフィルムのSUS板と接した面と反対側のグラファイトフィルムの表面には、保護層とアプリケーション層とが積層されている。
実施例29で得られたグラファイト複合フィルムを用いて放熱部品を作成した。具体的には、グラファイト複合フィルムのPETセパレーターを剥離し、ラミネーターを用いて、サイズ70mm×100mm、厚み0.2mmのSUS板とグラファイト複合フィルムとを、SUS板と露出した粘着層の粘着面とが一気に接触するように貼り合わせて放熱部品を製造した。このとき、複合グラファイトフィルムのSUS板と接した面と反対側のグラファイトフィルムの表面には、保護層とアプリケーション層とが積層されている。
2 高分子フィルム
3 加熱空間
4 黒鉛製の冶具
5 炭化フィルム
6 黒鉛化炉
7 重力方向
8 セパレーター
9 粘着剤溶液
10 グラビアコーター機のグラビアロール
11 スキージ
12 ドット印刷機により得られた積層品
13 積層品
14 セパレーター
15 第1粘着層
16 基材
17 第2粘着層(島状突起)
19 エンボス処理が施されたセパレーター
20 粘着剤溶液
21 スキージ
22 第2粘着層
23 基材
24 第1粘着層
25 セパレーター
26 セパレーター
27 凹凸構造を有しない粘着層
28 基材
29 粘着層(第1粘着層)
30 セパレーター
31 エンボス処理が施されたセパレーター
32 第2粘着層
33 SUS板
34 粘着層
35 グラファイトフィルム
36 保護層
37 発熱部品
38 凸部の上面
39 凹部の底面
40 島状突起の側面
41 グラファイトフィルム
42 粘着剤
43 第2粘着層
44 基材
45 第1粘着層
Claims (27)
- グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、
前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、
前記粘着層は、前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有するものであることを特徴とするグラファイト複合フィルム。 - 前記粘着層の凹凸構造を有する表面の表面粗さが、Ra0.19μm以上10μm以下であることを特徴とする請求項1に記載のグラファイト複合フィルム。
- 前記粘着層の凹凸構造を有する表面の表面粗さが、Rz1.6μm以上100μm以下であることを特徴とする請求項1又は2に記載のグラファイト複合フィルム。
- 前記粘着層の厚みが1.00μm以上20.00μm以下であることを特徴とする請求項1から3のいずれか1項に記載のグラファイト複合フィルム。
- 前記粘着層の表面の凹凸構造は、格子状又は縞状の溝、或いは、独立した複数の島状突起であることを特徴とする請求項1から4のいずれか1項に記載のグラファイト複合フィルム。
- 前記格子状又は縞状の溝のピッチが0.05mm以上2.0mm以下であることを特徴とする請求項5に記載のグラファイト複合フィルム。
- 前記粘着層は、第1粘着層、基材、及び第2粘着層を含むものであり、
前記粘着層は、前記グラファイトフィルム上に、前記グラファイトフィルム側から、前記第1粘着層、前記基材、前記第2粘着層の順に積層されており、
前記グラファイトフィルムの全面積に対する、第2粘着層の粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、
前記粘着層は、前記第2粘着層の基材と接した面と反対側の表面に前記凹凸構造を有するものであることを特徴とする請求項1から6の何れか1項に記載のグラファイト複合フィルム。 - 前記第2粘着層は、前記基材上に配置された複数の粘着部であり、
前記粘着層の表面の凹凸構造は、凸部が前記粘着部からなり、凹部には接着剤が存在せず前記基材が露出していることを特徴とする請求項7に記載のグラファイト複合フィルム。 - 前記粘着部の面積の粘着層全体の面積に占める割合が35%以上であることを特徴とする請求項8に記載のグラファイト複合フィルム。
- 前記粘着部が、規則的に配置された、多角形、棒状、帯状の島状突起である場合、島状突起の一辺と、当該辺と向かい合う隣接する島状突起の一辺との間の間隔は、0.01mm以上であることを特徴とする請求項8又は9に記載のグラファイト複合フィルム。
- 前記グラファイト複合フィルムとSUSとのピール強度が4.0N/25mm以上12.0N/25mm以下であることを特徴とする請求項1から10のいずれか1項に記載のグラファイト複合フィルム。
- 前記グラファイト複合フィルムの面積が3cm2以上であることを特徴とする請求項1から11のいずれか1項に記載のグラファイト複合フィルム。
- 前記グラファイトフィルムの厚みが90μm以上であることを特徴とする請求項1から12のいずれか1項に記載のグラファイト複合フィルム。
- 前記グラファイトフィルムは、グラファイトシートと接着層とが交互に積層されてなるグラファイト積層体であって、前記グラファイト積層体に含まれる前記グラファイトシートの積層数は3層以上であることを特徴とする請求項1から13のいずれか1項に記載のグラファイト複合フィルム。
- 前記グラファイトフィルムの体積は、50mm3以上であることを特徴とする請求項1から14のいずれか1項に記載のグラファイト複合フィルム。
- グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、
前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であるとともに、
少なくとも片面に凹凸構造を有する粘着層の、当該凹凸構造が、グラファイトフィルムと接した面と反対側に配置されるように、当該粘着層と当該グラファイトフィルムとを積層する工程を含むことを特徴とするグラファイト複合フィルムの製造方法。 - グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、
表面に凹凸構造を有するセパレーターの前記凹凸構造を前記粘着層の表面に転写することによって、少なくとも片面に凹凸構造を設けた粘着層を作製する工程と、
少なくとも片面に凹凸構造を有する粘着層の、当該凹凸構造が、グラファイトフィルムと接した面と反対側に配置されるように、当該粘着層と当該グラファイトフィルムとを積層する工程とを含むことを特徴とするグラファイト複合フィルムの製造方法。 - 前記セパレーターの凹凸構造を有する表面の粗さがRa0.06μm以上1.00μm以下、且つ、Rz0.3μm以上10.0μm以下であることを特徴とする請求項17に記載のグラファイト複合フィルムの製造方法。
- 前記セパレーターの凹凸構造を有する表面に粘着剤溶液を製膜して、凹凸構造を転写することを特徴とする請求項17又は18に記載のグラファイト複合フィルムの製造方法。
- 前記セパレーターを、溶媒残存率5%以下の前記粘着層に接触させて、前記粘着層の表面に前記凹凸構造を転写することを特徴とする請求項17又は18に記載のグラファイト複合フィルムの製造方法。
- グラファイトフィルムと当該グラファイトフィルムに接した粘着層を有するグラファイト複合フィルムの製造方法であって、
表面に凹凸構造を有するグラファイトフィルム上に粘着層を形成して、グラファイトフィルムの当該凹凸構造を当該粘着層表面に出現させることによって、当該粘着層の表面に凹凸構造を形成することを特徴とするグラファイト複合フィルムの製造方法。 - 前記グラファイトフィルムの凹凸構造を有する表面の表面粗さがRa0.55μm以上1.70μm以下、且つ、Rz2.3μm以上6.00μm以下であることを特徴とする請求項21に記載のグラファイト複合フィルムの製造方法。
- 前記グラファイトフィルムの厚みが5μm以上120μm以下であることを特徴とする請求項21又は22に記載のグラファイト複合フィルムの製造方法。
- 前記粘着層の凹凸構造を有する表面の表面粗さがRa0.8μm以下、Rz4.5μm以下であることを特徴とする請求項21から23のいずれか1項に記載のグラファイト複合フィルムの製造方法。
- グラファイト複合フィルムを含む放熱部品であって、前記グラファイト複合フィルムは、グラファイトフィルムと当該グラファイトフィルムに接した粘着層とを有し、前記グラファイトフィルムの全面積に対する、粘着剤で覆われているグラファイトフィルムの面積の割合は35%以上100%以下であり、前記粘着層は、前記グラファイトフィルムと接した面と反対側の表面に凹凸構造を有することを特徴とする放熱部品。
- 前記グラファイト複合フィルムを被着体に貼り合わせてなることを特徴とする請求項25に記載の放熱部品。
- 前記グラファイト複合フィルムの前記被着体と接した面と反対側の表面に保護層が積層されており、当該保護層の表面の表面粗さが、Ra0.15μm以上10μm以下、且つ、Rz1.0μm以上100μm以下であることを特徴とする請求項26に記載の放熱部品。
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