JP5648466B2 - Method for producing metal foil-clad laminate - Google Patents

Description

  The present invention relates to a method for producing a metal foil-clad laminate.

The end face of a conventional metal foil-clad laminate is smoothed by cutting with a shear cutter and then finishing the end face with a chamfering machine or cutting and cutting with a tip saw.
In such a conventional technique, the end face cut off of the metal foil-clad laminate is smoothed to reduce dust generation from the end face as much as possible, but the product handling and subsequent printed wiring board manufacturing process In this case, resin powder is generated from the end face. The generated resin powder adheres to the product and causes scratches on the surface of the metal foil, and in the printed wiring board manufacturing process, is a major factor in yield deterioration.

  As a measure for preventing this, for example, Patent Document 1 proposes a technique for preventing dust generation by covering a cut end surface of a copper-clad laminate with a resin.

JP-A-6-104549

  However, as in the technique proposed in Patent Document 1, in the method of coating a resin on the cut end surface of a metal foil-clad laminate, a solvent is used for the preparation of the coating liquid, so that the ignition is difficult. It was necessary to prepare the work environment in consideration of the dangers of workers and the harm to the health of workers. In addition, after the application, it is necessary to dry the applied resin for a sufficient time so that the solvent does not remain.

  The present invention has been made in view of such circumstances, and when a metal foil-clad laminate is produced, a coating resin layer is formed on the cut end surface of the metal foil-clad laminate without using a solvent. An object is to provide a method for producing a metal foil-clad laminate.

The method for producing a metal foil-clad laminate according to the present invention includes a step of laminating a plurality of materials including a metal foil and a prepreg to form a laminated base material, a step of cutting the laminated base material into a predetermined dimension, A step of arranging a transfer material provided with a transfer resin layer made of a thermosetting resin in a semi-cured state on a base film on the cut end surface of the laminated base material, and the transfer material using a heating roll with pressurized, the step of selectively curing the resin for forming the transfer resin layer in contact with the cut end faces of the laminated substrate, at least seen including a step of peeling the substrate film of the heat roll This is a method in which a concave portion corresponding to the width of the transfer material is provided on the pressing surface .

  By adopting such a method, it is not necessary to prepare a coating liquid using a solvent, and the coating resin layer is transferred to the cut end surface of the laminated base material, so that the coating resin layer is provided at the end portion. Since it is possible to manufacture metal foil-clad laminates, there is no need for maintenance of the work environment associated with the use of solvents, and in order to prevent the solvent from remaining when producing metal foil-clad laminates It is also possible to reduce the time required for manufacturing by omitting.

In the method for producing a metal foil-clad laminate according to the present invention, as the resin for forming the transfer resin layer, a thermosetting resin that can be completely cured by heating from a semi-cured state is used .

  Further, in the method for producing a metal foil-clad laminate according to the present invention, the step of pressurizing the transfer material after the step of arranging the transfer material on the cut end surface of the laminate substrate, Adhesion between the cut end surface of the substrate and the transfer resin layer can be improved.

Further, in the method for producing a metal foil-clad laminate according to the present invention, in the step of curing the resin forming the transfer resin layer, the resin in contact with the cut end surface of the laminated substrate is selectively cured, in the step of peeling the base film, wherein the remains of the resin semi-cured state is not in contact with the cut end faces of the laminated base material by a method of removing with the base film, laminated base material of various thicknesses This makes it possible to use a common transfer material.

A method of manufacturing a metal foil-clad laminate according to the present invention, as well as pressurizing the transfer material by using a heating roll, thereby selectively curing the resin in contact with the cut end faces of the laminated base material. And the transfer mechanism formed by combining the roll for feeding out the transfer material, the heating roll, and the roll for winding the peeled base sheet is moved along the cut end surface of the laminated base material. A step of placing the transfer material on the cut end surface of the laminated base material, a step of pressing the transfer material, and a resin forming the transfer resin layer in contact with the cut end surface of the laminated base material. By continuously performing the curing step and the substrate film peeling step, the coating resin layer can be efficiently transferred and formed.

  Further, the method for producing a metal foil-clad laminate according to the present invention corresponds to the shape of the cut end face of the laminated base material, or provided with a recess according to the width of the transfer material on the pressing surface of the heating roll. In this way, the coating resin layer can be reliably transferred and formed while preventing the transfer material from being displaced.

According to the present invention, it is not necessary to prepare a coating liquid using a solvent in forming a coating resin layer for preventing dust generation by transferring and forming a coating resin layer on the cut end surface of the laminated base material. In addition, in curing the resin forming the transfer resin layer while pressing the transfer material with the heating roll, the pressing surface of the heating roll is provided with a recess according to the width of the transfer material. Thus, it is possible to reliably transfer and form the coating resin layer while preventing the positional deviation.

It is explanatory drawing which shows the outline of embodiment of the manufacturing method of the metal foil tension laminated board which concerns on this invention. It is explanatory drawing which shows an example of the transfer mechanism in embodiment of the manufacturing method of the metal foil tension laminated board which concerns on this invention. It is explanatory drawing which shows an example of the heating roll used with embodiment of the manufacturing method of the metal foil tension laminated board which concerns on this invention. It is explanatory drawing which shows the other example of the heating roll used by embodiment of the manufacturing method of the metal foil tension laminated board which concerns on this invention.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is an explanatory view showing an outline of a method for producing a metal foil-clad laminate according to the present embodiment.

  The method for manufacturing a metal foil-clad laminate according to the present embodiment includes a step of laminating a plurality of materials including the metal foil 3 and the prepreg 4 to form a laminated substrate 2 (see FIG. 1A), and a laminated substrate. A step of cutting the material 2 into a predetermined size (see FIG. 1B), and a semi-cured transfer resin layer 6 is provided on the base film 7 on the cut end surface 2a of the laminated base material 2. A step of placing the transfer material 5 (see FIG. 1C) and a step of curing the resin 6a that forms the transfer resin layer 6 in contact with the cut end surface 2a of the laminated substrate 2 (see FIG. 1D). And a step of peeling the base film 7 (see FIG. 1 (e)), and by performing these steps in order, the metal foil-clad laminate 1 provided with the coating resin layer 8 at the end portion Is manufactured.

  The metal foil 3 used when forming the laminated base material 2 is not particularly limited. For example, a copper foil, a nickel foil, an aluminum foil, or the like suitable for manufacturing this type of metal foil-clad laminate is used. Similarly, the prepreg 4 that is suitable for manufacturing this type of metal foil-clad laminate can be used. Generally, the prepreg 4 is manufactured by impregnating an uncured thermosetting resin into a woven or non-woven fabric made of glass fiber or the like, and drying by heating. In the example shown in FIG. 1, the metal foil 3 is overlapped on both surfaces of the prepreg 4 and heated and pressurized, and the thermosetting resin impregnated in the prepreg 4 is cured at the interface with the metal foil 3, whereby both surfaces of the prepreg 4 are formed. An example in which a metal foil 3 is bonded and laminated is shown as an example of a laminated substrate 2.

The laminated base material 2 thus formed is cut into a predetermined size using a cutting device such as a rotary cutter, a shear cutter, or a slitter. The steps so far are carried out in the same manner as in the prior art. be able to.
In the example shown in FIG. 1, the portion of the laminated base material 2 that is cut is indicated by a one-dot chain line in FIG.

In this embodiment, the coating resin layer 8 that covers the cut end surface 2a of the laminated base material 2 is formed, thereby preventing dust generation from the end surface 2a. However, means for forming the coating resin layer 8 is conventionally used. It is very different from technology.
That is, in the present embodiment, after the laminated base material 2 is cut to a predetermined size, the cut end surface 2a is smoothed as necessary, and then, as shown in FIG. 1 (c). The transfer material 5 in which the transfer resin layer 6 made of a semi-cured resin is provided on the base film 7 is disposed on the end surface 2a. Then, as shown in FIG. 1 (d), the resin 6a of the transfer resin layer 6 in contact with the end face 2a is cured, and then the base film 7 of the transfer material 5 is peeled off as shown in FIG. 1 (e). Then, the cured resin 6 a of the transfer resin layer 6 is transferred to the end surface 2 a of the laminated base material 2. Thereby, the coating resin layer 8 which covers the cut end surface 2a of the laminated base material 2 is formed by transfer.

  According to the present embodiment as described above, it is not necessary to prepare a coating liquid using a solvent, and the coating resin layer 8 is transferred and formed on the cut end surface 2a of the laminated base material 2, so that the coating resin layer is formed on the end portion. The metal foil-clad laminate 1 provided with 8 can be manufactured. For this reason, it is not necessary to prepare a work environment associated with the use of a solvent, and in manufacturing the metal foil-clad laminate 1, the drying process for preventing the solvent from remaining is omitted, and the time required for the manufacture Can be shortened.

The transfer material 5 is provided with a transfer resin layer 6 on a base film 7 which has been subjected to a release treatment as necessary. Although the transfer resin layer 6 is in a semi-cured state, the transfer resin layer 6 can be formed on the base film 7 with a predetermined thickness, and further cured from the semi-cured state to thereby form the laminated base material 2. The end surface 2a is formed using a transferable resin. As such a resin, a thermosetting resin that does not have fluidity even in a semi-cured state and can be completely cured by heating can be used .

Examples of the thermosetting resin used in the present embodiment include an epoxy resin, a phenol resin, an unsaturated polyester resin, a urea resin, a melamine resin, and a polyimide resin, and an epoxy resin and a phenol resin are preferable, and an epoxy resin is more preferable. .

In forming the coating resin layer 8 by transfer, various conditions for transfer are appropriately set according to the resin forming the transfer resin layer 6, but the transfer material 5 is cut from the cut end surface 2 a of the laminated substrate 2. After the step of disposing, the step of pressurizing the transfer material 5 and pressing the transfer resin layer 6 against the end surface 2a to improve the adhesion between them . This step may be performed prior to curing the resin 6a of the transfer resin layer 6 in contact with the cut end surface 2a of the laminated substrate 2, and is performed at the same time or substantially simultaneously with the curing of the resin 6a. May be.

  Further, it is preferable that the width of the transfer material 5 is formed larger than the thickness of the laminated base material 2 as shown in FIG. If it does in this way, it will become possible to be able to be used in common with the laminated base material 2 of various thickness. For this reason, in the step of curing the resin of the transfer material layer 6, only the resin 6a in contact with the end surface 2a is selectively cured, and the other resin 6b is left in a semi-cured state, and the base sheet 7 It is preferable to be able to remove with peeling.

When the transfer resin layer 6 is formed of a thermosetting resin, the pressing of the transfer material 5 and the curing of the resin forming the transfer resin layer 6 can be performed by a heating roll. That is, the resin 6a in contact with the end surface 2a can be heated and cured while pressing the transfer material 5 with a heating roll.
At this time, the heating roll has a heating element (for example, nichrome) along the circumferential direction in a range not exceeding the thickness of the laminated base material 2 at a position in contact with the center of the laminated base material 2 through the transfer material 5. A linear resistance heating heating element such as a wire) is embedded and only the resin 6a in contact with the end face 2a is selectively cured by the heat conduction by appropriately adjusting the heat generation amount of the heating element. You should be able to.

When using a heating roll, for example, as shown in FIG. 2, a roll 9 that is configured to continuously feed the wound transfer material 5, a heating roll 10, and a peeled base sheet 7. It is possible to configure a transfer mechanism 12 that is combined with the roll 11 to be wound.
Then, the transfer mechanism 12 moves along the cut end surface 2a of the laminated base material 2 to arrange the transfer material 5 on the cut end surface 2a of the laminated base material 2, and the transfer material 5 The step of pressurizing, the step of curing the resin 6a that forms the transfer resin layer 6 in contact with the cut end surface 2a of the laminated base material 2, and the step of peeling the base material film 7 are performed in succession. By doing so, it is possible to efficiently transfer and form the coating resin layer 8.

Further, in curing the resin forming the transfer resin layer 6 while pressing the transfer material 5 with the heating roll 10, the pressing surface of the heating roll 10 has a width of the transfer material 5 as shown in FIG. 3. A combined recess 10a is provided . Furthermore, when the cut end surface 2a of the laminated base material 2 is not flat, for example, as shown in FIG. 4, a recess 10b corresponding to the shape of the end surface 2a can be provided.
By doing so, the covering resin layer 8 can be reliably transferred and formed while preventing the displacement of the transfer material 5.

  Although the present invention has been described with reference to the preferred embodiment, it is needless to say that the present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the present invention. .

  For example, in the above-described embodiment, the example in which the metal foil 3 is laminated on both surfaces of the prepreg 4 is shown, but the present invention is not limited to this. As long as the laminated base material 2 formed by laminating a plurality of materials including the metal foil 3 and the prepreg 4 is cut to a predetermined size, and the covering resin layer 8 is transferred and formed on the cut end surface 2a, The specific laminated structure of the metal foil-clad laminate 1 is arbitrary.

  The metal foil-clad laminate produced according to the present invention can be suitably used for producing a printed wiring board.

DESCRIPTION OF SYMBOLS 1 Metal foil tension laminated board 2 Laminate base material 3 Metal foil layer 4 Prepreg 5 Transfer material 6 Transfer resin layer 7 Base film 8 Covering resin layer 9 Roll 10 Heating roll 10a Recess 10b Recess 11 Roll 12 Transfer machine

Claims (4)

Laminating a plurality of materials including metal foil and prepreg to form a laminated base material,
Cutting the laminated substrate into a predetermined dimension;
A step of arranging a transfer material provided with a transfer resin layer made of a thermosetting resin in a semi-cured state on a base film on the cut end surface of the laminated base material;
A step of pressurizing the transfer material using a heating roll and selectively curing a resin forming the transfer resin layer in contact with the cut end surface of the laminated substrate;
At least it looks including a step of peeling the substrate film,
A method for producing a metal foil-clad laminate , wherein a concave portion corresponding to the width of the transfer material is provided on the pressing surface of the heating roll .   2. The metal foil-clad laminate according to claim 1, wherein in the step of peeling the base film, the resin in a semi-cured state that is not in contact with the cut end surface of the laminated base is removed together with the base film. Production method. By moving a transfer mechanism that is a combination of a roll that feeds out the transfer material, the heating roll, and a roll that winds up the peeled substrate sheet, along the cut end surface of the laminated substrate, The step of placing the transfer material on the cut end surface of the laminated base material, the step of pressing the transfer material, and the resin forming the transfer resin layer in contact with the cut end surface of the laminated base material are cured. The manufacturing method of the metal foil tension laminated board as described in any one of Claim 1 or 2 which performs a process and the process of peeling the said base film continuously. The manufacturing method of the metal foil tension laminated board as described in any one of Claims 1-3 which provides the recessed part equivalent to the shape of the cut end surface of the said laminated base material in the press surface of the said heating roll.

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