Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-12-20
2001-11-06
Moore, Margaret G. (Department: 1712)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C522S053000, C522S064000, C522S065000, C522S099000, C528S032000, C528S034000, C427S387000
Reexamination Certificate
active
06312553
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an adhesive silicone elastomer film useful as an adhesive film for electronic parts, and a covering method and a bonding method which make use of the same.
2. Description of the Prior Art
Epoxy types of adhesive films are conventionally used for the die bonding of semiconductor devices or for TAB (tape automated bonding) tapes. However, these adhesive films have problems that they have an insufficient heat resistance and they can not be made low-elastic (a high-elastic one makes it difficult to relax thermal and mechanical stress when used, e.g., as an adhesive layer by putting it between two substrates of different types, resulting in products with low reliability).
On the other hand, silicone films generally have remarkable heat resistance and low elasticity. But silicone adhesive films having sufficient adhesiveness and workability, which are produced with ease, are not known.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an adhesive silicone elastomer film that can be produced in a short time as clean films easy to handle and having a uniform shape, can rationalize work steps when used, and also has a low elasticity and sufficient heat resistance, adhesiveness and workability, and a covering method and a bonding method which make use of such a film.
To achieve the above object, the present invention provides an adhesive silicone elastomer film obtained by forming a radiation-curable silicone rubber composition into a film and curing the resulting film by radiation; the composition comprising;
(A) an organopolysiloxane represented by the general formula (I):
wherein R
1
's may be the same or different and are each a substituted or unsubstituted monovalent hydrocarbon group having 1 to 9 carbon atoms; X is a group represented by the general formula (II):
wherein R
2
is a divalent hydrocarbon group having 2 to 4 carbon atoms, or an oxygen atom; R
3
is a monovalent organic group having 4 to 25 carbon atoms, having 1 to 3 (meth)acryloyl groups; R
4
is a substituted or unsubstituted monovalent hydrocarbon group having 1 to 9 carbon atoms; R
5
is a monovalent hydrocarbon group having 1 to 18 carbon atoms; n is an integer of 1 to 3, m is an integer of 0 to 2, and n and m satisfy 1≦n+m≦3, provided that when n=1 the group represented by R
3
has a plurality of (meth)acryloyl groups, and when the groups R
4
and R
5
are each two or more in the molecule, R
4
's and R
5
's may each be the same or different; and L is an integer of 8 to 10,000;
(B) a radiation sensitizer; and
(C) a compound selected from the group consisting of an alkoxysilane represented by the general formula (III):
Si(OR
6
)
4
(III)
wherein R
6
is a substituted or unsubstituted lower alkyl group; and
a partial hydrolysis-condensation product thereof.
The present invention also provides a covering method comprising covering a substrate with the above adhesive silicone elastomer film partly or completely, followed by heating to cause the film to cure.
The present invention still also provides a bonding method comprising inserting the above adhesive silicone elastomer film between two articles or two parts of an article, followed by heating to cause the film to cure, to bond the both articles or the both parts stated above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described below in detail.
In the present specification, the terms (meth)acryloyl, (meth)acryloyloxyl and (meth)acrylate are meant to embrace acryloyl and methacryloyl, acryloyloxyl and methacryloyloxyl, and acrylate and methacrylate, respectively.
Adhesive Silicone Elastomer Film
The adhesive silicone elastomer film is formed using a radiation-curable silicone rubber composition containing the following components (A) to (C). Incidentally, the adhesive silicone elastomer film referred to in the present invention may embrace a sheet.
(A) Organopolysiloxane:
The component-(A) organopolysiloxane is a component used as a base polymer, and is represented by the above general formula (I).
In the general formula (I), R
1
's may be the same or different and are each a substituted or unsubstituted monovalent hydrocarbon group having 1 to 9 carbon atoms, and preferably 1 to 6 carbon atoms. As specific examples of this monovalent hydrocarbon group, it may include alkyl groups such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a tert-butyl group, a pentyl group, a hexyl group, a heptyl group, a 2-ethylhexyl group, an octyl group and a nonyl group; cycloalkyl groups such as a cyclohexyl group and a cycloheptyl group; alkenyl groups such as a vinyl group, an allyl group, a propenyl group, an isopropenyl group, a butenyl group and a hexenyl group; aryl groups such as a phenyl group and a tolyl group; aralkyl groups such as a benzyl group, a phenylethyl group and a phenylpropyl group; and corresponding substituted hydrocarbon groups formed by substitution of at least part of hydrogen atoms bonded to the carbon atom of the hydrocarbon groups exemplified above substituted with a substituent such as a halogen atom or a cyano group, as exemplified by a chloromethyl group, a cyanoethyl group and a trifluoropropyl group. Preferred are those in which 50 mole % or more of R
1
's is occupied by methyl groups, and 25 mole % or less by phenyl groups.
In the general formula (I), X is a group represented by the above general formula (II). R
2
in the general formula (II) is a divalent hydrocarbon group having 2 to 4 carbon atoms, or an oxygen atom. In view of water resistance, it may preferably, be the divalent hydrocarbon group. As specific examples of this divalent hydrocarbon group, it may include alkylene groups having 2to 4carbon atoms, such as an ethylene group, a propylene, group, a methylethylene group and a tetramethylene group. The ethylene group is preferred.
R
3
in the general formula (II) is a monovalent organic group having 4 to 25 carbon atoms, having 1 to 3, preferably 2 or 3, and more preferably 3, (meth)acryloyl groups (in particular, as (meth)acryloyloxyl groups). As specific examples of the (meth)acryloyl group or (meth)acryloyloxyl group represented by R
3
, it may include acrylic functional groups and methacrylic functional groups such as CH
2
═CHCOO—, CH
2
═C(CH
3
)COO—, CH
2
═CHCO— and CH
2
═C(CH
3
)CO—. As specific examples of the monovalent organic group containing such a (meth)acryloyl group, it may include alkyl groups having 1 to 10 carbon atoms, and preferably 2 to 6 carbon atoms, substituted with 1 to 3 acryloyloxyl groups or methacryloyloxyl groups, such as CH
2
═CHCOOCH
2
CH
2
—, [CH
2
═C(CH
3
)COOCH
2
]
3
C—CH
2
—, (CH
2
═CHCOOCH
2
)
3
C—CH
2
— and (CH
2
═CHCOOCH
2
)
2
C(C
2
H
5
)CH
2
—. Preferred are CH
2
═CHCOOCH
2
CH
2
—, [CH
2
═C(CH
3
)COOCH
2
]
3
C—(CH
2
—, (CH
2
═CHCOOCH
2
)
3
C—CH
2
—, (CH
2
═CHCOOCH
2
)
2
C(C
2
H
5
)CH
2
—, CH
2
═C(CH
3
)COOCH
2
CH
2
—, [CH
2
═C(CH
3
)COOCH
2
]
2
C(C
2
H
5
)—CH
2
— and (CH
2
═CHCOOCH
2
)[CH
2
═C(CH
3
)COOCH
2
]CH—. More preferred are [CH
2
═C(CH
3
)COOCH
2
]
3
C—CH
2
—, (CH
2
═CHCOOCH
2
)
3
C—CH
2
—, (CH
2
═CHCOOCH
2
)
2
C(C
2
H
5
)CH
2
— and (CH
2
═CHCOOCH
2
)[CH
2
═C(CH
3
)COOCH
2
]CH—.
R
4
in the general formula (II) may be the same or different when present in plurality, and is a substituted or unsubstituted monovalent hydrocarbon group having 1 to 9 carbon atoms, and preferably 1 to 6 carbon atoms. As specific examples of the group represented by R
4
, it may include the same one as those exemplified for R
1
in the general formula (I). Like the case of R
1
, preferred are those in which 50 mole % or more of R
4
's is occupied by methyl groups, and 25 mole % or less by phenyl groups.
R
5
in the general formula (II) is a monovalent hydrocarbon group having 1 to 18 carbon atom
Kashiwagi Tsutomu
Okinoshima Hiroshige
Moore Margaret G.
Pillsbury & Winthrop LLP
Shin-Etsu Chemical Co. , Ltd.
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