Microcavity carrier belt and method of manufacture

{
  "publication_number": "US9102851B2",
  "country": "US",
  "kind": "B2",
  "title": "Microcavity carrier belt and method of manufacture",
  "abstract": "A method for fabricating an electronic device or component such as an anisotropic conductive film comprising: distributing a plurality of conductive particles into an array of microcavities formed on a surface of a continuous carrier belt, rotating the belt carrying the conductive particles while conveying a surface of an adhesive layer into contact with the surface of the rotating belt, transferring the conductive particles from the microcavities on the belt to the adhesive layer in predefined locations in the adhesive layer corresponding to the array of microcavities on the belt, and separating the adhesive layer from the surface of the belt. In one embodiment, the position of the microcavities is varied in a controlled manner.",
  "claims": [
    "1. An anisotropic conductive film (ACF) comprising a plurality of conductive particles disposed in predefined non-random particle locations as a non-random array in or on an adhesive layer, wherein the ACF includes an oblique area that is essentially free from conductive particles that corresponds to an oblique line that runs across the ACF; wherein the ACF has an X-Y plane corresponding to its length and width and a Z-axis corresponding to its thickness and the ACF is insulating in the X-Y plane relative to the Z-axis which is conductive.",
    "2. The ACF of claim 1 wherein said conductive particles are partially buried in the adhesive layer.",
    "3. The ACF of claim 1 wherein the ACF is made by a method comprising: distributing a plurality of conductive particles into an array of microcavities formed on a surface of a continuous carrier belt, rotating the belt carrying the conductive particles while conveying a surface of an adhesive layer into contact with the surface of the rotating belt, transferring the conductive particles from the microcavities on the belt to the adhesive layer in predefined locations in the adhesive layer corresponding to the array of microcavities on the belt, and separating the adhesive layer from the surface of the belt, wherein the belt is a closed loop including a stitching line that runs across the belt from one edge of the belt to the opposite edge at an angle that is oblique with respect to the edges of the belt.",
    "4. The ACF of claim 3 wherein the oblique line is at an angle of about 30 to 80°.",
    "5. The ACF of claim 4 wherein the oblique line is at an angle of about 35 to 60°.",
    "6. The ACF of claim 1 wherein the oblique line is less than about 100μ wide.",
    "7. The ACF of claim 6 wherein the oblique line is less than about 20μ wide.",
    "8. The ACF of claim 1 wherein the adhesive comprises an acrylic, epoxy or phenoxy resin."
  ],
  "description_excerpt": "This invention relates to a method for manufacturing electronic devices and components such as anisotropic conductive films (ACF). This invention represents an improvement in the invention disclosed in U.S. Published Application 2010/0101700 to Liang et al. (“Liang '700”).\n\nFor a discussion of the background of the invention reference may be made to Liang '700 cited above. Liang '700 discloses a method for manufacturing ACFs having a non-random array of conductive particles by providing a carrier web having a non-random array of microcavities and distributing the conductive particles into the microcavities. Preferably, the particles are distributed on the carrier web so that there is one particle in each cavity. The carrier web is conveyed into contact with an adhesive film and the particles are transferred to the film upon contact.\n\nOne manifestation of the invention is a process for manufacturing an electronic device such as an ACF using a continuous belt or loop having an array of microcavities formed in one surface as the carrier web for conductive particles. The belt is used in a manner analogous to the web in the process disclosed in the Liang '700 publication.\n\nAnother manifestation of the invention is a carrier belt useful in manufacturing device components such as ACF in the aforementioned process and, more particularly, chip on film (COF) or chip on glass (COG) devices.\n\nAnother manifestation of the invention is a carrier belt or web in which the microcavities are arranged in a non-random but variable pattern to reduce the effect of periodic defects.",
  "cpc": [
    "C09J 9/02",
    "B32B 2255/10",
    "B32B 2255/26",
    "B32B 2264/105",
    "B32B 2266/045",
    "B32B 2307/202",
    "B32B 2309/08",
    "B32B 2310/0843",
    "B32B 2457/00",
    "B32B 27/14",
    "B32B 27/281",
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    "B32B 27/36",
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    "B32B 37/226",
    "B32B 38/06",
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    "B32B 7/12",
    "B65G 17/36",
    "C08K 2201/001",
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    "H05K 3/321",
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  ],
  "ipc": [
    "B32B 27/14",
    "B32B 27/28",
    "B32B 27/30",
    "B32B 27/36",
    "B32B 3/10",
    "B32B 37/12",
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    "B65G 17/36",
    "C08K 9/02",
    "C09J 7/10",
    "C09J 9/02",
    "H05K 3/32"
  ],
  "assignees": [
    "Trillion Science Inc"
  ],
  "inventors": [
    "Jiannrong Lee",
    "Yuhao Sun",
    "Maung Kyaw Aung",
    "Chin-Jen Tseng",
    "Chiapu Chang",
    "Shuji Rokutanda",
    "Rong-Chang Liang"
  ],
  "filing_date": "2011-09-15",
  "publication_date": "2015-08-11",
  "grant_date": "2015-08-11",
  "priority_date": "2011-09-15",
  "application_number": "US-201113233360-A",
  "family_id": "47040788",
  "cited_by_count": 7,
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