Anisotropic Conductive Film Carrying Tape and Packaging Method

Abstract

An anisotropic conductive film carrying tape (1) carrying on it an anisotropic conductive film is disclosed. A splice tape (5) is bonded by an adhesive tape (6) to one or both of longitudinal ends of a base film (3) of synthetic resin of the tape (1) on which has been affixed an anisotropic conductive film (2). On both the front and back surfaces of a base film (11) of the splice tape are layered polypropylene films (12), (13). The polypropylene films, formed on the respective surfaces of the base film (11), are dyed to different colors.

Description

TECHNICAL FIELD

This invention relates to an anisotropic conductive film carrying tape, used for a process for interconnecting a counterpart connecting member carrying a large number of electrodes, to an electronic part or component, as a connecting member facing the counterpart connecting member. The anisotropic conductive film carrying tape is used for a packaging process employing the anisotropic conductive film operating as a material for connection. This invention also relates to a method for packaging e.g. an electronic part or component using this anisotropic conductive film.

The present invention contains subject matter related to Japanese Patent Applications Nos. 2004-134510 and 2004-203787, filed in the Japanese Patent Office on Apr. 28, 2004 and on Jul. 9, 2004, respectively. The contents of these Applications are incorporated by reference in their entirety in the present Application.

BACKGROUND ART

Heretofore, in a process of affixing electronic devices, parts or components, in a preset pattern, using an anisotropic conductive film, the tape which has the anisotropic conductive film, coated thereon, and which has been wrapped around a reel-type packaging device, is paid out by an operator from the tape reel and set in position. Hence, each time the tape has been paid out from a given reel, the operator has to set a new reel in position by a manual operation.

This reel exchange operation takes ten to thirty minutes per reel and, during this time, the packaging device is in a standstill state, with the production being in a state of cessation. Moreover, this reel exchange operation occurs several times a day, which means loss of much time and represents a principal factor in lowering the production efficiency.

There is a method for increasing the length of a product of the anisotropic conductive film for reducing the load of the reel exchange operation for overcoming the above problem. However, since the film is wound on a reel, there is a limitation to the radial size of the tape wound on the reel, depending on the size of the device for packaging. In addition, if the tape carrying thereon an anisotropic conductive film of an excessive length is wound on a reel, it may be an occurrence that a given turn of the anisotropic conductive film is deviated from other turns, as the film is tightened, thus detracting from the quality of the anisotropic conductive film. This indicates that difficulties may be met in increasing the length of the anisotropic conductive film wound in a reel.

There has also been proposed a method consisting in interconnecting a plural number of tapes, each carrying an anisotropic conductive film, and for continuously driving the tapes, in order to overcome the aforementioned problem. However, a PET layer 101 and an anisotropic conductive film 102 cannot be thermally fused together, as shown in FIG. 1. On the other hand, if two PET layers 101 are to be connected to each other, as shown in FIG. 2, difficulties are met in the fusing because of the high melting point of the PET layer. If such fusion could be achieved, there is a fear that the resulting product is lowered in quality because of insufficiency in strength caused by excessive melting of a weld 103.

DISCLOSURE OF THE INVENTION

Problems to be solved by the Invention

Means to solve the Problem

It is an object of the present invention to provide an anisotropic conductive film carrying tape, which may be connected to another such tape easily reliably by thermal fusion, and a method for packaging electronic parts or components, for example, using this tape carrying thereon an anisotropic conductive film.

It is another object of the present invention to provide an anisotropic conductive film carrying tape in which a plural number of tapes, each carrying an anisotropic conductive film, are positively connected to one another to permit continued use of the tape to provide for effective elongation of the tape length without elongating the length of the individual tapes, and a packaging method. The production efficiency in the process of packaging the part or component on a substrate may be improved with the use of the anisotropic conductive film carrying tape.

The present invention provides an anisotropic conductive film carrying tape wherein a splice tape of synthetic resin is joined by an adhesive tape to one longitudinal end or to both longitudinal ends of a substrate of synthetic resin carrying an anisotropic conductive film thereon.

The present invention also provides an anisotropic conductive film carrying tape obtained on interconnecting a plurality of substrates of synthetic resin, each carrying thereon an anisotropic conductive film carrying tape, one after another, by splice tapes of synthetic resin. The splice tapes are joined by adhesive tapes to one or both of longitudinal ends of the substrates.

The present invention also provides a packaging method for affixing electronic devices or electronic parts or components in a preset pattern, using an anisotropic conductive film carrying tape including a substrate of synthetic resin carrying an anisotropic conductive film affixed thereon. The packaging method includes supplying an anisotropic conductive film carrying tape, as taken up on a tape reel, to a packaging unit, and detecting an end of the anisotropic conductive film carrying tape, as taken up on the tape reel, when the anisotropic conductive film carrying tape is about to be depleted. The packaging method also includes thermally fusing an end of the anisotropic conductive film carrying tape, as taken up on the tape reel, to an end of an anisotropic conductive film carrying tape, as taken up on another tape reel. This interconnects the anisotropic conductive film carrying tape, as taken up on the tape reel and the anisotropic conductive film carrying tape, as taken up on the other tape reel. The packaging method also includes exchanging the tape reel on which the anisotropic conductive film carrying tape is about to be depleted, for a new tape reel, carrying thereon an anisotropic conductive film carrying tape, for thereby enabling continued supply of the anisotropic conductive film carrying tape to a packaging unit for electronic devices or electronic parts or components. The packaging method further includes subsequently affixing the anisotropic conductive film carrying tape in a preset pattern.

According to the present invention, the splice tape, provided to an end of an anisotropic conductive film carrying tape, is heat-fused to a splice tape of another anisotropic conductive film carrying tape. Hence, plural anisotropic conductive film carrying tapes may be interconnected easily reliably to enable continued use of the anisotropic conductive film carrying tape.

Moreover, according to the present invention, the front and back surfaces of the splice tape, as a connecting part of the anisotropic conductive film carrying tape, are dyed to different colors, so that the front and back sides of the anisotropic conductive film carrying tape may be discriminated based on colored zones. Hence, the torsion of the anisotropic conductive film carrying tape may be detected and cured. Thus, according to the present invention, the tape torsion may be prevented, so that it is possible to interconnect the anisotropic conductive film carrying tapes of narrow tape widths that may be extremely liable to torsions.

Furthermore, according to the present invention, when an anisotropic conductive film carrying tape is about to be depleted, it may be connected to another anisotropic conductive film carrying tape easily reliably by thermal fusion in the course of the process of affixing the electronic devices or electronic parts or components with the use of the anisotropic conductive film carrying tape. Hence, the anisotropic conductive film carrying tape may be supplied in a continued manner without halting the operation, so that packaging may be carried out continuously without interrupting the driving.

Other objects and specified advantages of the present invention will become more apparent from the following explanation of preferred embodiments thereof especially when read in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view showing a conventional example of interconnecting an anisotropic conductive film carrying tape to another such tape.

FIG. 2 is a cross-sectional view showing another conventional example of interconnecting an anisotropic conductive film carrying tape to another such tape.

FIG. 3 is a cross-sectional view showing an anisotropic conductive film carrying tape according to the present invention.

FIG. 4 is a cross-sectional view showing the state of interconnection of two anisotropic conductive film carrying tapes according to the present invention.

FIG. 5 is a schematic view showing a state in which, in the packaging method of the present invention, an anisotropic conductive film carrying tape of a first reel support has been supplied.

FIG. 6 is a schematic view showing a process step of interconnecting anisotropic conductive film carrying tapes of the first and second reel supports in the packaging method of the present invention.

FIG. 7 is a schematic view showing the state in which, in the packaging method of the present invention, the anisotropic conductive film carrying tape of the second reel support has been supplied and the anisotropic conductive film carrying tape of the first reel support is exchanged for a newly supplied tape.

BEST MODE FOR CARRYING OUT THE INVENTION

An embodiment of an anisotropic conductive film carrying tape 1 according to the present invention will now be described with reference to the drawings.

The main part of the anisotropic conductive film carrying tape 1 of the present embodiment is a base film 3 of synthetic resin on which has been affixed an anisotropic conductive film 2, as shown in FIG. 3. This base film 3 may be a film of PET (polyethylene terephthalate), for example. That is, the anisotropic conductive film carrying tape 1 is mainly formed by the anisotropic conductive film 2, the PET film, as the base film 3, and a release part 4, when looking along the direction of tape thickness. The release part 4 is formed by applying releasing processing to the facing side(s) of the anisotropic conductive film 2 and/or the base film 3. Meanwhile, the release part 4 may be formed by providing a layer of a releasing agent, such as silicone, in a space between the anisotropic conductive film 2 and the base film 3.

A splice tape 5 of synthetic resin is provided at each end of the main part of the anisotropic conductive film carrying tape 1. This splice tape is designed to operate as a connection part for connection by thermal fusion to another anisotropic conductive film carrying tape. The splice tape 5 is joined by an adhesive tape 6 to the PET base film 3 of the main part of the anisotropic conductive film carrying tape 1.

The splice tape 5, as a connecting part, is made up of polypropylene films 12, 13, layered on the front and back surfaces along the direction of thickness of the PET film, as the base film 11. The polypropylene films 12, 13 are lower melting than the PET film, as the base film 11, and hence lend themselves to thermal fusion.

Meanwhile, in the splice tape 5, the polypropylene films 12, 13 for thermal fusion are layered on both sides of the base film 11. However, the material for thermal fusion is not limited to polypropylene such that any material suitable for thermal fusion, such as polyester, may be used.

The polypropylene films 12, 13, layered on the front and back surfaces of the base film 11, forming the splice tape 5, are dyed to respective different colors which are also different from the color of the main part. That is, the polypropylene film 12, layered on one of the surfaces of the base film 11, is dyed to a white color, while the polypropylene film 13, layered to the other surface of the base film 11, is dyed to a black color.

Since the splice tape 5, the two sides of which are dyed to different colors, are provided to both ends of the anisotropic conductive film carrying tape 1, these ends may be detected easily reliably with visual check or by optical detection means. Moreover, since the front and back sides of the splice tape 5 are dyed to different colors, those front and back sides may be discriminated by detecting the colors. The front and back sides of the anisotropic conductive film carrying tape 1, connected to these splice tapes 5, may also be discriminated from each other. Since the front and back sides of the anisotropic conductive film carrying tape 1 may be discriminated from each other, it is possible to detect and check for occurrence of tape torsion in which the tape as it is running has its front and back sides reversed partway.

Meanwhile, in the above splice tape 5, the polypropylene films 12, 13, the front and back sides of which have been dyed to different colors, are layered on the respective surfaces of the base film 11. It is however also possible to print colorant materials, such as inks of different colors, on the front and back sides of the base film, for coloring, and to apply a transparent polypropylene film on each of the colored layers.

With the anisotropic conductive film carrying tape 1 of the instant embodiment, the splice tape 5, in which the polypropylene films 12, 13, lower melting than the PET film, have been layered as the base film 11 on both sides of the base film 11, is provided at each end of the anisotropic conductive film carrying tape 1. Hence, the tape 1 may be connected easily reliably to the counterpart anisotropic conductive film carrying tape. That is, the anisotropic conductive film carrying tape 1 may be connected easily reliably to the counterpart anisotropic conductive film carrying tape by providing, on both sides of the splice tape 5, the polypropylene films 12, 13, which are low melting and hence lend themselves to thermal fusion.

Moreover, the anisotropic conductive film carrying tape 1 of the present invention may be connected easily reliably to the counterpart anisotropic conductive film carrying tape and hence may be continuously used in the packaging process, without interrupting the packaging process, thus improving the production efficiency.

Additionally, since the splice tape 5, connected to the anisotropic conductive film carrying tape 1 of the present invention, has its front and back sides dyed to different colors, it is possible to check the tape 1 for torsion, as the tape is being connected to the counterpart tape 1. By torsion is here meant the state in which the tape 1 has its front and back sides reversed. It is then possible to correct the tape 1 for torsion before connection to prevent the tape 1 from being connected to the counterpart tape in such a state in which the tape 1 has its front and back surfaces reversed. This torsion of the anisotropic conductive film carrying tape 1, which is liable to occur especially when the tape is elongated in length and reduced in width, may be detected beforehand and corrected. Hence, the anisotropic conductive film carrying tape 1 may be connected to the counterpart anisotropic conductive film carrying tape to form a continuous tape without surface reversion.

The above-described splice tape 5 is of a three-layered structure, comprised of the PET film as the base film 11 and the polypropylene films 12, 13 for thermal fusion, layered on the front and back sides of the base film 11. It is however sufficient to provide materials suited for thermal fusion on both sides of the splice tape. For example, a plural number of, e.g. two, polypropylene films may be layered together to form a double-layer structure. Or, the splice film may be formed by a sole polypropylene film. In case a plural number of polypropylene films are layered on the front and back sides of the base film 11, the polypropylene films, provided on the respective surfaces, are dyed to different colors in similar manner.

An anisotropic conductive film carrying tape 21, elongated in length by connecting a plural number of the anisotropic conductive film carrying tapes 1, described above, by splice tapes 5, as connecting parts, will now be described.

The anisotropic conductive film carrying tape 21 of the instant embodiment, elongated in length, is formed by interconnecting a plural number of the anisotropic conductive film carrying tapes 1, described above. Specifically, the anisotropic conductive film carrying tape 21 is formed by interconnecting a sole anisotropic conductive film carrying tape 1a and another sole anisotropic conductive film carrying tape 1b by thermal fusion of the splice tapes 5, provided as connecting parts at the ends of the tapes 1a and 1b, as shown in FIG. 4. The polypropylene films 12, 13, provided on the respective front and back surfaces of the splice tape 5, are low melting and hence allow for connection of the anisotropic conductive film carrying tapes 1a and 1b easily and optimally.

With the anisotropic conductive film carrying tape 21 of the instant embodiment, in which the anisotropic conductive film carrying tapes 1a and 1b are interconnected by thermal fusion of the splice tapes 5 provided on the end parts of the tapes 1a and 1b. Thus, the anisotropic conductive film carrying tape may be continuously supplied to a packaging part of a packaging device, for achieving effective tape elongation, without enlarging the anisotropic conductive film carrying tape, that is, without elongating the length of the tape wound in a tape reel.

With the elongated anisotropic conductive film carrying tape 21, obtained on interconnecting plural unit anisotropic conductive film carrying tapes 1, the front and back surfaces of the splice tapes 5, used for interconnecting the plural unit anisotropic conductive film carrying tapes 1, have been dyed to different colors, as described above. Hence, the distortion of the unit tapes, which may cause the front and back sides of the tapes to be reversed at the time of sequentially interconnecting the unit tapes, may be detected and cured prior to the interconnection, thereby preventing the unit tapes 1 from being interconnected in the distorted state.

Meanwhile, the unit anisotropic conductive film carrying tapes 1, taken up on the tape reel, may be sequentially interconnected by thermal fusion of the end of the anisotropic conductive film carrying tape 1a to the end of the counterpart anisotropic conductive film carrying tape 1b. In this interconnection process, the anisotropic conductive film carrying tapes, wound on the tape reel, may be sequentially interconnected to enable the resulting elongated tape to a packaging site of the anisotropic conductive film.

Referring to FIGS. 5 to 7, the method for packaging a part or a component on a substrate, using the above-described anisotropic conductive film carrying tape, will now be described with reference to FIGS. 5 to 7. This packaging method uses a plural number of anisotropic conductive film carrying tapes 1, coiled around a tape reel 15.

A packaging device 40, used for the packaging method according to the present invention, includes a first reel support 41, a second reel support 42 and a plural number of rolls 43. The first reel support 41 supports an anisotropic conductive film carrying tape 1, coiled around the tape reel 15, so as to pay out the tape 1. The second reel support 42 is used to pay out another anisotropic conductive film carrying tape 1 when the anisotropic conductive film carrying tape 1 coiled around the first reel support 41 has been used up. The rolls 43 guide the anisotropic conductive film carrying tapes from the first and second reel supports 41, 42 to a packaging site where the anisotropic conductive film carrying tape is to be affixed in position.

The packaging device 40 also includes a heat fusion unit 44 which, when the anisotropic conductive film carrying tape, supplied from the tape reel 15, carried on one of the first and second reel supports 41, 42, has been used up and depleted, overlays the end of the used-up anisotropic conductive film carrying tape on the end of the anisotropic conductive film carrying tape supplied from the tape reel carried by the other of the first and second reel supports, and thermally fuses the ends together to interconnect the two anisotropic conductive film carrying tapes.

Between the first reel support 41 and the heat fusion unit 44, there is provided a first sensor 45 for detecting the splice tape 5, as a connecting part for the trailing end of the anisotropic conductive film carrying tape supplied from the tape reel carried by the first reel support 41 when the tape is about to be depleted.

Between the second reel support 42 and the heat fusion unit 44, there is provided a second sensor 46 for detecting a bond part at the trailing end of the anisotropic conductive film carrying tape supplied from the tape reel carried by the second reel support 42 when the tape is about to be depleted.

The packaging device includes tape reel exchanging means, not shown, for supplying a new anisotropic conductive film carrying tape, coiled around a new tape reel, to the first or second reel support, when the anisotropic conductive film carrying tape of the tape reel carried by the first or second reel support is about to be depleted.

The packaging device also includes one or more torsion preventive sensors 47 between the heat fusion unit 44 and the packaging unit. These torsion preventive sensors 47 detect the colors of the front and back surfaces of the connecting part of the anisotropic conductive film carrying tape to help prevent distortion of the anisotropic conductive film carrying tape.

The packaging method of the present invention, employing the above-described packaging device, includes a tape supply step, an end detection step, an end connecting step and a tape reel exchange step.

In the tape supply step, the anisotropic conductive film carrying tape, wound on the tape reel on one of the first and second tape supports, for example, the anisotropic conductive film carrying tape 1a, coiled around the tape reel of the first reel support 41, is supplied to the packaging unit, as shown in FIG. 5. In the end detection step, the first sensor 45 detects the colored splice tape 5, provided at the end of the anisotropic conductive film carrying tape 1a, when the tape 1a is about to be depleted. In the end connecting step, the heat fusion unit 44 heat-fuses the splice tape 5 of the anisotropic conductive film carrying tape 1a of the first reel support 41 to the splice tape 5 of the anisotropic conductive film carrying tape 1b, coiled around another tape reel of the second reel support 42 and which is about to be used, as the two splice tapes are overlaid one on the other, as shown in FIG. 6. In the tape reel exchange step, the tape reel carried on the first reel support 41 and from which the anisotropic conductive film carrying tape 1a is about to be depleted, is exchanged for the new tape reel, carrying an anisotropic conductive film carrying tape 1c.

Returning then to the tape supplying step, the anisotropic conductive film carrying tape 1b, taken up on the tape reel of the second reel support 42, is supplied to the packaging unit, as shown in FIG. 7. Since the anisotropic conductive film carrying tape 1a from the tape reel of the first reel support 41, and the anisotropic conductive film carrying tape 1b from the tape reel of the second reel support 42, are supplied continuously, there is no necessity of halting the operation of the packaging unit.

Then, in the end detection step, a second sensor 46 detects the colored splice tape 5 at the end of the anisotropic conductive film carrying tape 1b. In the end connecting step, the heat fusion unit 44 heat-fuses the splice tape 5 of the anisotropic conductive film carrying tape 1b of the second reel support to the splice tape 5 of the anisotropic conductive film carrying tape 1c, coiled around a new tape reel of the first reel support 41 and which is about to be used, as the two splice tapes are overlaid one on the other. In the tape reel exchange step, the tape reel from which the anisotropic conductive film 1b, carried by the second reel support 42, is exchanged for a new tape reel, carrying an anisotropic conductive film carrying tape, as in the case of the first reel support 41 described above. Returning then to the tape supplying step, the above-described steps are repeated to provide for continuous use of the anisotropic conductive film carrying tapes.

In the above-described packaging method, the splice tape at the end part of the anisotropic conductive film carrying tape, wound on a reel and which is about to be depleted, is superposed on the splice tape of an anisotropic conductive film carrying tape, as taken up on another reel, which is ready for operation. The two splice tapes are thermally fused together and thereby interconnected extremely readily and reliably. Hence, the anisotropic conductive film carrying tapes may be supplied without interruptions to the packaging unit.

With the packaging method of the present invention, when an anisotropic conductive film carrying tape in operation is about to be depleted, the tape may be thermally fused to another anisotropic conductive film carrying tape easily reliably, as the packaging operation is continued. Hence, the anisotropic conductive film carrying tapes may be supplied in succession to the packaging unit, without halting the operation of the packaging device.

Moreover, with the packaging method, according to the present invention, the anisotropic conductive film carrying tape may be used continuously, and hence the tape length may effectively be increased, thereby improving the production efficiency.

Furthermore, with the packaging process, according to the present invention, the colors of the front and back surfaces of the connecting parts may be confirmed by the sensor. Thus, even if the anisotropic conductive film carrying tape is of a narrow width, it is possible to prevent packaging troubles otherwise caused by inversion of front or back sides caused in turn by distortion of the anisotropic conductive film carrying tape.

The present invention is not limited to the particular configurations of the embodiment explained with reference to the drawings. It will be appreciated that the present invention may encompass various changes or substitutions by equivalents such as may readily be arrived at by those skilled in the art within the scope and the principle of the invention.

INDUSTRIAL UTILIZABILITY

The anisotropic conductive film carrying tape according to the present invention may extensively be used as a connection material for counterpart connection members, such as electronic devices, parts or components.

Claims

1. An anisotropic conductive film carrying tape wherein a splice tape of synthetic resin is joined by an adhesive tape to one longitudinal end or to both longitudinal ends of a substrate of synthetic resin carrying thereon an anisotropic conductive film.

2. The anisotropic conductive film carrying tape according to claim 1 wherein front and back surfaces of said splice tape have been dyed to different colors.

3. The anisotropic conductive film carrying tape according to claim 1 wherein

said splice tape is a polyethylene terephthalate film on each of the front and back surfaces of which has been layered a polypropylene film; and wherein

said polypropylene films, formed on the front and back surfaces of said polyethylene terephthalate film, have been dyed to different colors.

4. An anisotropic conductive film carrying tape obtained on interconnecting a plurality of substrates of synthetic resin, each carrying thereon an anisotropic conductive film carrying tape, one after another, by splice tapes of synthetic resin, said splice tapes being bonded by adhesive tapes to one or both of longitudinal ends of said substrates.

5. The anisotropic conductive film carrying tape according to claim 4 wherein front and back surfaces of said splice tape have been dyed to different colors.

6. The anisotropic conductive film carrying tape according to claim 4 wherein

said splice tape is a polyethylene terephthalate film on each of the front and back surfaces of which has been layered a polypropylene film; and wherein

said polypropylene films, formed on the front and back surfaces of said polyethylene terephthalate film, have been dyed to different colors.

7. A packaging method for affixing electronic devices or electronic parts or components in a preset pattern, using an anisotropic conductive film carrying tape including a substrate of synthetic resin carrying an anisotropic conductive film affixed thereon, said packaging method comprising:

supplying an anisotropic conductive film carrying tape, as taken up on a tape reel, to a packaging unit;

detecting an end of the anisotropic conductive film carrying tape, as taken up on said tape reel, when said anisotropic conductive film carrying tape is about to be depleted, and thermally fusing an end of said anisotropic conductive film carrying tape, as taken up on said tape reel, to an end of an anisotropic conductive film carrying tape, as taken up on another tape reel, to interconnect the anisotropic conductive film carrying tape, as taken up on said tape reel, and the anisotropic conductive film carrying tape, as taken up on the other tape reel;

exchanging the tape reel from which the anisotropic conductive film carrying tape is about to be depleted, for a new tape reel, carrying thereon an anisotropic conductive film carrying tape, for thereby enabling continued supply of the anisotropic conductive film carrying tape to a packaging unit for electronic devices or electronic parts or components; and

subsequently affixing the anisotropic conductive film carrying tape in a preset pattern.

8. The packaging method according to claim 7 wherein

when the anisotropic conductive film carrying tape on said tape reel is about to be depleted, an end thereof is detected and the colors on the front and back surfaces of the slice tapes provided to the ends of said anisotropic conductive film carrying tape on said tape reel are detected to check for a given surface of the splice tapes being a front surface or a back surface; the anisotropic conductive film carrying tape on said tape reel being subsequently connected to the anisotropic conductive film carrying tape on said other tape reel.

9. The packaging method according to claim 7 wherein

the anisotropic conductive film carrying tape on said tape reel is connected to the anisotropic conductive film carrying tape on said other tape reel by heat fusion of a polypropylene film of the splice tape of synthetic resin formed at an end of said anisotropic conductive film carrying tape on said tape reel to a polypropylene film provided to a splice tape formed at an end of said anisotropic conductive film carrying tape on said other tape reel.