JP7240378B2 - Laminate for preventing warp of cured sealant, and method for manufacturing cured sealant - Google Patents

Description

TECHNICAL FIELD The present invention relates to a warp-preventing laminate for a cured sealant and a method for producing the cured sealant.

2. Description of the Related Art In recent years, electronic devices have become smaller, lighter, and more functional, and semiconductor chips are sometimes mounted in packages close to their size. Such a package is sometimes called a CSP (Chip Scale Package). Examples of CSP include WLP (Wafer Level Package), which is completed by processing up to the final package process on a wafer size, and PLP (Panel Level Package), which is completed by processing up to the final package process on a panel size larger than the wafer size. .

WLP and PLP are classified into fan-in type and fan-out type. In fan-out type WLP (hereinafter also referred to as "FOWLP") and PLP (hereinafter also referred to as "FOPLP"), a semiconductor chip is covered with a sealing material so as to have a region larger than the chip size, and the semiconductor chip is formed. Then, a rewiring layer and external electrodes are formed not only on the circuit surface of the semiconductor chip but also on the surface region of the encapsulant.

FOWLP and FOPLP include, for example, a mounting process of mounting a plurality of semiconductor chips on a temporary fixing sheet, a coating process of coating with a thermosetting sealing material, and a thermosetting of the sealing material to cure it. A curing step of obtaining a sealing body, a separation step of separating the cured sealing body and the temporary fixing sheet, and a rewiring layer forming step of forming a rewiring layer on the exposed semiconductor chip side surface. (Hereinafter, the processing performed in the coating step and the curing step is also referred to as “sealing processing”).

Patent Literature 1 discloses a heat-peelable pressure-sensitive adhesive sheet for temporary fixing when cutting an electronic component, in which a heat-expandable pressure-sensitive adhesive layer containing heat-expandable microspheres is provided on at least one side of a base material. It is also conceivable to use the heat-peelable pressure-sensitive adhesive sheet described in Patent Document 1 in the production of FOWLP and FOPLP.

Japanese Patent Application Laid-Open No. 2001-131507

However, according to the studies of the present inventors, when the adhesive sheet described in Patent Document 1 is used as a sheet for temporary fixing to prepare a cured sealing body, the temporary fixing layer is heated to heat the thermally expandable particles. It was found that the provisionally cured layer could not be peeled off from the cured resin layer formed by heating in the first stage prior to heating and foaming. This problem tends to become more pronounced as package sizes such as FOWLP and FOPLP increase.
A hardened sealing body with peeling failure may not only damage the sealing target itself such as a semiconductor chip, but also, for example, part of the thermally expandable adhesive layer may remain on the cured resin layer, or the cured resin may be damaged. If the resin layer itself is damaged, there may be adverse effects such as the inability to accurately carry out the processes such as grinding and dicing of the cured sealing body scheduled in the next process.

In view of the above problems, the present invention has a support layer and a curable resin layer, and can perform sealing processing by fixing an object to be sealed to the surface of the curable resin layer, and the sealing process can be performed. A warp-preventing lamination that can provide a cured resin layer as a warp-preventing layer to a cured sealing body formed by processing and can prevent the occurrence of poor separation between the curable resin layer and the support layer. It is an object of the present invention to provide a body and a method for manufacturing a cured sealing body using this anti-warp laminate.

The inventors of the present invention have made intensive studies to solve the above problems, and found that the above problems can be solved by setting the adhesive strength of the curable resin layer to a predetermined range, and completed the present invention. bottom.
That is, the present invention provides the following [1] to [10].

[1] Having a curable resin layer (I) containing a thermosetting resin layer (X1) and a support layer (II) supporting the curable resin layer (I),
The curable resin layer (I) has an adhesive surface with adhesiveness,
The support layer (II) has a substrate (Y) and an adhesive layer (V), at least one of the substrate (Y) and the adhesive layer (V) contains thermally expandable particles,
The curable resin layer (I), the adhesive layer (V), and the substrate (Y) are arranged in this order, and the adhesive surface of the curable resin layer (I) is the adhesive layer (V) placed opposite to the
The lowest curing temperature (T ₁ ) at which the curing of the curable resin layer (I) is completed within 2 hours to form the curable resin layer (I′) is higher than the foaming start temperature (T ₂ ) of the thermally expandable particles. low temperature,
A warp-preventing laminate of a cured sealing body produced by sealing an object to be sealed on the adhesive surface of the curable resin layer (I).
[2] The difference (T ₂ −T ₁ ) between the minimum curing temperature (T ₁ ) of the curable resin layer (I) and the expansion start temperature (T ₂ ) of the thermally expandable particles is 20° C. to 100° C. The anti-warp laminate according to [1] above.
[3] The curable resin layer (I) has two or more thermosetting resin layers (X1), and the minimum curing temperature (T ₁ ) in the two or more thermosetting resin layers (X1) The anti-warp laminate according to [1] or [2] above, wherein the value (T _1a ) is lower than the expansion start temperature (T ₂ ) of the thermally expandable particles.
[4] The laminate according to any one of [1] to [3] above, wherein the thermosetting resin layer (X1) has a thickness of 1 to 500 μm.
[5] The laminate according to any one of [1] to [4] above, wherein the substrate (Y) has an expandable substrate layer (Y1) containing the thermally expandable particles.
[6] The laminate according to [5] above, wherein the pressure-sensitive adhesive layer (V) is a non-expanding pressure-sensitive adhesive layer.
[7] The substrate (Y) has a non-expandable substrate layer (Y2) and an expandable substrate layer (Y1),
The above [5] or [6], wherein the support layer (II) has a non-expandable base layer (Y2), an expandable base layer (Y1), and an adhesive layer (V) in this order. laminate.
[8] The curable resin layer (I) has a first layer arranged on the support layer (II) side and a second layer arranged on the adhesive surface side,
The first layer is a thermosetting resin layer (X1-1),
The anti-warp laminate according to any one of [1] to [7] above, wherein the second layer is an energy ray-curable resin layer (X2).
[9] A method for producing a cured sealing body using the warp-preventing laminate according to any one of [1] to [7] above,
A step of placing an object to be sealed on a part of the adhesive surface of the curable resin layer (I) of the warp-preventing laminate;
a step of covering the sealing object and the adhesive surface of the curable resin layer (I) at least in the periphery of the sealing object with a thermosetting sealing material;
The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer, and a cured resin layer is formed. and obtaining a hardened encapsulant.
[10] A method for producing a cured sealing body using the anti-warp laminate according to [8] above,
A step of placing an object to be sealed on a part of the adhesive surface of the curable resin layer (I) of the warp-preventing laminate;
a step of irradiating an energy ray to cure the energy ray-curable resin layer (X2);
a step of covering the sealing object and the adhesive surface of the curable resin layer (I) at least in the periphery of the sealing object with a thermosetting sealing material;
The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer (I′), and a step of obtaining a cured sealing body with a cured resin layer.

According to the present invention, the sealing process can be performed by fixing the sealing object to the surface of the curable resin layer, and the cured sealing body formed by the sealing process has a warp prevention layer. A warp-preventing laminate that can be provided with a cured resin layer and can prevent the occurrence of poor peeling between the curable resin layer and the support layer, and a curing seal using this warp-preventing laminate A method for manufacturing a stop body can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS It is a cross-sectional schematic diagram of the said laminated body which shows the structure of the laminated body for warp prevention of the 1st aspect of this invention. It is a cross-sectional schematic diagram of the said laminated body which shows the structure of the laminated body for warp prevention of the 2nd aspect of this invention. It is a cross-sectional schematic diagram of the said laminated body which shows the structure of the laminated body for warp prevention of the 3rd aspect of this invention. It is a cross-sectional schematic diagram of the said laminated body which shows the structure of the laminated body for warpage prevention of the 4th aspect of this invention. It is a cross-sectional schematic diagram of the said laminated body which shows the structure of the laminated body for warpage prevention of the 5th aspect of this invention. It is a cross-sectional schematic diagram which shows the process of manufacturing a hardened sealing body with a hardened resin layer. It is a cross-sectional schematic diagram which shows the other manufacturing process of the hardened sealing body with a hardened resin layer.

First, the terms used in this specification will be explained.
In the present specification, whether or not the target layer is a "non-expandable layer" is the volume change rate calculated from the following formula before and after the treatment for expansion after performing the treatment for 3 minutes. is less than 5%, the layer is judged to be a "non-intumescent layer." On the other hand, when the volume change rate is 5% or more, the layer is judged to be an "expandable layer".
・ Volume change rate (%) = {(volume of the layer after treatment - volume of the layer before treatment) / volume of the layer before treatment} x 100
As for the "treatment for expansion", for example, in the case of a layer containing thermally expandable particles, heat treatment may be performed for 3 minutes at the expansion start temperature (t) of the thermally expandable particles. When the expandable particles are expanded by foaming, the expansion start temperature (t) may be referred to as the foam start temperature (T2).

As used herein, the term “active ingredient” refers to the components contained in the target composition, excluding the diluent solvent.
In the present specification, the mass average molecular weight (Mw) is a value in terms of standard polystyrene measured by a gel permeation chromatography (GPC) method, specifically a value measured based on the method described in Examples. is.
In this specification, for example, "(meth)acrylic acid" indicates both "acrylic acid" and "methacrylic acid", and the same applies to other similar terms.
In this specification, for preferred numerical ranges (for example, ranges of content etc.), the lower and upper limits described stepwise can be independently combined. For example, from the statement "preferably 10 to 90, more preferably 30 to 60", combining "preferred lower limit (10)" and "more preferred upper limit (60)" to "10 to 60" can also

As used herein, the term "energy ray" means an electromagnetic wave or charged particle beam that has an energy quantum, and examples thereof include ultraviolet rays, radiation, electron beams, and the like. Ultraviolet rays can be applied by using, for example, a high-pressure mercury lamp, a fusion lamp, a xenon lamp, a black light, an LED lamp, or the like as an ultraviolet light source. The electron beam can be generated by an electron beam accelerator or the like.
As used herein, "energy ray-curable" means the property of curing by irradiation with energy rays, and "non-energy ray-curable" means the property of not curing even when irradiated with energy rays. do.

In this specification, the minimum temperature at which curing of the curable resin is completed within 2 hours is sometimes referred to as "minimum curing temperature".
In the present specification, "curing is completed" means that the peak attributed to the curing reaction disappears from the temperature characteristic curve when the sample is measured using a differential scanning calorimeter.

Hereinafter, embodiments of the present invention (hereinafter sometimes referred to as "present embodiments") will be described.
[Warp prevention laminate]
A warp-preventing laminate of one embodiment of the present invention has a curable resin layer (I) containing a thermosetting resin layer (X1) and a support layer (II) that supports the curable resin layer (I). . In the following description, the anti-warp laminate may be simply referred to as "laminate".
The thermosetting resin layer (X1) is preferably laminated directly to the support layer (II).
The curable resin layer (I) has an adhesive surface with adhesiveness.
The support layer (II) has a substrate (Y) and an adhesive layer (V), and at least one of the substrate (Y) and the adhesive layer (V) contains thermally expandable particles.
The curable resin layer (I), the adhesive layer (V), and the substrate (Y) are arranged in this order, and the adhesive surface of the curable resin layer (I) is the adhesive layer (V) is placed on the opposite side.
The lowest curing temperature (T ₁ ) at which the curing of the curable resin layer (I) is completed within 2 hours to form the curable resin layer (I′) is higher than the foaming start temperature (T ₂ ) of the thermally expandable particles. Low temperature.

<Structure of warp-preventing laminate>
The configuration of the warp-preventing laminate of the present embodiment will be described with reference to the drawings.
FIGS. 1 to 5 are cross-sectional schematic views of laminates showing the configurations of warp-preventing laminates of the first to fifth embodiments of the present invention. In the laminates of the following first to fifth aspects, the adhesive surface of the adhesive layer (V1) attached to a support (not shown) and the first surface of the curable resin layer (I) (support layer From the viewpoint of protecting the surfaces of the curable resin layer (I) and the support layer (II), a release material may be further laminated on the surface opposite to (II). The release material is peeled off and removed when the anti-warp laminate is used.

[Warp-preventing laminate of the first embodiment]
Laminates 1a and 1b shown in FIG. 1 are exemplified as the warp-preventing laminate of the first aspect of the present invention.
Laminates 1a and 1b each include a support layer (II) having a base material (Y) and an adhesive layer (V1), and a curable resin layer (I). (I) is directly laminated.
In the following description, the surface of the curable resin layer (I) opposite to the support layer (II) is sometimes referred to as the "first surface", and the surface on the support layer (II) side is sometimes referred to as the "second surface". .
The first surface of the curable resin layer (I) is an adhesive surface having a predetermined adhesive force, and when an object to be sealed is placed thereon, the object to be sealed can be fixed by the adhesive force.
In the laminates 1a and 1b, the adhesive surface of the adhesive layer (V1) is attached to a support (not shown).

In the support layer (II), at least one of the substrate (Y) and the pressure-sensitive adhesive layer (V1) contains thermally expandable particles and has expandability. In the laminate 1a of FIG. 1(a), the substrate (Y) has an expandable substrate layer (Y1) containing thermally expandable particles.
The substrate (Y) may be a substrate having a single-layer structure consisting of only the expandable substrate layer (Y1), such as the laminate 1a shown in FIG. It may be a multilayer substrate having an expandable substrate layer (Y1) and a non-expandable substrate layer (Y2), like the laminate 1b shown in FIG.
In addition, in the warp-preventing laminate of the first aspect, when using a substrate (Y) having an expandable substrate layer (Y1) and a non-expandable substrate layer (Y2), as shown in FIG. In addition, a non-expanding base layer (Y2) is laminated on the surface of the pressure-sensitive adhesive layer (V1), and an expandable base layer (Y1) is laminated on the surface of the non-expanding base layer (Y2). It is preferred to have

In the laminate 1a shown in FIG. 1(a), thermally expandable particles contained in the expandable substrate layer (Y1) are expanded by expansion treatment by heating (hereinafter referred to as “heat expansion treatment”), and the substrate The surface of (Y) becomes uneven, and the contact area with the cured resin layer obtained by curing the cured resin layer (I) decreases. In addition, in the following description, the layer obtained by curing the curable resin layer is referred to as a cured resin layer (I').
At this time, the adhesive surface of the adhesive layer (V1) is attached to a support (not shown). The pressure-sensitive adhesive layer (V1) is attached so as to be sufficiently adhered to the support, so that the surface of the expandable substrate layer (Y1) on the pressure-sensitive adhesive layer (V1) side becomes uneven. Even if is generated, a repulsive force is likely to be generated from the pressure-sensitive adhesive layer (V1). Therefore, irregularities are less likely to be formed on the surface of the substrate (Y) on the pressure-sensitive adhesive layer (V1) side.
As a result, the laminate 1a can be easily separated collectively with a slight force at the interface P between the substrate (Y) of the support layer (II) and the cured resin layer (I').
The adhesive layer (V1) of the laminate 1a may be formed with an adhesive composition that increases the adhesive strength to the support, so that the interface P can be separated more easily. be. In the following description, the interface between the curable resin layer (I) and the support layer (II) may also be referred to as "interface P".

From the viewpoint of suppressing the transmission of the stress due to the thermally expandable particles to the adhesive layer (V1) side, the base material (Y) is an expandable group like the laminate 1b shown in FIG. 1(b). It preferably has a material layer (Y1) and a non-expandable substrate layer (Y2).
Since the stress due to the expansion of the thermally expandable particles of the expandable base layer (Y1) is suppressed by the non-expandable base layer (Y2), it is difficult to transmit to the pressure-sensitive adhesive layer (V1).
Therefore, the surface of the pressure-sensitive adhesive layer (V1) on the side of the support is less likely to be uneven, and the adhesion between the pressure-sensitive adhesive layer (V1) and the support is almost unchanged before and after the thermal expansion treatment, and good adhesion is maintained. can do. As a result, unevenness is easily formed on the surface of the expandable base layer (Y1) on the curable resin layer (I) side, and as a result, the expandable base layer (Y1) and the curable resin layer of the support layer (II) At the interface P with (I'), it becomes possible to easily separate them collectively with a slight force.

Note that, as in the laminate 1b shown in FIG. 1(b), the expandable substrate layer (Y1) and the curable resin layer (I) are directly laminated, and the non-expandable substrate layer (Y2) is cured. It is preferable that the pressure-sensitive adhesive layer (V1) is laminated on the surface opposite to the adhesive layer (I).
An adhesive layer or an anchor layer may be provided between the expandable base layer (Y1) and the non-expandable base layer (Y2) for bonding them together, or they may be directly laminated. .

[Second mode anti-warp laminate]
Warp-preventing laminates 2a and 2b shown in FIG. 2 are examples of the warp-preventing laminate of the second aspect of the present invention.
In the laminates 2a and 2b, the pressure-sensitive adhesive layer of the support layer (II) has the first pressure-sensitive adhesive layer (V1-1) and the second pressure-sensitive adhesive layer (V1-2), and the first pressure-sensitive adhesive layer ( V1-1) and the second adhesive layer (V1-2) sandwich the substrate (Y), and the adhesive surface of the second adhesive layer (V1-2) is the curable resin layer (I). It has a direct laminated configuration. Hereinafter, each pressure-sensitive adhesive layer when the support layer (II) is provided with a plurality of pressure-sensitive adhesive layers, and the pressure-sensitive adhesive layer when the support layer (II) is provided with a single pressure-sensitive adhesive layer are collectively referred to. It may be called an adhesive layer (V).
In addition, in the warp-preventing laminate of the second embodiment, the adhesive surface of the first adhesive layer (V1-1) is attached to a support (not shown).

Also in the warp-preventing laminate of the second aspect, the substrate (Y) preferably has an expandable substrate layer (Y1) containing thermally expandable particles.
The base material (Y) may be a base material having a single-layer configuration consisting only of the expandable base material layer (Y1), such as the laminate 2a shown in FIG. 2(a). Like the laminate 2b shown, the substrate may have a multi-layer structure having an expandable substrate layer (Y1) and a non-expandable substrate layer (Y2).

However, as described above, from the viewpoint of obtaining a laminate that can maintain good adhesion between the first pressure-sensitive adhesive layer (V1-1) and the support before and after the heat expansion treatment, as shown in FIG. Moreover, it is preferable that the substrate (Y) has an expandable substrate layer (Y1) and a non-expandable substrate layer (Y2).
In addition, in the warp-preventing laminate of the second aspect, when using the substrate (Y) having the expandable substrate layer (Y1) and the non-expandable substrate layer (Y2), as shown in FIG. Then, the second adhesive layer (V1-2) is laminated on the surface of the expandable base layer (Y1), and the first adhesive layer (V1-1) is laminated on the surface of the non-expandable base layer (Y2). It is preferred to have a laminated construction.

In the laminate of the second aspect, the thermal expansion treatment expands the thermally expandable particles in the expandable base layer (Y1) that constitutes the base (Y), and the surface of the expandable base layer (Y1) has Unevenness occurs.
Then, the second adhesive layer (V1-2) is pushed up by the unevenness generated on the surface of the expandable base layer (Y1), and unevenness is also formed on the adhesive surface of the second adhesive layer (V1-2). Therefore, the contact area between the second adhesive layer (V1-2) and the cured resin layer (I') is reduced. As a result, at the interface P between the second pressure-sensitive adhesive layer (V1-2) of the support layer (II) and the cured resin layer (I'), they can be easily separated collectively with a slight force.
In addition, in the laminate of the second aspect, from the viewpoint of forming a laminate that can be easily separated collectively with a small force at the interface P, the expandable group of the base material (Y) included in the support layer (II) It is preferable that the material layer (Y1) and the second adhesive layer (V1-2) are directly laminated.

[Warpage-preventing laminate of the third embodiment]
As the warp-preventing laminate of the third aspect of the present invention, there is a warp-preventing laminate 3 shown in FIG.
The laminate 3 shown in FIG. 3 has a first adhesive layer (V1), which is a non-expanding adhesive layer, on one surface side of the substrate (Y), and the other surface of the substrate (Y). On the surface side, a support layer (II) having a second adhesive layer (V2) which is an expandable adhesive layer containing thermally expandable particles is provided, and the second adhesive layer (V2) and a curable resin It has a structure in which the layer (I) is directly laminated.
In the laminate 3, the adhesive surface of the first adhesive layer (V1) is attached to a support (not shown).
In addition, it is preferable that the base material (Y) of the laminate 3 of the present third aspect is composed of a non-expandable base material layer (Y2).
In the laminate 3 of the third aspect, the thermal expansion treatment expands the thermally expandable particles in the second pressure-sensitive adhesive layer (V2), which is an expandable pressure-sensitive adhesive layer, and the second pressure-sensitive adhesive layer (V2) The surface becomes uneven, and the contact area between the second pressure-sensitive adhesive layer (V2) and the curable resin layer (I) decreases.
On the other hand, since the substrate (Y) side surface of the first pressure-sensitive adhesive layer (V1) is laminated on the substrate (Y), unevenness is less likely to occur.
Therefore, due to the heat expansion treatment, irregularities are likely to be formed on the surface of the second adhesive layer (V2) on the curable resin layer (I) side, and as a result, the second adhesive layer (V2) of the support layer (II). and the cured resin layer (I') can be easily separated collectively with a slight force.

[Fourth embodiment anti-warp laminate]
As the warp-preventing laminate of the fourth aspect of the present invention, there is a warp-preventing laminate 4 shown in FIG.
The laminate 4 shown in FIG. 4 has a configuration in which a non-expanding adhesive layer (V1), an expandable base layer (Y1), and a curable resin layer (I) are laminated in this order.
In the laminate 4, the curable resin layer (I) is located on the side opposite to the first thermosetting resin layer (X1-1) located on the substrate (Y) side and the substrate (Y). It consists of a curable resin layer (I) provided with a second thermosetting resin layer (X1-2). Both the first thermosetting resin layer (X1-1) and the second thermosetting resin layer (X1-2) are non-expansive.
Here, the second thermosetting resin layer (X1-2) has higher surface adhesion than the first thermosetting resin layer (X1-1). In the laminate 4, by forming the curable resin layer (I) with two thermosetting resin layers, different properties can be used. For example, a thermosetting resin layer containing a highly adhesive composition is selected for the curable resin layer on the side opposite to the support layer (II), and the curable resin layer on the support layer (II) side is A material having better separability from the support layer (II) can be selected.

[Warp-preventing laminate of the fifth aspect]
As the warp-preventing laminate of the fifth aspect of the present invention, there is a warp-preventing laminate 5 shown in FIG.
The laminate 5 shown in FIG. 5 has a configuration in which a non-expanding adhesive layer (V1), an expandable base layer (Y1), and a curable resin layer (I) are laminated in this order.
In the laminate 5, the curable resin layer (I) consists of a thermosetting resin layer (X1-1) located on the side of the substrate (Y) and an energy ray-curable layer located on the side opposite to the substrate (Y). and a curable resin layer (X2). Both the first thermosetting resin layer (X1-1) and the energy ray-curable resin layer (X2) are non-expansive.
In the laminate 5, the curable resin layer (I) is divided into an energy ray curable resin layer (X2) and a thermosetting resin layer (X1-1), so that different properties are used. can be done. For example, on the side opposite to the support layer (II), an energy-curable resin layer made of an energy ray-curable composition that can be easily adjusted to have relatively high adhesive strength is arranged, and on the support layer (II) side, A thermosetting resin layer having better separability from the later-described sealing material can be arranged.

[Use of warp-preventing laminate]
In the warp-preventing laminate of the present embodiment, the object to be sealed is placed on the surface of the curable resin layer, and the object to be sealed and the thermosetting resin layer at least around the periphery of the object to be sealed The surface is coated with a sealing material, and the sealing material is cured to produce a cured sealed body including an object to be sealed.
In addition, the concrete aspect regarding manufacture of the hardening sealing body using the laminated body for warpage prevention is mentioned later.

For example, as used in the manufacturing method described in Patent Document 1, after placing the sealing object on the adhesive surface of an adhesive laminate such as a general wafer mount tape, the sealing object and its surroundings Consider the case where the adhesive surface of the part is coated with a sealing material and the sealing material is thermally cured to produce a cured sealing body.
When the encapsulating material is thermally cured, the encapsulating material is subject to shrinkage stress, but since the adhesive laminate is fixed to the support, the stress of the encapsulating material is suppressed.
However, it is difficult to suppress the shrinkage stress of the cured sealing body obtained by separating from the support and the adhesive laminate. In the cured sealing body after separation, the amount of the sealing material is different between the surface side on which the sealing object is present and the opposite surface side, so that a difference in shrinkage stress is likely to occur. The difference in shrinkage stress causes warping of the cured encapsulant.
Moreover, from the viewpoint of productivity, the cured sealing body after heating is generally separated from the support and the adhesive laminate while being heated to some extent. Therefore, even after the separation, the curing of the sealing material progresses and shrinkage occurs due to natural cooling, so that the cured sealing body is more likely to warp.

On the other hand, when the warp-preventing laminate of one embodiment of the present invention is used, it is possible to obtain a cured sealing body in which warping is effectively suppressed for the following reasons.
That is, when the object to be sealed is placed on the surface of the thermosetting resin layer of the warp-preventing laminate of one embodiment of the present invention, covered with a sealing material, and the sealing material is thermally cured, at the same time, The thermosetting resin layer is also thermoset. At this time, since the thermosetting resin layer is provided on the surface side of the object to be sealed, which is considered to have less shrinkage stress due to curing of the sealing material because the amount of the sealing material is small. , contraction stress due to thermosetting of the thermosetting resin layer acts.
As a result, it is thought that the difference in shrinkage stress between the two surfaces of the cured sealing body can be reduced, and a cured sealing body in which warpage is effectively suppressed can be obtained.

Further, the thermosetting resin layer that contributes to suppressing the warp of the cured sealing body can be converted into a cured resin layer by thermosetting.
That is, by using the warp-preventing laminate of one embodiment of the present invention, a cured resin layer can be simultaneously formed on one surface of the cured sealing body by going through the above-described sealing step. A process for forming a cured resin layer can be omitted, which contributes to an improvement in productivity.

Furthermore, in the warp-preventing laminate of one aspect of the present invention, at least one of the substrate (Y) and the pressure-sensitive adhesive layer (V) contained in the support layer (II) contains thermally expandable particles, The lowest curing temperature (T ₁ ) at which the curing of the curable resin layer (I) is completed within 2 hours to form the curable resin layer (I′) is higher than the foaming start temperature (T ₂ ) of the thermally expandable particles. Low temperature. Therefore, when the thermally expandable particles are expanded by heating, it is possible to prevent the occurrence of poor separation between the curable resin layer (I) and the support layer (II).

<Various physical properties of the laminate>
(Minimum curing temperature (T ₁ ) of curable resin layer (I))
In the anti-warp laminate of one aspect of the present invention, at least one of the substrate (Y) and the pressure-sensitive adhesive layer (V) contained in the support layer (II) contains thermally expandable particles, The minimum curing temperature (T ₁ ) at which the curing of the resin layer (I) is completed within 2 hours to form the cured resin layer (I′) is lower than the expansion start temperature (T ₂ ) of the thermally expandable particles. be. Therefore, thermal expansion of the thermally expandable particles is suppressed while the curable resin layer is heated and cured. As a result, when the thermally expandable particles are thermally expanded, excessive increase in adhesion between the curable resin layer (I) and the support layer (II) can be avoided, resulting in poor separation between the two. can be prevented.
One of the reasons why the peeling failure is suppressed is not limited to this, but is presumed as follows. When the thermally expandable particles thermally expand while the curable resin layer is heated and cured, unevenness occurs at the interface with the curable resin layer, and the curable resin layer hardens to strongly adhere to the unevenness. For this reason, even if the thermally expandable particles are heated and expanded after the curable resin layer is cured, the releasability from the cured resin layer is considered to be lowered. On the other hand, in the laminate of the present embodiment, the thermal expansion of the thermally expandable particles is suppressed while the curable resin layer is heated and cured. It is presumed that even if sufficient unevenness occurs at the interface with the cured resin layer, sufficient releasability can be ensured between the two.

The difference (T ₂ −T ₁ ) between the minimum curing temperature (T ₁ ) of the curable resin layer (I) and the expansion start temperature (T ₂ ) of the thermally expandable particles is preferably 20 to 100° C., more preferably is 20 to 90°C, more preferably 20 to 80°C. By setting the temperature difference T ₂ −T ₁ within the above temperature range, it is possible to provide a sufficient temperature difference, and as a result, it becomes easier to suppress peeling defects, and the physical properties of the thermally expandable fine particles and the selection of materials can be improved. The degree of freedom can be increased.

(Adhesive strength of first surface of curable resin layer (I))
In the laminate of one aspect of the present invention, the curable resin layer (I) is the surface (first surface) on which the sealing target is placed, from the viewpoint of improving the adhesion to the sealing target. is preferably tacky.
The adhesive strength of the first surface of the curable resin layer (I) was determined by attaching the first surface to a glass plate at a temperature of 70° C., and peeling at a temperature of 23° C., a peeling angle of 180°, and a peeling speed of 300 mm/min. The value when the resin layer is peeled off and measured is preferably 1.7 N/25 mm or more, more preferably 2.3 N/25 mm or more, still more preferably 3.0 N/25 mm or more, and still more. It is preferably 4.0 N/25 mm or more, preferably 20 N/25 mm or less, more preferably 15 N/25 mm or less, and still more preferably 10 N/25 mm or less.
When the adhesive strength of the first surface of the curable resin layer (I) is 1.7 N/25 mm or more, when the sealing target is fixed to the surface of the curable resin layer (I), the sealing target This makes it easier to prevent objects from being misaligned. If the adhesive strength of the first surface of the curable resin layer (I) is 20 N/25 mm or less, it becomes easy to select the material for the curable resin layer (I).

(Shear force of curable resin layer (I))
In the laminate of one aspect of the present invention, the curable resin layer (I) has an appropriate shear force from the viewpoint of holding the object to be sealed well when sealing the object. is preferred. Specifically, a silicon chip (mirror surface) having a thickness of 350 μm and a size of 3 mm × 3 mm is used as the measurement adherend, and the shear strength of the curable resin layer (I) to the measurement adherend is at a temperature of 70 ° C. , the specular surface of the adherend for measurement is pressed and attached to the curable resin layer for 1 second at 130 gf, and the value when measured at a speed of 200 μm / s is preferably 20 N / (3 mm × 3 mm) or more, more It is preferably 25 N/(3 mm × 3 mm), more preferably 30 N/(3 mm × 3 mm) or more, preferably 100 N/(3 mm × 3 mm) or less, more preferably 90 N/(3 mm × 3 mm) or less. .
When the shear strength of the curable resin layer (I) with respect to the adherend for measurement is 20 N/(3 mm × 3 mm) or more, the object to be sealed is fixed to the surface of the curable resin layer (I) and sealed. When covering the object to be sealed with the material, it becomes easier to prevent the object from being displaced or tilted due to the flow of the sealing material. Further, when the shear strength is 100 N/(3 mm×3 mm) or less, it becomes easy to select the material for the curable resin layer (I).

(Adhesive strength of thermosetting resin layer (X1))
In the laminate of one embodiment of the present invention, the adhesive strength of the thermosetting resin layer (I) alone at room temperature (23° C.) is preferably 0.1 to 10.0 N/25 mm, more preferably 0.2. ~8.0 N/25 mm, more preferably 0.4 to 6.0 N/25 mm, even more preferably 0.5 to 4.0 N/25 mm.
When having a first thermosetting resin layer (X1-1) and a second thermosetting resin layer (X1-2) like the laminate 4 shown in FIG. 4, each has the above adhesive strength In particular, it is preferable to make the adhesion of the second thermosetting resin layer (X1-2) higher than that of the first thermosetting resin layer (X1-1). By making the adhesive force of the second thermosetting resin layer (X1-2) higher than the adhesive force of the first thermosetting resin layer (X1-1), the object to be sealed is cured more reliably. can be fixed to the first surface of the flexible resin layer (I).

(Adhesive strength of energy ray-curable resin layer (X2))
In the laminate of one embodiment of the present invention, the adhesive strength of the energy ray-curable resin layer (X2) alone at room temperature (23° C.) is preferably 0.1 to 10.0 N/25 mm, more preferably 0.1 to 10.0 N/25 mm. 2 to 8.0 N/25 mm, more preferably 0.4 to 6.0 N/25 mm, and even more preferably 0.5 to 4.0 N/25 mm.

(Adhesive strength of adhesive layer (V))
In the laminate of one embodiment of the present invention, the pressure-sensitive adhesive layer (V) (the first pressure-sensitive adhesive layer (V1) and the second pressure-sensitive adhesive layer (V2)) of the support layer (II) at room temperature (23 ° C.) The adhesive strength is preferably 0.1 to 10.0 N/25 mm, more preferably 0.2 to 8.0 N/25 mm, still more preferably 0.4 to 6.0 N/25 mm, still more preferably 0.5 ~4.0N/25mm. In the following description, regardless of whether the pressure-sensitive adhesive layer is single or multiple, the pressure-sensitive adhesive layer located on the curable resin layer (I) side is the first pressure-sensitive adhesive layer, and the side opposite to the curable resin layer. The pressure-sensitive adhesive layer positioned at is sometimes referred to as a second pressure-sensitive adhesive layer.
When the support layer (II) has a first adhesive layer (V1-1) or (V1) and a second adhesive layer (V1-2) or (V2), the first adhesive layer (V1-1 ) or (V1) and the second pressure-sensitive adhesive layer (V1-2) or (V2) are preferably in the above ranges, respectively, but the adhesion to the support is improved, and the interface P is collectively From the viewpoint of making it easier to separate by ) is more preferable.

(Measurement of adhesive strength of first surface of curable resin layer (I))
In the specification of the present application, the adhesive strength of the first surface of the curable resin layer (I) is measured by the following procedure.
First, a warpage-preventing laminate comprising a curable resin layer (I) and a support layer (II) is cut into a piece of 25 mm width×250 mm length (250 mm in the MD direction) to prepare a primary sample. Also, a glass plate (3 mm float plate glass manufactured by Yuko Co., Ltd. (JIS R3202 product)) is prepared as an adherend. Using a laminator (manufactured by Taisei Laminator Co., Ltd., model VA-400), a glass plate is attached so as to be in direct contact with the first surface of the curable resin layer (I) to obtain a test piece. At this time, the roller temperature is set at 70° C. and the application speed is set at 0.2 m/min. After leaving the test piece thus obtained in an environment of 23° C. and 50% RH (relative humidity) for 24 hours, under the same environment, a tensile load measuring machine (Aand The test piece was peeled from the glass plate under the conditions of a peeling angle of 180 °, a peeling speed of 300 mm / min, and a peeling temperature of 23 ° C. with Tensilon, manufactured by Day Co., Ltd.), and the adhesive strength was measured. It is the adhesive strength of the first surface of the resin layer (I).

(Measurement of shear force of curable resin layer (I))
In the specification of the present application, the shear force of the curable resin layer (I) is measured by the following procedure.
First, a silicon chip having a thickness of 350 μm and having a mirror surface of 3 mm×3 mm is used as an adherend for measurement. Then, on the first surface of the curable resin layer (I) of each laminate obtained in each Example and Comparative Example described later, at a temperature of 70 ° C. and 130 gf for 1 second, a mirror surface of the above-mentioned adherend for measurement was applied. Press and stick. Then, using a universal bond tester (DAGE4000 manufactured by Nordson Advanced Technologies), the shear force is measured at a speed of 200 μm/s.

(Measurement of Adhesion of Adhesive Layer (V), Thermosetting Resin Layer (X1), and Energy Ray Curing Resin Layer (X2))
Adhesive tape (manufactured by Lintec Corporation, product name “PL Shin ”).
Then, the surface of the pressure-sensitive adhesive layer (V), the thermosetting resin layer (X1), or the energy ray-curable resin layer (X2) exposed by peeling off the release film is adhered to the glass plate. It was attached to a 3 mm float plate glass manufactured by a commercial company (JIS R3202 product). At this time, the sticking temperature of the pressure-sensitive adhesive layer (V) was 23°C, and the sticking temperature of the thermosetting resin layer (X1) and the energy ray-curable resin layer (X2) was 70°C. Then, the glass plate to which each layer was attached was allowed to stand in an environment of 23 ° C. and 50% RH (relative humidity) for 24 hours, and then under the same environment, it was pulled 180 ° based on JIS Z 0237: 2000. The pressure-sensitive adhesive layer (V), the thermosetting resin layer (X1), or the energy ray-curable resin layer (X2) is peeled off together with the adhesive tape from the glass plate at a pulling speed of 300 mm/min by a peeling method. This measures the adhesive force at 23°C.

(Peel force (F ₀ ) before expansion treatment)
Before curing the curable resin layer (I) and before the expansion treatment, the support layer (II) and the curable resin are used from the viewpoint of sufficiently fixing the sealing object so as not to adversely affect the sealing operation. It is preferable that the adhesiveness to the layer (I) is high.
From the above viewpoint, in the laminate of one embodiment of the present invention, the interface P between the support layer (II) and the curable resin layer (I) before curing the curable resin layer (I) and before performing the heat expansion treatment The peel force (F ₀ ) when separating with is preferably 100 mN/25 mm or more, more preferably 130 mN/25 mm or more, still more preferably 160 mN/25 mm or more, and preferably 50,000 mN/25 mm or less. be.
In addition, peeling force ( _F0 ) is a value measured by the following measuring method.
(Measurement of peel force (F ₀ ))
After the laminate was allowed to stand in an environment of 23° C. and 50% RH (relative humidity) for 24 hours, the support layer (II) side of the laminate was covered with a glass plate (Float manufactured by Yuko Co., Ltd.) through an adhesive layer. It is attached to a plate glass of 3 mm (JIS R3202 product). Also, an adhesive tape (manufactured by Lintec Corporation, product name “PL Shin”) is attached to the first surface side of the laminate. Next, the end of the glass plate to which the laminate was attached is fixed to the lower chuck of a universal tensile tester (manufactured by Orientec Co., Ltd., product name “Tensilon UTM-4-100”).
Subsequently, it was attached to the curable resin layer (I) of the laminate with an upper chuck of a universal tensile tester so that it was peeled off at the interface P between the support layer (II) and the curable resin layer (I) of the laminate. Fix the ends of the adhesive tape. Then, under the same environment as above, the curable resin layer (I) and the adhesive tape are attached at the interface P to the support layer (II ) is defined as “peeling force (F ₀ )”.

(Peel force after expansion treatment (F ₁ ))
A laminate of one embodiment of the present invention includes a support layer (II), a curable resin layer (I), or a cured resin layer (I′) obtained by curing the curable resin layer (I) by expansion treatment. can be easily separated collectively with a slight force at the interface P of .
Here, in the laminate of one embodiment of the present invention, after the curable resin layer (I) is cured to form the cured resin layer (I′), the support layer (II) and the cured resin layer (I ') when separating at the interface _P is usually 2,000 mN/25 mm or less, preferably 1,000 mN/25 mm or less, more preferably 500 mN/25 mm or less, more preferably 150 mN/ It is 25 mm or less, more preferably 100 mN/25 mm or less, even more preferably 50 mN/25 mm or less, and most preferably 0 mN/25 mm.
When the peel force (F ₁ ) is 0 mN/25 mm, even if an attempt is made to measure the peel force, the measurement may not be possible because the peel force is too small.
The peel force (F ₁ ) is a value measured by the following measuring method.

(Measurement of peel force (F ₁ ))
The support layer (II) side of the laminate is attached to a glass plate (3 mm float plate glass manufactured by Yuko Co., Ltd. (JIS R3202 product)) via an adhesive layer. Next, the glass plate and laminate are heated at 130° C. for 2 hours to cure the curable resin layer (I) to form a cured resin layer (I′). When the curable resin layer (I) includes the energy ray-curable resin layer (X2), as in the laminate 4 in FIG. Energy rays capable of curing the curable resin layer (X2) are irradiated (in the case of ultraviolet rays, irradiation is performed three times at an illumination intensity of 215 mW/cm ² and a light intensity of 187 mJ/cm ² ) to form the energy ray-curable resin layer (X2). Harden.
Next, the thermally expandable particles contained in the support layer (II) are expanded. Specifically, the glass plate to which the laminate is attached is heated at 240° C. for 3 minutes, and the thermally expandable particles in the expandable substrate layer (Y1) or the expandable pressure-sensitive adhesive layer (V2) of the laminate are inflate. After that, an adhesive tape (manufactured by Lintec Co., Ltd., product name "PL Shin") was attached to the first surface side of the laminate, and the peel force (F ₀ ) was measured in the same manner as described above, and supported under the above conditions. The peeling force measured at the interface P between the layer (II) and the cured resin layer (I′) is defined as “peeling force (F ₁ )”.
In the measurement of the peel force (F ₁ ), when trying to fix the end of the adhesive tape attached to the cured resin layer (I') of the laminate with the upper chuck of the universal tensile tester, the interface P If the cured resin layer (I') is completely separated in , and fixing for measurement cannot be performed, the measurement is terminated, and the peeling force (F ₁ ) at that time is set to "0 mN / 25 mm". .

(Probe tack value of substrate (Y))
The substrate (Y) of the support layer (II) is a non-adhesive substrate.
In one aspect of the present invention, the determination of whether or not the substrate is non-adhesive is based on the probe tack value measured in accordance with JIS Z 0237: 1991 for the surface of the target substrate is less than 50 mN/5 mmφ. If so, the substrate is judged to be a “non-adhesive substrate”. On the other hand, if the probe tack value is 50 mN/5 mmφ or more, the substrate is judged to be "adhesive substrate".
The probe tack value on the surface of the substrate (Y) of the support layer (II) used in one aspect of the present invention is usually less than 50 mN/5 mmφ, preferably less than 30 mN/5 mmφ, more preferably less than 10 mN/5 mmφ. , and more preferably less than 5 mN/5 mmφ.
The probe tack value on the surface of the substrate (Y) is a value measured by the following measuring method.
(Measurement of probe tack value)
A test sample is obtained by cutting a base material to be measured into a square having a side of 10 mm, and leaving the square for 24 hours in an environment of 23° C. and 50% RH (relative humidity). In an environment of 23 ° C. and 50% RH (relative humidity), using a tacking tester (manufactured by Nihon Tokushu Sokki Co., Ltd., product name "NTS-4800"), the probe tack value on the surface of the test sample is measured according to JIS. Measure according to Z0237:1991. Specifically, a stainless steel probe with a diameter of 5 mm is brought into contact with the surface of the test sample for 1 second with a contact load of 0.98 N/cm ² , and then the probe is moved at a speed of 10 mm/second to the test sample. The force required to remove it from the surface is measured and the resulting value is taken as the probe tack value for that test sample.

Next, each layer constituting the warp-preventing laminate of one embodiment of the present invention will be described.
<Curable resin layer (I)>
A warp-preventing laminate of one embodiment of the present invention has a curable resin layer (I) including a thermosetting resin layer (X1).
The curable resin layer (I) is cured to reduce the difference in shrinkage stress between the two surfaces of the cured encapsulant due to curing of the encapsulant, and warp that may occur in the resulting cured encapsulant. contributes to the suppression of
The curable resin layer (I) becomes a curable resin layer (I') by curing. A cured resin layer (I′) is formed on one surface of the resulting cured sealing body.

As described above, the curing of the curable resin layer (I) is completed within 2 hours to form the cured resin layer (I′), and the minimum curing temperature (T ₁ ) is the thermal expansion included in the support layer (II). It is lower than the expansion start temperature (T ₂ ) of the organic particles. Such physical properties are mainly provided by the thermosetting resin layer (X1) contained in the curable resin layer (I).

The storage elastic modulus E' of the cured resin layer (I') at 23.degree. 0×10 ⁷ Pa or more, more preferably 1.0×10 ⁸ Pa or more, still more preferably 1.0×10 ⁹ Pa or more, still more preferably 5.0×10 ⁹ Pa or more, and preferably It is 1.0×10 ¹³ Pa or less, more preferably 1.0×10 ¹² Pa or less, still more preferably 5.0×10 ¹¹ Pa or less, and even more preferably 1.0×10 ¹¹ Pa or less.

The storage elastic modulus E' of the cured resin layer (I') is measured by the following procedure.
First, after laminating the curable resin layer (I) so as to have a thickness of 200 μm, the state in which the curing is substantially completed (when the exothermic peak disappears at 130° C. in the measurement using a differential scanning calorimeter) ). In the case of the thermosetting resin layers (X1), (X1-1), and (X1-2), it is placed in an oven under an air atmosphere and heated at 130 ° C. of the resin for 2 hours to form a heat layer having a thickness of 200 μm. The curable resin layer is thermally cured. When the energy ray-curable resin layer (X2) and the thermosetting resin layer (X1-1) are included, energy rays are irradiated (in the case of ultraviolet rays, the illumination intensity is 215 mW/cm ² and the light intensity is 187 mJ/cm ² three times. After curing the energy ray-curable resin layer (X2) by irradiation), the thermosetting resin layer (X1-1) is thermally cured under the above conditions.
Next, using a dynamic viscoelasticity measuring device (manufactured by TA Instruments, product name "DMAQ800"), the test start temperature is 0 ° C., the test end temperature is 300 ° C., the temperature increase rate is 3 ° C./min, and the frequency is 11 Hz. , and an amplitude of 20 μm at 23° C., the storage elastic modulus E′ of the formed cured resin layer is measured.

The first surface of the curable resin layer (I), which is the surface opposite to the support layer, has adhesiveness. Then, as described above, the adhesive force is obtained by attaching the first surface to the glass plate at a temperature of 70 ° C., peeling the curable resin layer at a temperature of 23 ° C., a peeling angle of 180 °, and a peeling speed of 300 mm / min. It is preferably 1.7 N/25 mm or more.
In the present specification, in the measurement of the adhesive strength of the curable resin layer (I), the phrase “applied at a temperature of 70°C” means that the laminate is pressed with a pressing body such as a pressure roller having a heat generation temperature of 70°C. Pressing against the glass plate means sticking the laminate to the glass plate.
An object to be sealed is placed on the first surface of the curable resin layer (I). When the object to be sealed such as a semiconductor chip is placed on the first surface, the object to be sealed is tilted, and after placing the object to be sealed, the sealing against the curable resin layer (I) This prevents the position of the object to be stopped from deviating from the intended position.

In addition, the shear strength of the curable resin layer (I) to the measurement adherend was obtained by using a silicon chip (mirror surface) with a thickness of 350 μm and a size of 3 mm × 3 mm as the measurement adherend, at a temperature of 70 ° C., at 130 gf. The value obtained when the specular surface of the measurement adherend is pressed against the curable resin layer for 1 second and measured at a speed of 200 μm/s is preferably 20 N/(3 mm×3 mm) or more.

The adhesive strength of the first surface of the curable resin layer (I) and the shear force of the curable resin layer (I) against the adherend for measurement are determined by the thermosetting resin composition constituting the curable resin layer (I). By adjusting the types and compounding ratios of the components of the energy ray-curable resin composition, the above numerical range can be obtained. Adhesion and shearing force vary depending on the components and compounding ratio of the resin composition, and shearing force also varies depending on the composition of the entire layer of the curable resin layer (I). Using an acrylic polymer, which will be described later, as a polymer component, using an epoxy resin as a thermosetting component, or using a coupling agent makes it easier to obtain a high value. In addition, the shear force can be easily increased by increasing the content of the inorganic filler or the cross-linking agent, for example.

The thickness of the curable resin layer (I) is preferably 1-500 μm, more preferably 5-300 μm, still more preferably 10-200 μm, and even more preferably 15-100 μm.

(Thermosetting resin layer (X1))
The thermosetting resin layers (X1), (X1-1), and (X1-2) may be formed from a thermosetting resin composition containing a polymer component (A) and a thermosetting component (B). preferable. The thermosetting resin layers (X1), (X1-1), and (X1-2) may be collectively referred to as the thermosetting resin layer (X1).
The curable resin composition may further contain one or more selected from colorants (C), coupling agents (D), and inorganic fillers (E). At least the inorganic filler (E) is preferably contained from the viewpoint of producing a warp-preventing laminate capable of suppressing warping and producing a cured sealing body having a flat surface.

The thermosetting resin layer (X1) itself is cured so that the minimum curing temperature (T ₁ ) of the curable resin layer (I) satisfies the above-described relationship. is completed within 2 hours to form the cured resin layer (I'), the minimum curing temperature (T ₁ ) is lower than the foaming start temperature (T ₂ ) of the thermally expandable particles contained in the support layer (II) It is preferable to be The minimum curing temperature (T ₁ ) _of the thermosetting resin layer (X1) is preferably 20° C. or higher, more preferably 25° C. or higher, and still more preferably Lower than 30°C.
In order to lower the minimum curing temperature, a curing accelerator may be added, the amount of the curing accelerator or cross-linking agent may be increased, or a more easily cross-linked monomer may be selected.

The thickness of the thermosetting resin layer (X1) may be in the same numerical range as the thickness of the curable resin layer (I).
When the thermosetting resin layer (X1) includes a plurality of layers, such as the thermosetting resin layers (X1-1) and (X1-2), the total thickness thereof is the thickness of the curable resin The thickness may be set within the same numerical range as the thickness of the layer (I). The thickness of the thinnest layer among these layers is preferably 10% or more, more preferably 20% or more, and still more preferably 30% or more of the thickness of the thickest layer.

The curing initiation temperature of the thermosetting resin layer (X1) is preferably 80 to 200°C, more preferably 90 to 160°C, still more preferably 100 to 150°C.
As the thermosetting resin layer (X1), one having a curing initiation temperature lower than the expansion initiation temperature of the thermally expandable particles is used. The curing initiation temperature of the thermosetting resin layer (X1) is preferably 5° C. or lower, more preferably 10° C. or lower, still more preferably 20° C. or lower than the expansion initiation temperature of the thermally expandable particles.

(Polymer component (A))
The polymer component (A) contained in the thermosetting resin composition means a compound having a mass average molecular weight of 20,000 or more and having at least one repeating unit.
By containing the polymer component (A) in the thermosetting resin composition, the formed thermosetting resin layer has flexibility and film-forming properties, and the property maintenance property of the laminate is improved. be able to.
The mass average molecular weight (Mw) of the polymer component (A) is preferably 20,000 or more, more preferably 20,000 to 3,000,000, more preferably 50,000 to 2,000,000, still more preferably 100,000 to 1,500,000, more preferably More preferably, it is 200,000 to 1,000,000.

The content of component (A) is preferably 5 to 50% by mass, more preferably 8 to 40% by mass, more preferably 10% by mass, relative to the total amount (100% by mass) of the active ingredients of the thermosetting resin composition. ~30% by mass.

Examples of the polymer component (A) include acrylic polymers, polyesters, phenoxy resins, polycarbonates, polyethers, polyurethanes, polysiloxanes, rubber polymers and the like.
These polymer components (A) may be used alone or in combination of two or more.
In this specification, the acrylic polymer having an epoxy group and the phenoxy resin having an epoxy group have thermosetting properties. Any compound having such repeating units is included in the concept of the polymer component (A).

Among these, the polymer component (A) preferably contains the acrylic polymer (A1).
The content of the acrylic polymer (A1) in the polymer component (A) is preferably from 60 to 60 with respect to the total amount (100% by mass) of the polymer component (A) contained in the thermosetting resin composition. 100% by mass, more preferably 70 to 100% by mass, even more preferably 80 to 100% by mass, still more preferably 90 to 100% by mass.

(Acrylic polymer (A1))
The mass average molecular weight (Mw) of the acrylic polymer (A1) is preferably 20,000 to 3,000,000, more preferably 10,000, from the viewpoint of imparting flexibility and film-forming properties to the thermosetting resin layer to be formed. 10,000 to 1,500,000, more preferably 150,000 to 1,200,000, and even more preferably 250,000 to 1,000,000.

The glass transition temperature (Tg) of the acrylic polymer (A1) is from the viewpoint of imparting good adhesiveness to the surface of the thermosetting resin layer to be formed, and using the anti-warp laminate. From the viewpoint of improving the reliability of the cured sealing body with a cured resin layer, preferably -60 to 50°C, more preferably -50 to 30°C, even more preferably -40 to 10°C, and even more preferably -35 to -35°C. 5°C.

Examples of the acrylic polymer (A1) include polymers containing an alkyl (meth)acrylate as a main component, specifically an alkyl (meth)acrylate (a1′) having an alkyl group having 1 to 18 carbon atoms. An acrylic polymer containing a structural unit (a1) derived from (hereinafter also referred to as "monomer (a1')") is preferable, and together with the structural unit (a1), a functional group-containing monomer (a2') (hereinafter referred to as "monomer ( a2′)”) is more preferred.
The acrylic polymer (A1) may be used alone or in combination of two or more.
When the acrylic polymer (A1) is a copolymer, the form of the copolymer may be block copolymer, random copolymer, alternating copolymer, or graft copolymer. good.

The number of carbon atoms in the alkyl group of the monomer (a1′) is preferably 1 to 18, more preferably 1 to 12, more preferably 1 to 12, from the viewpoint of imparting flexibility and film-forming properties to the thermosetting resin layer to be formed. 1 to 8 are preferred. The alkyl group may be a straight-chain alkyl group or a branched-chain alkyl group.
These monomers (a1') may be used alone or in combination of two or more.

From the viewpoint of improving the reliability of the cured sealing body with a cured resin layer, which is produced using the anti-warp laminate, the monomer (a1′) is an alkyl (meth) having an alkyl group having 1 to 3 carbon atoms. It preferably contains acrylate, and more preferably contains methyl (meth)acrylate.
From the above viewpoint, the content of the structural unit (a11) derived from an alkyl (meth)acrylate having an alkyl group having 1 to 3 carbon atoms is based on the total structural units (100% by mass) of the acrylic polymer (A1). , preferably 1 to 80% by mass, more preferably 5 to 80% by mass, still more preferably 10 to 80% by mass.

Further, the monomer (a1') preferably contains an alkyl (meth)acrylate having an alkyl group having 4 or more carbon atoms, more preferably an alkyl (meth)acrylate having an alkyl group having 4 to 6 carbon atoms. , butyl (meth)acrylate.
From the above point of view, the content of the structural unit (a12) derived from an alkyl (meth)acrylate having an alkyl group having 4 or more carbon atoms (preferably 4 to 6, more preferably 4) is the acrylic polymer (A1) is preferably from 1 to 70% by mass, more preferably from 5 to 65% by mass, and still more preferably from 10 to 60% by mass, relative to the total structural units (100% by mass) of.

The content of the structural unit (a1) is preferably 50% by mass or more, more preferably 50 to 99% by mass, still more preferably 55% by mass, based on the total structural units (100% by mass) of the acrylic polymer (A1). to 90% by mass, more preferably 60 to 90% by mass.

As the monomer (a2'), one or more selected from hydroxyl group-containing monomers and epoxy group-containing monomers are preferred.
The monomer (a2') may be used alone or in combination of two or more.

Examples of hydroxy group-containing monomers include 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, 3-hydroxybutyl ( hydroxyalkyl (meth)acrylates such as meth)acrylate and 4-hydroxybutyl (meth)acrylate; and unsaturated alcohols such as vinyl alcohol and allyl alcohol.
Among these, the hydroxy group-containing monomer is preferably hydroxyalkyl (meth)acrylate, more preferably 2-hydroxyethyl (meth)acrylate.

Examples of epoxy-containing monomers include glycidyl (meth)acrylate, β-methylglycidyl (meth)acrylate, (3,4-epoxycyclohexyl)methyl (meth)acrylate, and 3-epoxycyclo-2-hydroxypropyl (meth)acrylate. epoxy group-containing (meth)acrylates such as; glycidyl crotonate, allyl glycidyl ether, and the like;
Among these, epoxy group-containing (meth)acrylates are preferred as epoxy-containing monomers, and glycidyl (meth)acrylates are more preferred.

The content of the structural unit (a2) is preferably 1 to 50% by mass, more preferably 5 to 45% by mass, still more preferably 10 to 40% by mass, more preferably 10 to 30% by mass.

The acrylic polymer (A1) may have structural units derived from monomers other than the above structural units (a1) and (a2) as long as the effects of the present invention are not impaired.
Other monomers include, for example, vinyl acetate, styrene, ethylene, α-olefins and the like.

(Thermosetting component (B))
The thermosetting component (B) is a compound having a mass-average molecular weight of less than 20,000, and serves to thermoset the formed thermosetting resin layer to form a hard cured resin layer.
The weight average molecular weight (Mw) of the thermosetting component (B) is preferably 10,000 or less, more preferably 100-10,000.
As the thermosetting component (B), an epoxy compound (B1 ) and a heat curing agent (B2), and more preferably contain a curing accelerator (B3) together with the epoxy compound (B1) and the heat curing agent (B2).

Examples of the epoxy compound (B1) include polyfunctional epoxy resins, bisphenol A diglycidyl ether and hydrogenated products thereof, ortho-cresol novolac epoxy resins, dicyclopentadiene type epoxy resins, biphenyl type epoxy resins, and bisphenol A type epoxy resins. , bisphenol F-type epoxy resins, phenylene skeleton type epoxy resins, and other epoxy compounds having at least two functionalities in the molecule and having a weight average molecular weight of less than 20,000.
The epoxy compound (B1) may be used alone or in combination of two or more.

The content of the epoxy compound (B1) is the polymer contained in the thermosetting resin composition from the viewpoint of obtaining a warp-preventing laminate that can suppress warpage and produce a cured sealing body having a flat surface. It is preferably 1 to 500 parts by mass, more preferably 3 to 300 parts by mass, even more preferably 10 to 150 parts by mass, and even more preferably 20 to 120 parts by mass based on 100 parts by mass of component (A).

The thermosetting agent (B2) functions as a curing agent for the epoxy compound (B1).
As the thermosetting agent, a compound having two or more functional groups capable of reacting with an epoxy group in one molecule is preferable.
Such functional groups include phenolic hydroxyl groups, alcoholic hydroxyl groups, amino groups, carboxyl groups, acid anhydrides, and the like. Among these, a phenolic hydroxyl group, an amino group, or an acid anhydride is preferable from the viewpoint of suppressing warpage and producing a cured sealing body with a cured resin layer having a flat surface. A hydroxyl group or an amino group is more preferred, and an amino group is even more preferred.

Examples of phenol-based thermosetting agents having phenol groups include polyfunctional phenol resins, biphenols, novolac-type phenol resins, dicyclopentadiene-type phenol resins, Zyloc-type phenol resins, and aralkyl phenol resins.
Examples of the amine-based thermosetting agent having an amino group include dicyandiamide.
These thermosetting agents (B2) may be used alone or in combination of two or more.

The content of the heat curing agent (B2) is 100 mass of the epoxy compound (B1) from the viewpoint of suppressing warpage and producing a cured sealing body with a cured resin layer having a flat surface. part, preferably 0.1 to 500 parts by mass, more preferably 1 to 200 parts by mass.

The curing accelerator (B3) is a compound having a function of increasing the speed of thermosetting when thermosetting the thermosetting resin layer to be formed.
Examples of the curing accelerator (B3) include tertiary amines such as triethylenediamine, benzyldimethylamine, triethanolamine, dimethylaminoethanol, tris(dimethylaminomethyl)phenol; 2-methylimidazole, 2-phenylimidazole, imidazoles such as 2-phenyl-4-methylimidazole, 2-phenyl-4,5-dihydroxymethylimidazole, 2-phenyl-4-methyl-5-hydroxymethylimidazole; tributylphosphine, diphenylphosphine, triphenylphosphine and the like organic phosphines; tetraphenylboron salts such as tetraphenylphosphonium tetraphenylborate and triphenylphosphine tetraphenylborate;
These curing accelerators (B3) may be used alone or in combination of two or more.

The content of the curing accelerator (B3) is the epoxy compound (B1) and the thermosetting agent ( It is preferably 0.01 to 10 parts by mass, more preferably 0.1 to 6 parts by mass, and still more preferably 0.3 to 4 parts by mass, relative to 100 parts by mass of B2).

(Colorant (C))
The thermosetting resin composition used in one aspect of the present invention may further contain a coloring agent (C).
The thermosetting resin layer formed from the thermosetting resin composition containing the coloring agent (C) makes it easy to determine from the appearance whether or not the cured resin layer is attached when the cured resin layer is formed by thermosetting. In addition to being able to provide effects, it is possible to provide effects such as blocking infrared rays and the like generated from surrounding devices to prevent malfunction of sealing objects (semiconductor chips, etc.).

Organic or inorganic pigments and dyes can be used as the colorant (C).
As dyes, for example, any dyes such as acid dyes, reactive dyes, direct dyes, disperse dyes, and cationic dyes can be used.
Moreover, the pigment is not particularly limited, and can be appropriately selected from known pigments and used.
Among these, black pigments are preferred from the viewpoint of good shielding properties against electromagnetic waves and infrared rays.
Examples of black pigments include carbon black, iron oxide, manganese dioxide, aniline black, and activated carbon. Carbon black is preferred from the viewpoint of increasing the reliability of semiconductor chips.
These coloring agents (C) may be used alone or in combination of two or more.

However, in the thermosetting resin composition used in one aspect of the present invention, the content of the colorant (C) is 8% by mass with respect to the total amount (100% by mass) of the active ingredients in the thermosetting resin composition. It is preferably less than
If the content of the coloring agent (C) is less than 8% by mass, a warp-preventing laminate can be obtained in which the presence or absence of cracks on the chip surface and chipping can be visually confirmed.
From the above viewpoint, in the thermosetting resin composition used in one aspect of the present invention, the content of the colorant (C) is preferably based on the total amount (100% by mass) of the active ingredients in the thermosetting resin composition. is less than 5% by weight, more preferably less than 2% by weight, even more preferably less than 1% by weight, even more preferably less than 0.5% by weight.
In addition, from the viewpoint of exhibiting the effect of shielding infrared rays etc. in the cured resin layer formed by thermosetting the thermosetting resin layer formed, the content of the coloring agent (C) is the effective amount of the thermosetting resin composition. Preferably 0.01% by mass or more, more preferably 0.05% by mass or more, still more preferably 0.10% by mass or more, and even more preferably 0.15% by mass with respect to the total amount (100% by mass) of the components That's it.

(Coupling agent (D))
The thermosetting resin composition used in one aspect of the present invention may further contain a coupling agent (D).
A thermosetting resin layer formed from a thermosetting resin composition containing a coupling agent (D) can improve adhesion to an object to be sealed when the object to be sealed is placed. A cured resin layer obtained by thermosetting a thermosetting resin layer can also improve water resistance without impairing heat resistance.

As the coupling agent (D), a compound that reacts with the functional group of the component (A) or the component (B) is preferred, and specifically, a silane coupling agent is preferred.
Silane coupling agents include, for example, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-(methacryloxy propyl)trimethoxysilane, 3-aminopropyltrimethoxysilane, N-6-(aminoethyl)-3-aminopropyltrimethoxysilane, N-6-(aminoethyl)-3-aminopropylmethyldiethoxysilane, N -phenyl-3-aminopropyltrimethoxysilane, 3-ureidopropyltriethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropylmethyldimethoxysilane, bis(3-triethoxysilylpropyl)tetrasulfane, methyltri methoxysilane, methyltriethoxysilane, vinyltrimethoxysilane, vinyltriacetoxysilane, imidazolesilane, and the like.
These coupling agents (D) may be used alone or in combination of two or more.

The molecular weight of the coupling agent (D) is preferably 100 to 15,000, more preferably 125 to 10,000, more preferably 150 to 5,000, still more preferably 1,75 to 3,000, and more preferably It is preferably 200 to 2,000.

The content of component (D) is preferably 0.01 to 10% by mass, more preferably 0.05 to 7% by mass, relative to the total amount (100% by mass) of the active ingredients of the thermosetting resin composition, More preferably 0.10 to 4 mass %, still more preferably 0.15 to 2 mass %.

(Inorganic filler (E))
The thermosetting resin composition used in one aspect of the present invention further includes an inorganic filler (E ) is preferably contained.
By forming the thermosetting resin layer from the thermosetting resin composition containing the inorganic filler (E), when the sealing material is thermally cured, the contraction stress between the two surfaces of the cured sealing body The degree of thermosetting of the thermosetting resin layer can be adjusted so as to reduce the difference. As a result, it becomes possible to manufacture a cured sealing body having a flat surface while suppressing warpage.
Moreover, the thermal expansion coefficient of the cured resin layer obtained by thermosetting the thermosetting resin layer formed can be adjusted to an appropriate range, and the reliability of the sealing object can be improved. Also, the moisture absorption rate of the cured resin layer can be reduced.

Examples of the inorganic filler (E) include powders of silica, alumina, talc, calcium carbonate, titanium oxide, iron oxide, silicon carbide, boron nitride, beads obtained by spheroidizing these powders, single crystal fibers, glass fibers, and the like. Non-thermally expandable particles are included.
These inorganic fillers (E) may be used alone or in combination of two or more.
Among these, silica or alumina is preferable from the viewpoint of obtaining a warp-preventing laminate capable of suppressing warping and producing a cured sealing body having a flat surface.

The average particle size of the inorganic filler (E) is preferably 0.01 to 50 μm, more preferably 0.01 to 50 μm, from the viewpoint of improving the gloss value of the cured resin layer formed by thermosetting the thermosetting resin layer to be formed. 0.1 to 30 μm, more preferably 0.3 to 30 μm, particularly preferably 0.5 to 10 μm.

The content of the component (E) is the total amount of the active ingredients of the thermosetting resin composition ( 100% by mass), preferably 25 to 80% by mass, more preferably 30 to 70% by mass, even more preferably 40 to 65% by mass, and even more preferably 45 to 60% by mass.

(Other additives)
The thermosetting resin composition used in one aspect of the present invention may further contain additives other than the above-described components (A) to (E) within a range that does not impair the effects of the present invention.
Other additives include, for example, cross-linking agents, leveling agents, plasticizers, antistatic agents, antioxidants, ion scavengers, gettering agents, chain transfer agents and the like.
However, the total content of other additives other than components (A) to (E) is preferably 0 to 20% by mass with respect to the total amount (100% by mass) of the active ingredients of the thermosetting resin composition. , more preferably 0 to 10% by mass, more preferably 0 to 5% by mass.

When the curable resin layer (I) consists of a single thermosetting resin layer (X1) as shown in FIGS. 1, 2 and 3, the single thermosetting resin layer (X1) has the above configuration. The curable resin layer (I) is, as shown in FIG. When the thermosetting resin layer (X1) has two or more layers, as in the case of including the second thermosetting resin layer (X1-2) located on the first surface side), the two or more layers The minimum value (T _1a ) of the minimum curing temperature (T ₁ ) in the thermosetting resin layer (X1) is lower than the expansion start temperature (T ₂ ) of the thermally expandable particles contained in the support layer (II). Preferably. Even if the minimum curing temperature (T ₁ ) of the layers contained in the thermosetting resin layer (X1) is different, the curable resin layer exhibiting the minimum value (T _1a ) is the thermally expandable particle. Since the minimum curing temperature (T ₁ ) is lower than the foaming start temperature (T ₂ ), expansion of the thermally expandable particles is suppressed when the curable resin layer is cured, and excessive adhesion with the curable resin layer is achieved. is prevented. Among the plurality of layers constituting the thermosetting resin layer (X1), this effect is remarkable when the layer having _T1a is arranged closest to the support layer. Even when the layer exhibits (T _1a ), it is possible to make it difficult for the peelability between the cured resin layer (I′) and the support layer (II) to be impaired. One reason for this is that the other layer is cured while the expansion of the thermally expandable particles is suppressed, so when the thermally expandable particles are expanded later, the presence of the other layer after curing causes peeling. It is presumed that this is because it enhances sexuality.

Also, the first thermosetting resin layer (X1-1) and the second thermosetting resin layer (X1-2) may have different adhesive strengths, for example. In this case, the second thermosetting resin layer (X1-2) located on the first surface side is the second thermosetting resin layer (X1-1) having a higher surface adhesion than the first thermosetting resin layer (X1-1). It is preferably a thermosetting resin layer (X1-2). As a method for making the adhesive strength of the second thermosetting resin layer higher than the adhesive strength of the first thermosetting resin layer, for example, the type of coupling agent is changed to produce higher adhesive strength. For example, the amount of the inorganic filler to be added should be reduced.
Further, the shearing force of the first thermosetting resin layer (X1-1) and the shearing force of the second thermosetting resin layer (X1-2) may be made different to increase the former. In this case, for example, by increasing the amount of inorganic filler added to the first thermosetting resin layer (X1-1), the shear force is made larger than that of the second thermosetting resin layer (X1-2). can do.

(Energy ray-curable resin layer)
As shown in FIG. 5, the curable resin layer (I) may comprise a thermosetting resin layer (X1-1) and an energy ray curable resin layer (X2).
In this case, the curable resin layer (I) includes a first layer located on the support layer side and a second layer located on the first surface side, and the first layer is a thermosetting resin layer (X1- 1), and the second layer is preferably the energy ray-curable resin layer (X2). The thermosetting resin layer (X1-1) has the structure described above.
The energy ray-curable resin layer (X2) is preferably formed from an energy ray-curable adhesive composition containing an energy ray-curable adhesive resin and a photopolymerization initiator.
Compared to the thermosetting resin layer, the energy ray-curable resin layer (X2) is easier to adjust for increasing the adhesive force, and thus more reliably fixes the sealing target to the first surface.
By irradiating the energy ray-curable resin layer using such an energy ray-curable pressure-sensitive adhesive composition with an energy ray to cure it, the curing property is reduced during the heat curing of the encapsulant, which will be described later. Curing shrinkage of the resin layer can be made difficult to occur, which is advantageous in preventing warping of the cured sealing body. In addition, when the thermosetting pressure-sensitive adhesive composition is heated at a high temperature, it softens mainly in the initial stage of curing, which may lead to tip slippage. , since it is not softened by curing by irradiation with energy beams, it is possible to avoid the occurrence of tip displacement due to curing.
Examples of energy rays include ultraviolet rays, electron rays, radiation, and the like, but ultraviolet rays are preferable from the viewpoints of easy availability of the curable resin composition and ease of handling of the energy ray irradiation device.

The energy ray-curable adhesive composition is a composition containing an energy ray-curable adhesive resin in which a polymerizable functional group such as a (meth)acryloyl group or vinyl group is introduced into the side chain of the above adhesive resin. It may be a product or a composition containing a monomer or oligomer having a polymerizable functional group.
These compositions preferably further contain a photopolymerization initiator.

Examples of photopolymerization initiators include 1-hydroxy-cyclohexyl-phenyl-ketone, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin propyl ether, benzylphenyl sulfide, tetramethylthiuram monosulfide, azobisisobutyrol. nitrile, dibenzyl, diacetyl, 8-chloroanthraquinone and the like.
These photopolymerization initiators may be used alone or in combination of two or more.
The content of the photopolymerization initiator is preferably 0.01 to 10 parts by mass, more preferably 0, per 100 parts by mass of the energy ray-curable adhesive resin or 100 parts by mass of the monomer or oligomer having a polymerizable functional group. 0.03 to 5 parts by mass, more preferably 0.05 to 3 parts by mass, particularly preferably 0.1 to 3 parts by mass.

By making the shearing force of the thermosetting resin layer (X1-1) larger than the shearing force of the energy ray-curable resin layer (X2), the shearing force of the entire curable resin layer (I) is increased. may

<Support layer (II)>
The support layer (II) included in the laminate of one embodiment of the present invention has a substrate (Y) and an adhesive layer (V), and at least one of the substrate (Y) and the adhesive layer (V) is heated. It preferably contains expandable particles. As described above, the support layer (II) is a layer separated from the curable resin layer (I) by expansion treatment or the like, and serves as a temporary fixing layer.
The support layer (II) used in one embodiment of the present invention, depending on whether the layer containing thermally expandable particles is included in the structure of the base material (Y) or in the case of the pressure-sensitive adhesive layer (V). is divided into the following aspects.
- A first aspect of the support layer (II): a support layer (II) comprising a substrate (Y) having an expandable substrate layer (Y1) containing thermally expandable particles.
- Second aspect of support layer (II): A second pressure-sensitive adhesive layer (V2), which is an expandable pressure-sensitive adhesive layer containing thermally expandable particles, is provided on one surface of the substrate (Y), A support layer (II) having a first pressure-sensitive adhesive layer (V1), which is a non-expanding pressure-sensitive adhesive layer, on the other side.

(First aspect of support layer (II))
As a first embodiment of the support layer (II), as shown in FIGS. 1 to 2, 4 and 5, the substrate (Y) has an expandable substrate layer (Y1) containing thermally expandable particles. things are mentioned.
The adhesive layer (V) is preferably a non-expanding adhesive layer from the viewpoint of making it possible to easily separate the layers together at the interface P with a slight force.
Specifically, in the support layer (II) included in the laminates 1a and 1b shown in FIG. 1, the laminate 4 shown in FIG. 4, and the laminate 5 shown in FIG. A non-expansive pressure-sensitive adhesive layer is preferred.
Further, in the support layer (II) of the laminates 2a and 2b shown in FIG. 2, both the first adhesive layer (V1-1) and the second adhesive layer (V1-2) are non-expanding It is preferably an adhesive layer.
Since the substrate (Y) has the expandable substrate layer (Y1) as in the first embodiment of the support layer (II), the pressure-sensitive adhesive layer (V1) does not need to have expandability. is not bound by the composition, configuration and process for imparting As a result, when designing the pressure-sensitive adhesive layer (V1), it is possible to design with priority given to desired performance other than expansibility, such as performance such as adhesion, productivity, and economic efficiency. The degree of design freedom of V) can be improved.

The thickness of the substrate (Y) before expansion treatment in the first embodiment of the support layer (II) is preferably 10 to 1,000 μm, more preferably 20 to 700 μm, still more preferably 25 to 500 μm, and still more preferably 25 to 500 μm. It is preferably 30 to 300 μm.

The thickness of the pressure-sensitive adhesive layer (V) before expansion treatment in the first embodiment of the support layer (II) is preferably 1 to 60 μm, more preferably 2 to 50 μm, even more preferably 3 to 40 μm, even more preferably. is 5-30 μm.

In this specification, for example, as shown in FIG. 2, when the support layer (II) has a plurality of adhesive layers, the above "thickness of the adhesive layer (V)" It means the thickness of the adhesive layer (the thickness of each of the first adhesive layer (V1-1) and the second adhesive layer (V1-2) in FIG. 2).
Moreover, in this specification, the thickness of each layer constituting the laminate means a value measured by the method described in Examples.

In the first embodiment of the support layer (II), the thickness ratio [(Y1)/(V)] between the expandable substrate layer (Y1) and the pressure-sensitive adhesive layer (V) before expansion treatment is: It is preferably 1,000 or less, more preferably 200 or less, even more preferably 60 or less, and even more preferably 30 or less.
If the thickness ratio is 1,000 or less, the laminate can be easily separated collectively with a slight force at the interface P between the support layer (II) and the cured resin layer (I′) by expansion treatment. can be
The thickness ratio is preferably 0.2 or more, more preferably 0.5 or more, still more preferably 1.0 or more, and even more preferably 5.0 or more.

In addition, in the first embodiment of the support layer (II), the substrate (Y) may be composed only of the expandable substrate layer (Y1) as shown in FIG. 1(a). , having an expandable substrate layer (Y1) on the curable resin layer (I) side and a non-expandable substrate layer (Y2) on the adhesive layer (V) side, as shown in FIG. may have.

In the first embodiment of the support layer (II), the thickness ratio [(Y1)/(Y2)] between the expandable substrate layer (Y1) and the non-expandable substrate layer (Y2) before expansion treatment is is preferably 0.02 to 200, more preferably 0.03 to 150, still more preferably 0.05 to 100.
In the first embodiment of the support layer (II), the thickness of the support layer (II) is preferably 0.02-200 μm, more preferably 0.03-150 μm, still more preferably 0.05-100 μm.

(Second aspect of support layer (II))
As a second aspect of the support layer (II), as shown in FIG. 3, a first pressure-sensitive adhesive layer (V1), which is a non-expanding pressure-sensitive adhesive layer, is arranged on one surface of the substrate (Y). and a second pressure-sensitive adhesive layer (V2), which is an expandable pressure-sensitive adhesive layer containing thermally expandable particles, is disposed on the other surface.
In the second aspect of the support layer (II), the second pressure-sensitive adhesive layer (V2), which is an expandable pressure-sensitive adhesive layer, and the curable resin layer (I) are in direct contact.
In the second aspect of support layer (II), substrate (Y) is preferably a non-expanding substrate. It is preferable that the non-expanding base material is composed only of the non-expanding base layer (Y2).

In the second aspect of the support layer (II), the second pressure-sensitive adhesive layer (V2) which is an expandable pressure-sensitive adhesive layer and the first pressure-sensitive adhesive layer (which is a non-expandable pressure-sensitive adhesive layer) before the expansion treatment ( The thickness ratio [(V2)/(V1)] to V1) is preferably from 0.1 to 80, more preferably from 0.3 to 50, and still more preferably from 0.5 to 15.

Further, in the second aspect of the support layer (II), the thickness ratio [(V2 )/(Y)] is preferably 0.05 to 20, more preferably 0.1 to 10, still more preferably 0.2 to 3.
In the second embodiment of the support layer (II), the thickness of the support layer (II) is preferably 0.05-20 μm, more preferably 0.1-10 μm, still more preferably 0.2-3 μm.

The thermally expandable particles that can be contained in any layer constituting the support layer (II) are described below, and then the expandable base layer (Y1) constituting the base material (Y) and the non-expandable base material The layer (Y2) and adhesive layer (V) will be described in detail.

(Thermal expandable particles)
The expansive particles used in one embodiment of the present invention expand themselves by heating to form irregularities on the adhesive surface of the adhesive layer (V2), which can reduce the adhesive force to the adherend. It is not particularly limited as long as it is a substance.
Thermally expandable particles are superior in versatility and handleability compared to energy linearly expandable particles and the like that expand upon irradiation with energy rays.
The thermally expandable particles used in one aspect of the present invention have an average particle size before expansion at 23° C. of preferably 3 to 100 μm, more preferably 4 to 70 μm, even more preferably 6 to 60 μm, still more preferably 10 to 10 μm. 50 μm.
The average particle size of the thermally expandable particles before expansion is the volume-median particle size (D ₅₀ ), and is measured by a laser diffraction particle size distribution analyzer (for example, manufactured by Malvern, product name "Mastersizer 3000"). In the particle distribution of the thermally expandable particles before expansion measured using , the particle size corresponding to a cumulative volume frequency of 50% calculated from the smallest particle size of the thermally expandable particles before expansion.

The 90% particle diameter (D ₉₀ ) before expansion at 23° C. of the thermally expandable particles used in one aspect of the present invention is preferably 10 to 150 μm, more preferably 20 to 100 μm, still more preferably 25 to 90 μm, Even more preferably, it is 30 to 80 μm.
The 90% particle diameter (D ₉₀ ) of the thermally expandable particles before expansion is measured using a laser diffraction particle size distribution analyzer (for example, manufactured by Malvern, product name “Mastersizer 3000”). In the particle distribution of the thermally expandable particles before expansion, it means a particle size corresponding to a cumulative volume frequency of 90% calculated from the smallest particle size of the thermally expandable particles before expansion.

The thermally expandable particles used in one aspect of the present invention may be particles that do not expand when the encapsulant is cured and have an expansion start temperature (t) higher than the curing temperature of the encapsulant. Specifically, thermally expandable particles having an expansion start temperature (t) adjusted to 60 to 270°C are preferred.
Note that the expansion start temperature (t) is appropriately selected according to the curing temperature of the sealing material to be used.
Further, in this specification, the expansion start temperature (t) of the thermally expandable particles means a value measured based on the method described in Examples.

The thermally expandable particles are microencapsulated foaming agents composed of an outer shell made of a thermoplastic resin and an encapsulated component that is encapsulated in the outer shell and vaporizes when heated to a predetermined temperature. Preferably.
Examples of thermoplastic resins constituting the shell of the microencapsulated foaming agent include vinylidene chloride-acrylonitrile copolymer, polyvinyl alcohol, polyvinyl butyral, polymethyl methacrylate, polyacrylonitrile, polyvinylidene chloride, and polysulfone.

Examples of encapsulated components encapsulated in the outer shell include propane, butane, pentane, hexane, heptane, octane, nonane, decane, isobutane, isopentane, isohexane, isoheptane, isooctane, isononane, isodecane, cyclopropane, cyclobutane, and cyclopentane. , cyclohexane, cycloheptane, cyclooctane, neopentane, dodecane, isododecane, cyclotridecane, hexylcyclohexane, tridecane, tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nanodecane, isotridecane, 4-methyldodecane, isotetradecane, isopentadecane, iso Hexadecane, 2,2,4,4,6,8,8-heptamethylnonane, isoheptadecane, isooctadecane, isonanodecane, 2,6,10,14-tetramethylpentadecane, cyclotridecane, heptylcyclohexane, n-octylcyclohexane , cyclopentadecane, nonylcyclohexane, decylcyclohexane, pentadecylcyclohexane, hexadecylcyclohexane, heptadecylcyclohexane, octadecylcyclohexane, and the like.
These inclusion components may be used alone or in combination of two or more.
The expansion start temperature (t) of the thermally expandable particles can be adjusted by appropriately selecting the type of inclusion component, and is adjusted to be higher than the minimum curing temperature _T1 of the curable resin layer (I).

The maximum volume expansion coefficient when heated to a temperature equal to or higher than the expansion start temperature (t) of the thermally expandable particles used in one aspect of the present invention is preferably 1.5 to 100 times, more preferably 2 to 80 times, and further It is preferably 2.5 to 60 times, and more preferably 3 to 40 times.

<Expandable base layer (Y1)>
The expandable base layer (Y1) included in the support layer (II) used in one aspect of the present invention is a layer that contains thermally expandable particles and can be expanded by a predetermined thermal expansion treatment.

In addition, from the viewpoint of improving the interlayer adhesion between the expandable base layer (Y1) and other layers to be laminated, the surface of the expandable base layer (Y1) is subjected to an oxidation method, a roughening method, or the like. A treatment, an easy-adhesion treatment, or a primer treatment may be applied.
Examples of oxidation methods include corona discharge treatment, plasma discharge treatment, chromic acid treatment (wet), hot air treatment, ozone, and ultraviolet irradiation treatment. Examples of roughening methods include sandblasting and solvent treatment. etc.

In one aspect of the present invention, the expandable base layer (Y1) preferably satisfies the following requirement (1).
Requirement (1): The storage elastic modulus E'(t) of the expandable base material layer (Y1) at the expansion start temperature (t) of the thermally expandable particles is 1.0×10 ⁷ Pa or less.
In addition, in this specification, the storage elastic modulus E' of the expandable base layer (Y1) at a predetermined temperature means a value measured by the method described in Examples.

The above requirement (1) can be said to be an index indicating the rigidity of the expandable base material layer (Y1) immediately before the thermally expandable particles expand.
In order to make the interface P between the support layer (II) and the cured resin layer (I′) easily separable with a slight force, the support layer ( It is necessary to facilitate the formation of unevenness on the surface of II) on which the curable resin layer (I) is laminated.
That is, the expandable base material layer (Y1) that satisfies the above requirement (1) becomes sufficiently large due to expansion of the thermally expandable particles at the expansion start temperature (t), and the curable resin layer (I) is laminated. Concavities and convexities are likely to be formed on the surface of the support layer (II) on the side where the particles are present.
As a result, a laminate that can be easily separated with a slight force at the interface P between the support layer (II) and the cured resin layer (I') can be obtained.

The storage elastic modulus E′(t) of the expandable substrate layer (Y1) defined in requirement (1) is preferably 9.0×10 ⁶ Pa or less, more preferably 8.0×10 It is ⁶ Pa or less, more preferably 6.0×10 ⁶ Pa or less, and even more preferably 4.0×10 ⁶ Pa or less.
In addition, the flow of the expanded thermally expandable particles is suppressed, the shape retention of the unevenness formed on the surface of the support layer (II) on the side where the curable resin layer (I) is laminated is improved, and the interface P From the viewpoint of making it easier to separate with a slight force ^at Pa or more, more preferably 1.0×10 ⁴ Pa or more, and still more preferably 1.0×10 ⁵ Pa or more.

The expandable substrate layer (Y1) is preferably formed from a resin composition (y) containing a resin and thermally expandable particles.
In addition, the resin composition (y) may contain additives for base materials, if necessary, as long as the effects of the present invention are not impaired.
Examples of base material additives include ultraviolet absorbers, light stabilizers, antioxidants, antistatic agents, slip agents, antiblocking agents, colorants, and the like.
These base material additives may be used alone, or two or more of them may be used in combination.
When these base additives are contained, the content of each base additive is preferably 0.0001 to 20 parts by mass, more preferably 0.001 to 20 parts by mass, relative to 100 parts by mass of the resin. 10 parts by mass.

The content of the thermally expandable particles is preferably 1- 40% by mass, more preferably 5 to 35% by mass, still more preferably 10 to 30% by mass, and even more preferably 15 to 25% by mass.

The resin contained in the resin composition (y), which is the material for forming the expandable substrate layer (Y1), may be a non-adhesive resin or a tacky resin.
That is, even if the resin contained in the resin composition (y) is an adhesive resin, the adhesive resin is polymerizable in the process of forming the expandable substrate layer (Y1) from the resin composition (y). It is sufficient that the resin obtained by polymerization reaction with the compound becomes a non-adhesive resin, and the expandable substrate layer (Y1) containing the resin becomes non-adhesive.

The mass average molecular weight (Mw) of the resin contained in the resin composition (y) is preferably 1,000 to 1,000,000, more preferably 1,000 to 700,000, and still more preferably 1,000 to 500,000. is.
Further, when the resin is a copolymer having two or more structural units, the form of the copolymer is not particularly limited, and may be a block copolymer, a random copolymer, or a graft copolymer. may be

The content of the resin is preferably 50 to 99 mass with respect to the total mass (100 mass%) of the expandable substrate layer (Y1) or the total mass (100 mass%) of the active ingredients of the resin composition (y). %, more preferably 60 to 95 mass %, still more preferably 65 to 90 mass %, still more preferably 70 to 85 mass %.

From the viewpoint of forming the expandable substrate layer (Y1) that satisfies the requirement (1), the resin contained in the resin composition (y) is selected from acrylic urethane-based resins and olefin-based resins. It is preferred to contain more than one seed.
As the acrylic urethane resin, an acrylic urethane resin (U1) obtained by polymerizing a urethane prepolymer (UP) and a vinyl compound containing a (meth)acrylic acid ester is preferable.

(Acrylic urethane resin (U1))
Examples of the urethane prepolymer (UP) that forms the main chain of the acrylic urethane resin (U1) include reaction products of polyols and polyvalent isocyanates.
In addition, it is preferable that the urethane prepolymer (UP) is obtained by subjecting the urethane prepolymer (UP) to a chain extension reaction using a chain extension agent.

Examples of polyols used as raw materials for urethane prepolymers (UP) include alkylene-type polyols, ether-type polyols, ester-type polyols, esteramide-type polyols, ester/ether-type polyols, and carbonate-type polyols.
These polyols may be used alone or in combination of two or more.
The polyol used in one embodiment of the present invention is preferably a diol, more preferably an ester-type diol, an alkylene-type diol or a carbonate-type diol, and still more preferably an ester-type diol or a carbonate-type diol.

Examples of ester diols include alkanediols such as 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol and 1,6-hexanediol; ethylene glycol, propylene glycol, 1 or 2 or more selected from diols such as alkylene glycols such as diethylene glycol and dipropylene glycol; ,4'-dicarboxylic acid, succinic acid, adipic acid, azelaic acid, sebacic acid, het acid, maleic acid, fumaric acid, itaconic acid, cyclohexane-1,3-dicarboxylic acid, cyclohexane-1,4-dicarboxylic acid, hexa Condensation products of one or more selected from dicarboxylic acids such as hydrophthalic acid, hexahydroisophthalic acid, hexahydroterephthalic acid, methylhexahydrophthalic acid, and anhydrides thereof may be mentioned.
Specifically, polyethylene adipate diol, polybutylene adipate diol, polyhexamethylene adipate diol, polyhexamethylene isophthalate diol, polyneopentyl adipate diol, polyethylene propylene adipate diol, polyethylene butylene adipate diol, polybutylene hexamethylene adipate diol, Polydiethylene adipate diol, poly(polytetramethylene ether) adipate diol, poly(3-methylpentylene adipate) diol, polyethylene azelate diol, polyethylene sebacate diol, polybutylene azelate diol, polybutylene sebacate diol and polyneo pentyl terephthalate diol and the like.

Examples of alkylene type diols include alkanediols such as 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol and 1,6-hexanediol; ethylene glycol, propylene glycol, alkylene glycols such as diethylene glycol and dipropylene glycol; polyalkylene glycols such as polyethylene glycol, polypropylene glycol and polybutylene glycol; polyoxyalkylene glycols such as polytetramethylene glycol;

Examples of carbonate-type diols include 1,4-tetramethylene carbonate diol, 1,5-pentamethylene carbonate diol, 1,6-hexamethylene carbonate diol, 1,2-propylene carbonate diol, and 1,3-propylene carbonate diol. , 2,2-dimethylpropylene carbonate diol, 1,7-heptamethylene carbonate diol, 1,8-octamethylene carbonate diol, 1,4-cyclohexane carbonate diol and the like.

Aromatic polyisocyanates, aliphatic polyisocyanates, alicyclic polyisocyanates, and the like are examples of polyvalent isocyanates that are raw materials for urethane prepolymers (UP).
These polyvalent isocyanates may be used alone or in combination of two or more.
Further, these polyvalent isocyanates may be trimethylolpropane adduct-type modified products, biuret-type modified products reacted with water, and isocyanurate-type modified products containing an isocyanurate ring.

Among these, diisocyanates are preferable as the polyvalent isocyanate used in one embodiment of the present invention, and 4,4′-diphenylmethane diisocyanate (MDI), 2,4-tolylene diisocyanate (2,4-TDI), 2,6 At least one selected from -tolylene diisocyanate (2,6-TDI), hexamethylene diisocyanate (HMDI), and alicyclic diisocyanate is more preferred.

Alicyclic diisocyanates include, for example, 3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate (isophorone diisocyanate, IPDI), 1,3-cyclopentane diisocyanate, 1,3-cyclohexane diisocyanate, 1,4-cyclohexane Examples include diisocyanate, methyl-2,4-cyclohexanediisocyanate, methyl-2,6-cyclohexanediisocyanate, and isophorone diisocyanate (IPDI) is preferred.

In one aspect of the present invention, the urethane prepolymer (UP), which is the main chain of the acrylic urethane resin (U1), is a reaction product of a diol and a diisocyanate and is a straight chain having ethylenically unsaturated groups at both ends. Urethane prepolymers are preferred.
As a method for introducing ethylenically unsaturated groups at both ends of the linear urethane prepolymer, an NCO group at the terminal of the linear urethane prepolymer obtained by reacting a diol and a diisocyanate compound, and a hydroxyalkyl (meth)acrylate and a method of reacting with.

Hydroxyalkyl (meth)acrylates include, for example, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 3-hydroxy Butyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate and the like can be mentioned.

The vinyl compound that becomes the side chain of the acrylic urethane resin (U1) contains at least a (meth)acrylic acid ester.
As the (meth)acrylic acid ester, one or more selected from alkyl (meth)acrylates and hydroxyalkyl (meth)acrylates is preferable, and it is more preferable to use alkyl (meth)acrylates and hydroxyalkyl (meth)acrylates together.

When alkyl (meth)acrylate and hydroxyalkyl (meth)acrylate are used in combination, the ratio of hydroxyalkyl (meth)acrylate to 100 parts by mass of alkyl (meth)acrylate is preferably 0.1 to 100 parts by mass, more It is preferably 0.5 to 30 parts by mass, more preferably 1.0 to 20 parts by mass, and even more preferably 1.5 to 10 parts by mass.

The alkyl group of the alkyl (meth)acrylate preferably has 1 to 24 carbon atoms, more preferably 1 to 12 carbon atoms, still more preferably 1 to 8 carbon atoms, and even more preferably 1 to 3 carbon atoms.

Examples of hydroxyalkyl (meth)acrylates include the same hydroxyalkyl (meth)acrylates used for introducing ethylenically unsaturated groups to both ends of the linear urethane prepolymer described above.

Examples of vinyl compounds other than (meth)acrylic esters include aromatic hydrocarbon-based vinyl compounds such as styrene, α-methylstyrene, and vinyltoluene; vinyl ethers such as methyl vinyl ether and ethyl vinyl ether; vinyl acetate and vinyl propionate. , (meth)acrylonitrile, N-vinylpyrrolidone, (meth)acrylic acid, maleic acid, fumaric acid, itaconic acid, meta(acrylamide) and other polar group-containing monomers;
These may be used alone or in combination of two or more.

The content of the (meth)acrylic acid ester in the vinyl compound is preferably 40 to 100% by mass, more preferably 65 to 100% by mass, and still more preferably 80 to 100% by mass, more preferably 90 to 100% by mass.

The total content of alkyl (meth)acrylate and hydroxyalkyl (meth)acrylate in the vinyl compound is preferably 40 to 100% by mass, more preferably 65 to 100% by mass, based on the total amount (100% by mass) of the vinyl compound. 100% by mass, more preferably 80 to 100% by mass, and even more preferably 90 to 100% by mass.

In the acrylic urethane resin (U1) used in one aspect of the present invention, the content ratio of the structural unit (u11) derived from the urethane prepolymer (UP) and the structural unit (u12) derived from the vinyl compound [(u11 )/(u12)] is preferably 10/90 to 80/20, more preferably 20/80 to 70/30, still more preferably 30/70 to 60/40, still more preferably 35 /65 to 55/45.

(Olefin resin)
The olefinic resin suitable as the resin contained in the resin composition (y) is a polymer having at least a structural unit derived from an olefin monomer.
As the olefin monomer, α-olefins having 2 to 8 carbon atoms are preferable, and specific examples include ethylene, propylene, butylene, isobutylene, 1-hexene, and the like.
Among these, ethylene and propylene are preferred.

Specific olefin resins include, for example, ultra-low density polyethylene (VLDPE, density: 880 kg/m ³ or more and less than 910 kg/m ³ ), low density polyethylene (LDPE, density: 910 kg/m ³ or more and less than 915 kg/m ³ ), medium density polyethylene (MDPE, density: 915 kg/m ³ or more and less than 942 kg/m ³ ), high density polyethylene (HDPE, density: 942 kg/m ³ or more), polyethylene resin such as linear low density polyethylene; polypropylene resin (PP); polybutene resin (PB); ethylene-propylene copolymer; olefin elastomer (TPO); poly (4-methyl-1-pentene) (PMP); ethylene-vinyl acetate copolymer (EVA); vinyl alcohol copolymers (EVOH); olefinic terpolymers such as ethylene-propylene-(5-ethylidene-2-norbornene);

In one aspect of the present invention, the olefin-based resin may be a modified olefin-based resin further subjected to one or more modifications selected from acid modification, hydroxyl modification, and acrylic modification.

For example, the acid-modified olefin resin obtained by subjecting an olefin resin to acid modification is a modified polymer obtained by graft-polymerizing an unsaturated carboxylic acid or its anhydride to the above-described unmodified olefin resin. are mentioned.
Examples of unsaturated carboxylic acids or anhydrides thereof include maleic acid, fumaric acid, itaconic acid, citraconic acid, glutaconic acid, tetrahydrophthalic acid, aconitic acid, (meth)acrylic acid, maleic anhydride, and itaconic anhydride. , glutaconic anhydride, citraconic anhydride, aconitic anhydride, norbornenedicarboxylic anhydride, tetrahydrophthalic anhydride and the like.
The unsaturated carboxylic acid or its anhydride may be used alone, or two or more of them may be used in combination.

The acrylic-modified olefin-based resin obtained by subjecting an olefin-based resin to acrylic modification includes modification obtained by graft-polymerizing an alkyl (meth)acrylate as a side chain to the above-described unmodified olefin-based resin that is the main chain. polymers.
The number of carbon atoms in the alkyl group of the above alkyl (meth)acrylate is preferably 1-20, more preferably 1-16, still more preferably 1-12.
Examples of the above alkyl (meth)acrylates include the same compounds as the compounds that can be selected as the monomer (a1′) described later.

Examples of the hydroxyl group-modified olefin resin obtained by modifying the olefin resin with hydroxyl groups include a modified polymer obtained by graft polymerizing a hydroxyl group-containing compound to the above-described unmodified olefin resin that is the main chain.
Examples of the above hydroxyl group-containing compounds include 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 3-hydroxybutyl hydroxyalkyl (meth)acrylates such as (meth)acrylate and 4-hydroxybutyl (meth)acrylate; and unsaturated alcohols such as vinyl alcohol and allyl alcohol.

(Resins other than acrylic urethane resins and olefin resins)
In one aspect of the present invention, the resin composition (y) may contain a resin other than the acrylic urethane resin and the olefin resin as long as the effects of the present invention are not impaired.
Examples of such resins include vinyl resins such as polyvinyl chloride, polyvinylidene chloride and polyvinyl alcohol; polyester resins such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate; polystyrene; acrylonitrile-butadiene-styrene copolymer; Coalescence; cellulose triacetate; polycarbonate; polyurethane not applicable to acrylic urethane resins; polysulfone; polyetheretherketone; polyethersulfone; polyphenylene sulfide; Fluorinated resins and the like are included.

However, from the viewpoint of forming the expandable base layer (Y1) that satisfies the above requirement (1), the content of the resin other than the acrylic urethane resin and the olefin resin in the resin composition (y) should be as small as possible. preferable.
The content of the resin other than the acrylic urethane resin and the olefin resin is preferably less than 30 parts by mass, more preferably 20 parts by mass, with respect to 100 parts by mass of the resin contained in the resin composition (y). less than 10 parts by weight, more preferably less than 5 parts by weight, and even more preferably less than 1 part by weight.

(Solvent-free resin composition (y1))
As the resin composition (y) used in one embodiment of the present invention, an oligomer having an ethylenically unsaturated group having a mass average molecular weight (Mw) of 50,000 or less, an energy ray-polymerizable monomer, and the above-described thermally expandable particles and a solvent-free resin composition (y1) containing no solvent.
The solvent-free resin composition (y1) does not contain a solvent, but the energy ray-polymerizable monomer contributes to improving the plasticity of the oligomer.
By irradiating the coating film formed from the solvent-free resin composition (y1) with energy rays, it is easy to form the expandable substrate layer (Y1) that satisfies the requirement (1).
The type, shape and compounding amount (content) of the thermally expandable particles to be compounded in the solvent-free resin composition (y1) are as described above.

The weight average molecular weight (Mw) of the oligomer contained in the solventless resin composition (y1) is 50,000 or less, preferably 1,000 to 50,000, more preferably 20,00 to 40. ,000, more preferably 3,000 to 35,000, even more preferably 4,000 to 30,000.

Further, as the oligomer, among the resins contained in the above resin composition (y), those having an ethylenically unsaturated group having a mass average molecular weight of 50,000 or less may be used. Polymers (UP) are preferred.
A modified olefinic resin having an ethylenically unsaturated group can also be used as the oligomer.

The total content of the oligomer and the energy ray-polymerizable monomer in the solvent-free resin composition (y1) is preferably 50 to 50% with respect to the total amount (100% by mass) of the solvent-free resin composition (y1). 99% by mass, more preferably 60 to 95% by mass, even more preferably 65 to 90% by mass, and even more preferably 70 to 85% by mass.

Energy beam-polymerizable monomers include, for example, isobornyl (meth)acrylate, dicyclopentenyl (meth)acrylate, dicyclopentanyl (meth)acrylate, dicyclopentenyloxy (meth)acrylate, cyclohexyl (meth)acrylate, adamantane ( Alicyclic polymerizable compounds such as meth) acrylate and tricyclodecane acrylate; Aromatic polymerizable compounds such as phenylhydroxypropyl acrylate, benzyl acrylate, and phenol ethylene oxide-modified acrylate; Examples include heterocyclic polymerizable compounds such as vinylpyrrolidone and N-vinylcaprolactam.
These energy ray-polymerizable monomers may be used alone or in combination of two or more.

The blending ratio of the oligomer and the energy ray-polymerizable monomer (the oligomer/energy ray-polymerizable monomer) is preferably 20/80 to 90/10, more preferably 30/70 to 85/15, still more preferably 35/65. ~80/20.

In one aspect of the present invention, the solventless resin composition (y1) preferably further contains a photopolymerization initiator.
By containing a photopolymerization initiator, the curing reaction can be sufficiently advanced even by irradiation with relatively low-energy energy rays.

Examples of photopolymerization initiators include 1-hydroxy-cyclohexyl-phenyl-ketone, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin propyl ether, benzylphenyl sulfide, tetramethylthiuram monosulfide, azobisisobutyrol. nitrile, dibenzyl, diacetyl, 8-chloroanthraquinone and the like.
These photopolymerization initiators may be used alone or in combination of two or more.

The amount of the photopolymerization initiator is preferably 0.01 to 5 parts by mass, more preferably 0.01 to 4 parts by mass, and further preferably 0.01 to 4 parts by mass, based on the total amount (100 parts by mass) of the oligomer and the energy ray-polymerizable monomer. It is preferably 0.02 to 3 parts by mass.

<Non-expandable base layer (Y2)>
Examples of the material for forming the non-expanding base layer (Y2) that constitutes the base (Y) include paper materials, resins, metals, etc., and are appropriately selected according to the application of the laminate of one embodiment of the present invention. can be selected.
Here, in one aspect of the present invention, when the thermally expandable particles contained in the expandable base layer (Y1) expand, the non-expandable base layer (Y2) side of the expandable base layer (Y1) From the viewpoint of suppressing the formation of unevenness on the surface of the non-expandable substrate layer (Y1) and predominantly forming unevenness on the surface of the adhesive layer (V1) side of the expandable substrate layer (Y2) preferably has such rigidity that it does not deform due to the expansion of the thermally expandable particles. Specifically, the non-expandable base layer (Y2) has a storage elastic modulus E′(t) of 1.1×10 ⁷ Pa or more at the temperature (t) at which the thermally expandable particles start to expand. is preferred.

Examples of the paper material include thin paper, medium quality paper, fine paper, impregnated paper, coated paper, art paper, parchment paper, and glassine paper.
Examples of resins include polyolefin resins such as polyethylene and polypropylene; vinyl resins such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymer, and ethylene-vinyl alcohol copolymer; polyester resins such as butylene terephthalate and polyethylene naphthalate; polystyrene; acrylonitrile-butadiene-styrene copolymer; cellulose triacetate; polycarbonate; polyether sulfone; polyphenylene sulfide; polyimide-based resins such as polyetherimide and polyimide; polyamide-based resins; acrylic resins;
Examples of metals include aluminum, tin, chromium, and titanium.

These forming materials may be composed of one type, or two or more types may be used in combination.
The non-expanding base material layer (Y2) using two or more kinds of forming materials in combination includes a paper material laminated with a thermoplastic resin such as polyethylene, a resin film or sheet containing a resin, and a metal film formed on the surface of the sheet. and the like.
As a method for forming the metal layer, for example, a method of depositing the above metal by a PVD method such as vacuum deposition, sputtering, or ion plating, or a method of attaching a metal foil made of the above metal using a general adhesive. and the like.

From the viewpoint of improving the interlayer adhesion between the non-expanding base layer (Y2) and other layers to be laminated, when the non-expanding base layer (Y2) contains a resin, the non-expanding base layer The surface of (Y2) may also be subjected to a surface treatment such as an oxidation method or roughening method, an adhesion-facilitating treatment, or a primer treatment, as in the case of the expandable base layer (Y1) described above.

Moreover, when the non-expanding base material layer (Y2) contains a resin, it may contain the above base material additives that can also be contained in the resin composition (y) together with the resin.

The non-expanding base layer (Y2) is a non-expanding layer determined based on the method described above.
Therefore, the volume change rate (%) of the non-expandable base layer (Y2) calculated from the above formula is less than 5% by volume, preferably less than 2% by volume, and more preferably less than 1% by volume. , more preferably less than 0.1% by volume, and even more preferably less than 0.01% by volume.

In addition, the non-expandable base layer (Y2) may contain thermally expandable particles as long as the volume change rate is within the above range. For example, by selecting a resin to be contained in the non-expandable base layer (Y2), it is possible to adjust the volume change rate within the above range even if thermally expandable particles are contained.
However, the non-expandable base layer (Y2) preferably does not contain thermally expandable particles. When the non-expandable base layer (Y2) contains thermally expandable particles, the content thereof is preferably as small as possible. With respect to the total mass (100% by mass) of usually less than 3% by mass, preferably less than 1% by mass, more preferably less than 0.1% by mass, more preferably less than 0.01% by mass, still more preferably 0 less than 0.001 mass %.

<Adhesive layer (V)>
The pressure-sensitive adhesive layer (V) included in the support layer (II) used in one aspect of the present invention can be formed from the pressure-sensitive adhesive composition (v) containing a pressure-sensitive adhesive resin.
Moreover, the pressure-sensitive adhesive composition (v) may contain additives for pressure-sensitive adhesive such as a cross-linking agent, a tackifier, a polymerizable compound, and a polymerization initiator, if necessary.
Each component contained in the pressure-sensitive adhesive composition (v) is described below.
Note that even when the support layer (II) has the first adhesive layer (V1-1) or (V1) and the second adhesive layer (V1-2) or (V2), the first adhesive layer (V1-1) or (V1) and the second adhesive layer (V1-2) or (V2) can also be formed from the adhesive composition (v) containing each component shown below.

(adhesive resin)
As the adhesive resin used in one aspect of the present invention, it is preferable that the resin alone has adhesiveness and is a polymer having a mass average molecular weight (Mw) of 10,000 or more.
The mass average molecular weight (Mw) of the adhesive resin used in one aspect of the present invention is preferably 10,000 to 2,000,000, more preferably 20,000 to 1,500,000, and still more preferably 30,000 from the viewpoint of improving adhesive strength. ~1 million.

Examples of specific adhesive resins include acrylic resins, urethane resins, rubber resins such as polyisobutylene resins, polyester resins, olefin resins, silicone resins, and polyvinyl ether resins.
These adhesive resins may be used alone or in combination of two or more.
In addition, when these adhesive resins are copolymers having two or more structural units, the form of the copolymer is not particularly limited, and may be block copolymers, random copolymers, and graft copolymers. Any polymer may be used.

In one aspect of the present invention, the adhesive resin preferably contains an acrylic resin from the viewpoint of exhibiting excellent adhesive strength.
When using the support layer (II) having the first adhesive layer (V1-1) or (V1) and the second adhesive layer (V1-2) or (V2), the curable resin layer (I ) in contact with the first adhesive layer (V1-1) or (V1) contains an acrylic resin, forming unevenness on the surface of the first adhesive layer (V1-1) or (V1) can be made easier.

The content of the acrylic resin in the adhesive resin is preferably from 30 to 30 with respect to the total amount (100% by mass) of the adhesive resin contained in the adhesive composition (v) or the adhesive layer (V). 100% by mass, more preferably 50 to 100% by mass, still more preferably 70 to 100% by mass, and even more preferably 85 to 100% by mass.

The content of the adhesive resin is preferably 35 to 100 with respect to the total weight (100% by mass) of the active ingredients of the adhesive composition (v) or the total weight (100% by mass) of the adhesive layer (V). % by mass, more preferably 50 to 100% by mass, still more preferably 60 to 98% by mass, and even more preferably 70 to 95% by mass.

(crosslinking agent)
In one aspect of the present invention, when the pressure-sensitive adhesive composition (v) contains a pressure-sensitive adhesive resin having a functional group, it is preferred that the pressure-sensitive adhesive composition (v) further contains a cross-linking agent.
The cross-linking agent reacts with the adhesive resin having a functional group to cross-link the adhesive resins with the functional group as a cross-linking starting point.

Examples of cross-linking agents include isocyanate-based cross-linking agents, epoxy-based cross-linking agents, aziridine-based cross-linking agents, and metal chelate-based cross-linking agents.
These cross-linking agents may be used alone or in combination of two or more.
Among these cross-linking agents, isocyanate-based cross-linking agents are preferred from the viewpoints of increasing cohesive strength and improving adhesive strength, and from the viewpoint of availability and the like.

The content of the cross-linking agent is appropriately adjusted according to the number of functional groups possessed by the adhesive resin. It is more preferably 0.03 to 7 parts by mass, still more preferably 0.05 to 5 parts by mass.

(Tackifier)
In one aspect of the present invention, the pressure-sensitive adhesive composition (v) may further contain a tackifier from the viewpoint of further improving the adhesive strength.
As used herein, the term "tackifier" refers to a component that supplementarily improves the adhesive strength of the adhesive resin described above, and refers to an oligomer having a weight average molecular weight (Mw) of less than 10,000. It is distinguished from the hard resin.
The weight average molecular weight (Mw) of the tackifier is preferably 400 to 10,000, more preferably 500 to 8,000, still more preferably 800 to 5,000.

Examples of tackifiers include rosin-based resins, terpene-based resins, styrene-based resins, pentene produced by thermal decomposition of petroleum naphtha, isoprene, piperine, obtained by copolymerizing C5 fractions such as 1,3-pentadiene. and C9 petroleum resins obtained by copolymerizing C9 fractions such as indene and vinyl toluene produced by thermal decomposition of petroleum naphtha, and hydrogenated resins obtained by hydrogenating these.

The softening point of the tackifier is preferably 60 to 170°C, more preferably 65 to 160°C, still more preferably 70 to 150°C.
In addition, in this specification, the "softening point" of a tackifier means the value measured based on JISK2531.
The tackifiers may be used alone, or two or more of them having different softening points, structures, etc. may be used in combination.
When two or more tackifiers are used, the weighted average of the softening points of the tackifiers preferably falls within the above range.

The content of the tackifier is preferably 0.01 to 0.01 with respect to the total amount (100% by mass) of the active ingredients of the adhesive composition (v) or the total amount (100% by mass) of the adhesive layer (V). 65% by mass, more preferably 0.1 to 50% by mass, still more preferably 1 to 40% by mass, and even more preferably 2 to 30% by mass.

(Adhesive additive)
In one aspect of the present invention, the pressure-sensitive adhesive composition (v) contains additives for pressure-sensitive adhesives that are commonly used in pressure-sensitive adhesives, in addition to the above additives, within a range that does not impair the effects of the present invention. You may have
Examples of such adhesive additives include antioxidants, softeners (plasticizers), rust inhibitors, pigments, dyes, retarders, reaction accelerators (catalysts), ultraviolet absorbers, antistatic agents, and the like. is mentioned.
In addition, these additives for pressure-sensitive adhesives may be used alone, respectively, or two or more of them may be used in combination.
When these adhesive additives are contained, the content of each adhesive additive is preferably 0.0001 to 20 parts by mass, more preferably 0.001, per 100 parts by mass of the adhesive resin. ~10 parts by mass.

In addition, when using the support layer (II) of the above-described third embodiment having the second pressure-sensitive adhesive layer (V2) which is an expansive pressure-sensitive adhesive layer, the second pressure-sensitive adhesive layer (V2) which is an expandable pressure-sensitive adhesive layer ) is formed from the above-described adhesive composition (v) and an expandable adhesive composition (v22) containing thermally expandable particles.
The thermally expandable particles are as described above.
The content of the thermally expandable particles is preferably 1 to 70% by mass, more preferably 2 to 60% by mass, still more preferably 3 to 50% by mass, and even more preferably 5 to 40% by mass.

On the other hand, when the pressure-sensitive adhesive layer (V) is a non-expanding pressure-sensitive adhesive layer, the pressure-sensitive adhesive composition (v), which is the material for forming the non-expanding pressure-sensitive adhesive layer, may not contain thermally expandable particles. preferable.
When containing thermally expandable particles, the content is preferably as small as possible, the total amount of active ingredients of the adhesive composition (v) (100% by mass) or the total amount of the adhesive layer (V) (100% by mass) is preferably less than 1% by mass, more preferably less than 0.1% by mass, even more preferably less than 0.01% by mass, and even more preferably less than 0.001% by mass.

In addition, like the laminates 2a and 2b shown in FIG. 2, the support layer having the first adhesive layer (V1-1) and the second adhesive layer (V1-2), which are non-expanding adhesive layers When using (II), the storage shear modulus G' (23) of the first pressure-sensitive adhesive layer (V1-1), which is a non-expanding pressure-sensitive adhesive layer, at 23°C is preferably 1.0 × 10 ⁸ Pa or less, more preferably 5.0×10 ⁷ Pa or less, and even more preferably 1.0×10 ⁷ Pa or less.
If the storage shear modulus G′(23) of the first pressure-sensitive adhesive layer (V1-1), which is a non-expanding pressure-sensitive adhesive layer, is 1.0×10 ⁸ Pa or less, for example, the laminate shown in FIG. 2a, 2b, the first pressure-sensitive adhesive in contact with the cured resin layer (I′) due to the expansion of the thermally expandable particles in the expandable base layer (Y1) due to the heat expansion treatment Asperities are easily formed on the surface of the layer (V1-1).
As a result, it is possible to obtain a laminate that can be easily separated collectively at the interface P between the support layer (II) and the cured resin layer (I') with a slight force.
The storage shear modulus G′(23) of the first pressure-sensitive adhesive layer (V1-1), which is a non-expanding pressure-sensitive adhesive layer, at 23° C. is preferably 1.0×10 ⁴ Pa or more, more preferably is 5.0×10 ⁴ Pa or more, more preferably 1.0×10 ⁵ Pa or more.

The light transmittance at a wavelength of 365 nm of the support layer (II) included in the laminate of one embodiment of the present invention is preferably 30% or higher, more preferably 50% or higher, and even more preferably 70% or higher. When the light transmittance is within the above range, the degree of cure of the curable resin layer (I) is further improved when the curable resin layer (I) is irradiated with energy rays (ultraviolet rays) through the support layer (II). do. Although the upper limit of the light transmittance at a wavelength of 365 nm is not particularly limited, it can be, for example, 95% or less.
From the viewpoint of achieving the above light transmittance, it is preferable that the substrate (Y) and the pressure-sensitive adhesive layer (V) of the support layer (II) do not contain a colorant.
When a coloring agent is contained, the content thereof is preferably as small as possible. is preferably less than 1% by mass, more preferably less than 0.1% by mass, still more preferably less than 0.01% by mass, and even more preferably less than 0.001% by mass, and in the substrate (Y) is preferably less than 1% by mass, more than It is preferably less than 0.1% by mass, more preferably less than 0.01% by mass, and even more preferably less than 0.001% by mass.

(Object to be sealed)
Examples of objects to be sealed placed on part of the surface of the curable resin layer (I) include semiconductor chips, semiconductor wafers, compound semiconductors, semiconductor packages, electronic components, sapphire substrates, displays, panel substrates, and the like. is mentioned.

For example, when the object to be sealed is a semiconductor chip, a semiconductor chip with a cured resin layer can be manufactured by using the warp-preventing laminate of one embodiment of the present invention.
A conventionally known semiconductor chip can be used, and an integrated circuit composed of circuit elements such as transistors, resistors, and capacitors is formed on the circuit surface.
The semiconductor chip is preferably placed so that the back surface opposite to the circuit surface is covered with the surface of the thermosetting resin layer. In this case, after the mounting, the circuit surface of the semiconductor chip is exposed.
A known device such as a flip chip bonder or a die bonder can be used for mounting the semiconductor chip.
The layout of arrangement of semiconductor chips, the number of arrangement, etc. may be appropriately determined according to the form of the intended package, the production volume, and the like.

[Method for producing warp-preventing laminate]
The anti-warp laminate can be produced by the following method.
First, a curable resin composition is applied onto a release film and dried to form a curable resin layer (I).
When the curable resin layer (I) is composed of two layers, each curable resin composition is formed on a separate release film, and both layers are overlapped so that they are in direct contact with each other to form a laminated curable layer. A resin layer is produced. The first curable resin composition is applied and dried on a release film to form a first curable resin layer (X1-1), and then on this first curable resin layer (X1-1) A laminated curable resin layer can also be produced by coating and drying the second curable resin layer (X1-2) or (X2).
By attaching the pressure-sensitive adhesive layer (V) of the support layer (II) to the curable resin layer (I), or via a pressure-sensitive adhesive layer separate from the support layer (II), the curable By attaching the resin layer (I) and the support layer (II), a warp-preventing laminate can be obtained.
The support layer (II) is formed by coating and drying an adhesive composition on a release film to form an adhesive layer (V). It can be prepared by coating and drying the adhesive on the adhesive layer, or by attaching a sheet-like substrate to the pressure-sensitive adhesive layer to form a substrate layer. When the base material layer is composed of a plurality of layers, after forming the first base material layer, the resin material constituting the second base material layer is coated and dried on the first base material layer to form the second base material layer. to form a substrate layer of In the case of a support layer having a second adhesive layer on a second substrate layer, the adhesive composition is coated and dried on the second substrate layer to form the second adhesive layer. .

[First Method for Producing Cured Encapsulant]
A first aspect of the method for producing a hardened sealed body of the present invention is a method for producing a hardened sealed body using the laminate of one embodiment of the present invention, wherein the following steps (i) to (iv) are performed. have.
Step (i): An object to be sealed is placed on part of the first surface of the curable resin layer (I) of the anti-warp laminate.
Step (ii): covering the object to be sealed and the first surface of the curable resin layer (I) at least around the object to be sealed with a thermosetting sealing material.
Step (iii): The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer (I′). to obtain a cured encapsulant.
Step (iv): The cured resin layer (I') and the support layer (II) are separated at their interface by a treatment for expanding the thermally expandable particles to obtain a cured sealing body with the cured resin layer.

FIG. 6 is a schematic cross-sectional view showing the process of manufacturing a cured sealing body with a cured resin layer. It is a cross-sectional schematic diagram showing the process of manufacturing the. Each of the above steps will be described below with reference to FIG. 6 as appropriate.

<Step (i)>
In step (i), an object to be sealed is placed on part of the surface of the curable resin layer (I) of the warp-preventing laminate of one embodiment of the present invention.
FIG. 6(a) shows a state in which the adhesive surface of the adhesive layer (V1) of the support layer (II) is attached to the support 50 using the anti-warp laminate 1b, and FIG. shows how the sealing object 60 is placed on part of the surface of the curable resin layer (I).
FIG. 6 shows an example using the laminate 1b shown in FIG. , the anti-warp laminate, and the object to be sealed are laminated or placed in this order.

As for the temperature conditions in step (i), it is preferable to perform the step (i) at a temperature at which the thermally expandable particles do not expand, for example, in an environment of 0 to 80°C (where the expansion start temperature (t) is 60 to 80°C). In some cases, it is preferably performed in an environment below the expansion start temperature (t).

The support is preferably attached to the entire adhesive surface of the adhesive layer (V1) of the laminate.
Therefore, the support is preferably plate-like. Further, the area of the adhesive surface of the adhesive layer (V1) and the surface of the support on the sticking side is preferably equal to or greater than the area of the adhesive surface of the adhesive layer (V1), as shown in FIG.

The material constituting the support is appropriately selected depending on the type of the sealing object, the type of sealing material used in step (ii), etc., taking into consideration the required properties such as mechanical strength and heat resistance. selected.
Specific materials constituting the support include, for example, metallic materials such as SUS; nonmetallic inorganic materials such as glass and silicon wafers; epoxy resins, ABS resins, acrylic resins, engineering plastics, super engineering plastics, polyimide resins, Resin materials such as polyamide-imide resins; composite materials such as glass epoxy resins; among these, SUS, glass, and silicon wafers are preferred.
Engineering plastics include nylon, polycarbonate (PC), and polyethylene terephthalate (PET).
Super engineering plastics include polyphenylene sulfide (PPS), polyethersulfone (PES), polyetheretherketone (PEEK), and the like.

The thickness of the support is appropriately selected according to the type of sealing object, the type of sealing material used in step (ii), etc., and is preferably 20 μm or more and 50 mm or less, more preferably 60 μm or more. 20 mm or less.

On the other hand, the sealing object to be placed on part of the surface of the curable resin layer (I) includes, for example, semiconductor chips, semiconductor wafers, compound semiconductors, semiconductor packages, electronic parts, sapphire substrates, displays, and panels. substrates and the like. In the following description, the case where a semiconductor chip is used as the sealing object 60 will be described as an example.

When the object to be sealed is a semiconductor chip, a semiconductor chip with a cured resin layer can be manufactured using the laminate of one embodiment of the present invention.
A conventionally known semiconductor chip can be used, and an integrated circuit composed of circuit elements such as transistors, resistors, and capacitors is formed on the circuit surface.
The semiconductor chip is preferably placed so that the back surface opposite to the circuit surface is covered with the surface of the curable resin layer (I). In this case, after the mounting, the circuit surface of the semiconductor chip is exposed.
A known device such as a flip chip bonder or a die bonder can be used for mounting the semiconductor chip.
The layout of arrangement of semiconductor chips, the number of arrangement, etc. may be appropriately determined according to the form of the intended package, the production volume, and the like.

The surface of the curable resin layer (I) of the present embodiment (in the example of FIG. 6, the surface of the non-expanding thermosetting resin layer (X1) opposite to the support layer (II)) is a curable However, by setting the adhesive strength to be as described above, when bonding the semiconductor chip 60 as a sealing object to the surface of the curable resin layer (I), the semiconductor chip 60 is It is fixed securely, making it easier to prevent misalignment.

Here, the laminated body of one embodiment of the present invention includes a semiconductor chip covered with a sealing material in a region larger than the chip size, such as FOWLP and FOPLP, so that not only the circuit surface of the semiconductor chip but also the sealing material is preferably applied to a package in which a rewiring layer is formed even in the surface region of
Therefore, the semiconductor chips are placed on a part of the surface of the curable resin layer (I), and the plurality of semiconductor chips are placed on the surface in a state of being aligned at regular intervals. More preferably, a plurality of semiconductor chips are placed on the surface in a state of being aligned in a matrix of multiple rows and multiple columns at regular intervals.
The distance between the semiconductor chips may be appropriately determined according to the form of the intended package.

<Step (ii)>
In the step (ii), the object to be sealed placed on the curable resin layer (I) and the first surface of the curable resin layer (I) at least in the periphery of the object to be sealed are heated. It is covered with a curable sealing material (hereinafter also referred to as “coating treatment”).
In the coating process, first, the object to be sealed and at least the periphery of the object to be sealed on the surface of the curable resin layer (I) are coated with the sealing material. Specifically, as shown in FIG. 6(c), a laminated body 1b is attached on a support 50, and a semiconductor chip 60, which is an object to be sealed, is placed on the curable resin layer (I). , the mold 70 is positioned within the mold of the mold 70 . Then, the sealing material is injected through the injection hole 71 into the molding space 72 formed between the molding die 70 and the laminate 1b and the sealing object 60 .
The sealing material covers the entire exposed surface of the semiconductor chip 60, which is the object to be sealed, and also fills the gaps between the plurality of semiconductor chips.
When the molding die 70 is removed after the injection of the sealing resin and the resin molding are completed, the surfaces of the semiconductor chip 60 and the curable resin layer (I) are all covered with the sealing material 80 as shown in FIG. 6(d). covered.

When injecting the sealing material 80 into the molding space 72 using a resin molding method of a type in which a resin material is injected into a molding die, represented by a transfer molding method, the curable resin (I) is A flow of the sealing material 80 is generated along the surface (see the arrow in FIG. 6(c)). In the manufacturing method of this aspect, the object 60 to be sealed is fixed by the curable resin layer (I), and the shear strength of the curable resin layer (I) with respect to the adherend for measurement is set as described above. Therefore, it becomes easy to prevent the object 60 to be sealed from shifting or tilting.

The encapsulant has the function of protecting the object to be sealed and the elements associated therewith from the external environment.
The sealing material 80 used in the manufacturing method of one embodiment of the present invention is a thermosetting sealing material containing a thermosetting resin.

The encapsulant may be solid such as granules, pellets, or films at room temperature, or it may be liquid in the form of a composition. From the viewpoint of workability, a sealing resin film, which is a film-like sealing material, is preferable.

As the coating method, in addition to the transfer molding method, it is possible to appropriately select and apply from among the methods applied to the conventional sealing process according to the type of the sealing material, for example, the roll lamination method. , a vacuum press method, a vacuum lamination method, a spin coat method, a die coat method, a compression mold method, and the like can be applied.

<Step (iii)>
In step (iii), the encapsulant after the coating treatment is thermally cured to form a cured encapsulant including the object to be encapsulated. The curable resin layer (I) is also cured to form a cured resin layer (I').
Specifically, as shown in FIG. 6E, by curing the sealing material 80, a cured sealing body 85 in which the semiconductor chip 60, which is the object to be sealed, is covered with the cured sealing material 81. get As a result, the semiconductor chip 60 is protected with a hard material while maintaining its layout. At this time, since the thermosetting resin layer (X1) is used as the curable resin layer (I) in the manufacturing method of this aspect, the curing start temperature is set to the curing start temperature of the thermosetting sealing material 80 By setting the temperature to be about the same as the temperature, or if the curing start temperatures of both are different, by heating to the higher curing start temperature or higher, the sealing material is cured and the thermosetting resin layer is cured by heating once. curing (formation of the cured thermosetting resin layer (X1')) can proceed at the same time. Therefore, in these cases, the number of heating steps for curing can be reduced, and the manufacturing process can be simplified.

In addition, in the manufacturing method of this aspect, since the curable resin layer (I) is provided, it is possible to reduce the difference in shrinkage stress between the two surfaces of the cured sealing body 85 to be obtained. Warping of the sealing body 85 can be effectively suppressed. In particular, by thermosetting the thermosetting resin layer (X1) simultaneously with the thermosetting of the sealing material, the difference in contraction stress between the two surfaces of the cured sealing body 85 can be reduced even in the process of curing. and the warpage is more effectively suppressed.
In addition, as described above, the heating temperature for curing in step (iii) is lower than the heating temperature for expansion in step (iv).

<Step (iv)>
In the step (iv), the cured resin layer (I′) and the support layer (II) are expanded at their interface by performing a treatment to expand the thermally expandable particles contained in the expandable base material layer (Y1). By separating, a cured sealing body with a cured resin layer is obtained.
FIG. 6( f ) shows that the expandable base layer (Y1) becomes an expanded expandable base layer (Y1′) by the treatment of expanding the thermally expandable particles, and the cured resin layer (I′) and the expanded support layer (Y1′) become expanded. It shows a separated state at the interface with layer (II').
As shown in FIG. 6( f ), by separating at the interface, a cured sealing body 85 in which the sealing object 60 is sealed and a cured resin layer (I′) are included. A sealed body 200 can be obtained.
The presence of the cured resin layer (I') has the function of effectively suppressing warpage occurring in the cured sealing body, and contributes to improving the reliability of the sealing object.

The “expansion treatment” in step (iv) is treatment for expanding the thermally expandable particles by heating at the expansion start temperature (t) or higher, and the treatment expands the support layer on the side of the cured resin layer (I′). Irregularities are generated on the surface of (II). As a result, they can be easily separated collectively at the interface P with a slight force.
The "expansion start temperature (t) or higher temperature" for expanding the thermally expandable particles is preferably "expansion start temperature (t) + 10°C" or higher and "expansion start temperature (t) + 60°C" or lower. More preferably, the temperature is not less than "expansion start temperature (t) + 15°C" and not more than "expansion start temperature (t) + 40°C".
The heating method for expanding the thermally expandable particles is not particularly limited, and examples thereof include heating methods using a hot plate, an oven, a kiln, an infrared lamp, a hot air blower, and the like. From the viewpoint of facilitating separation at the interface P with the cured resin layer (I′), a method in which a heat source for heating is provided on the support 50 side is preferred.

The cured sealing body 200 with the cured resin layer thus obtained is then subjected to further necessary processing. The cured resin layer as the warp correction layer is removed by grinding or the like during the final manufacture of the semiconductor device, and does not remain in the final semiconductor device.

[Second method for producing cured seal]
A second aspect of the method for producing a cured sealant of the present invention is a method for producing a cured sealant using the laminate of one embodiment of the present invention, comprising the following steps (i′) to (iv) have
Step (i′): On a part of the surface opposite to the first layer of the energy ray-curable resin layer (X2), which is the first surface of the curable resin layer of the warp-preventing laminate, An object to be sealed is placed.
Step (ii')-1: The energy ray-curable resin layer (X2) is cured by irradiation with energy rays.
Step (ii′)-2: Covering the sealing object and the first surface of the curable resin layer at least in the periphery of the sealing object with a thermosetting sealing material.
Step (iii′): The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer (I′). to obtain a cured encapsulant.
Step (iv): The cured resin layer (I') and the support layer (II) are separated at their interface by a treatment for expanding the expandable particles to obtain a cured sealing body with the cured resin layer.

Each step will be described in detail below, but in order to avoid redundancy, the steps and operations similar to those in the first aspect of the production method described above are the same as those described in the first aspect of the production method. , detailed description is omitted.

<Step (i')>
In step (i'), the object to be sealed is placed on part of the surface of the curable resin layer (I) of the warp-preventing laminate of one embodiment of the present invention.
In FIG. 7A, the curable resin layer (I) consists of a thermosetting resin layer (X1-1) on the side of the support layer (II) and an energy ray-curable layer on the side opposite to the support layer (II). The adhesive surface of the adhesive layer (V1) of the support layer (II) is attached to the support 50 using the anti-warp laminate 5 (see FIG. 5) including the resin layer (X2). 7(b) shows a state in which an object to be sealed 60 is placed on part of the surface of the curable resin layer (I).

The surface of the curable resin layer (I) of the present embodiment (in the example of FIG. 7, the surface of the energy ray-curable resin layer (X2) opposite to the support layer (II)) has curability. However, the adhesive force is such that the first surface is attached to the glass plate at a temperature of 70 ° C., and the curable resin layer (I) is peeled off at a temperature of 23 ° C., a peeling angle of 180 °, and a peeling speed of 300 mm / min. By setting the value to 1.7 N/25 mm or more when measured by It is fixed, making it easier to prevent positional deviations including tilt deviations.

<Step (ii′)-1>
In step (ii′)-1, the energy ray-curable resin layer (X2) is irradiated with energy rays to form a cured resin layer (I ^* ) by curing the energy ray-curable resin layer (X2). It is a process to do.

FIG. 7C shows that in this step, the energy ray-curable resin layer (X2) is cured to form a cured energy ray-curable resin layer (X2′), which is partially cured ( In other words, it shows a state in which a cured resin layer (I ^* ) is formed in which the layer on the first surface side is cured.
The type and irradiation conditions of the energy ray are not particularly limited as long as the type and conditions are such that the energy ray-curable resin layer (X2) can sufficiently exhibit its function. It may be appropriately selected according to the process to be performed.
When an ultraviolet curable resin composition is used as the material for the energy ray curable resin layer (X2), the range of material selection is wide and the energy ray source for curing the composition is easily available. It is possible to use an ultraviolet irradiation device which is also excellent in handleability.
The illuminance of the energy ray during curing of the energy ray-curable resin layer (X2) is preferably 4 to 280 mW/cm ² , and the light amount of the energy ray during curing is 3 to 1,000 mJ/cm. ² is preferred.

By irradiating the energy beam in the step (ii′)-1 prior to the step (iii′) including heat curing, it is avoided that the energy beam curable resin is cleaved by heating and the curing reaction progresses, and the energy Curing reaction by rays can proceed efficiently. It is also possible to prevent low-molecular-weight components (such as photopolymerization initiators) contained in the energy ray-curable resin from volatilizing due to heating and contaminating the object to be sealed. Furthermore, by curing the energy ray-curable resin layer with energy rays prior to heat curing, the energy ray-curable resin (X2) is prevented from curing and shrinking due to heating for heat curing, and the sealing resin and the energy ray-curable resin (X2) can be prevented from deteriorating in adhesion.

<Step (ii′)-2>
After the sealing object 60 is arranged and the cured energy ray curable resin layer (X2′) is formed by irradiating the energy ray, in step (ii′)-2, FIG. In the same manner as described in 1. above, the sealing material 80 is injected using a molding die (not shown). At this time, the sealing material flows in the surface direction, but the sealing object 60 is fixed by the cured energy ray curable resin layer (X2′) and is used for measurement of the curable resin layer (I). The shear strength to the adherend was measured by using a 350 μm thick silicon chip with a 3 mm × 3 mm mirror surface as the above measurement adherend, and curing the mirror surface of the measurement adherend for 1 second at 130 gf at a temperature of 70 ° C. A value of 20 N/(3 mm×3 mm) or more when pressed and attached to the resin layer (I) and measured at a speed of 200 μm/s prevents the sealing object 60 from shifting or tilting. easier to prevent.
When the injection of the sealing resin is completed, as shown in FIG. will be

<Step (iii')>
In step (iii'), the encapsulant after the coating treatment is thermally cured to form a cured encapsulant including the object to be encapsulated. In addition, the thermosetting resin layer (X1-1) is also cured to form a cured resin layer (X1-1'), and both the first layer and the second layer are cured to form a cured resin layer (I'). do.
By curing the sealing material 80, as shown in FIG. 7E, a cured sealing body 85 in which the sealing object 60 is covered with the cured sealing material 81 is obtained. At this time, in this production example, since the thermosetting resin layer (X1-1) is used as the curable resin layer (I), the curing start temperature of the thermosetting sealing material 80 is assumed to be about the same. Alternatively, if the curing start temperatures are different, by heating to the higher curing start temperature or higher, the curing of the sealing material and the curing of the thermosetting resin layer are simultaneously proceeded with a single heating. be able to.

<Step (iv)>
In step (iv), the cured resin layer (I′) and the support layer (II) are separated at their interface by performing a treatment to expand the expandable particles contained in the expandable base material layer (Y1). to obtain a cured sealing body with a cured resin layer.
FIG. 7(f) shows that the expandable base layer (Y1) becomes an expandable base layer (Y1′) by expanding the expandable particles, and the cured resin layer (I′) and the expanded support layer (II′) are formed. ) is separated at the interface.
As shown in FIG. 7( f ), by separating at the interface, a cured sealing body 85 in which the sealing object 60 is sealed and a cured resin layer (I′) are included. A sealing body 201 can be obtained.

After the hardened sealing body 85 is produced by the above procedure, the hardened sealing body 201 with the hardened resin layer is subjected to necessary processing.

Next, specific examples of the present invention will be described, but the present invention is not limited by these examples.
In the following description, the curable resin layer (I) includes both the "energy ray curable resin layer (X2)" and the "thermosetting resin layers (X1-1) and (X1-2)". shall mean.
In addition, the physical property values in the following production examples and examples are values measured by the following methods.

<Mass average molecular weight (Mw)>
Using a gel permeation chromatograph (manufactured by Tosoh Corporation, product name “HLC-8020”), measurement was performed under the following conditions, and the values measured in terms of standard polystyrene were used.
(Measurement condition)
・ Column: "TSK guard column HXL-L", "TSK gel G2500HXL", "TSK gel G2000HXL", "TSK gel G1000HXL" (both manufactured by Tosoh Corporation) are sequentially connected ・Column temperature: 40 ° C.
・Developing solvent: tetrahydrofuran ・Flow rate: 1.0 mL/min

<Measurement of thickness of each layer>
It was measured using a constant pressure thickness measuring instrument manufactured by Teclock Co., Ltd. (model number: “PG-02J”, standard specifications: JIS K6783, Z1702, Z1709).

<Minimum curing temperature of curable resin layer>
A plurality of measurement samples are prepared in advance using the same composition, and a differential scanning calorimeter (TA Instruments, Q2000) is used to set temperatures from 60 ° C. to 20 ° C. , the time until the peak attributed to the curing reaction disappeared. At this time, the temperature was raised from room temperature to the set temperature at a temperature elevation rate of 10° C./min. In the above measurement, the temperature at which the curing reaction peak disappeared after 2 hours was defined as the minimum curing temperature.
<Peelability after curing of curable resin layer>
Prepare two samples in which a curable resin layer is attached to a glass plate attached with a support layer (float glass 3 mm (JIS R3202 product) manufactured by Yuko Co., Ltd.), one is heated at 130 ° C. for 2 hours, and the other is Heated at 160° C. for 1 hour. After heating, the measurement samples were heated on a hot plate at the maximum expansion temperature of the support layer of each sample +30° C. for 3 minutes. After allowing to cool to room temperature, the peelability between the support layer and the cured resin layer was evaluated. When the curable resin layer did not peel off by itself (peeling without external force), the edge of the curable resin layer was pinched with tweezers and peeled at the interface between the support layer and the curable resin layer for evaluation.
◯ = Self-peeled over the entire surface, and no abnormality was observed in the appearance of the peeled surface of the cured resin layer.
.DELTA.=Peeling required with tweezers, part of interface P not peeled off. There is no abnormality in the appearance of the peeled surface of the cured resin layer.
× = The curable resin layer cannot be peeled off even with tweezers, or there are places where the curable resin layer cannot be peeled off.

<Measurement of expansion start temperature (t) and maximum expansion temperature of thermally expandable particles>
The expansion start temperature (t) of the thermally expandable particles used in each example was measured by the following method.
An aluminum cup with a diameter of 6.0 mm (inner diameter of 5.65 mm) and a depth of 4.8 mm was filled with 0.5 mg of thermally expandable particles to be measured, and an aluminum lid (5.6 mm in diameter and 0.6 mm in thickness) was placed thereon. 1 mm) is placed on the sample.
Using a dynamic viscoelasticity measuring device, the height of the sample is measured while a force of 0.01 N is applied to the sample from the top of the aluminum lid with a pressurizer. Then, while applying a force of 0.01 N by the pressurizer, heat is applied from 20° C. to 300° C. at a temperature increase rate of 10° C./min, and the amount of displacement in the vertical direction of the pressurizer is measured. Let the displacement start temperature be the expansion start temperature (t).
Further, the maximum expansion temperature refers to the temperature at which the displacement amount becomes maximum.

<Measurement of expansion coefficient of support layer at curing temperature of curable resin layer>
Let the amount of displacement obtained when measuring the maximum expansion temperature described above be the thickness (Dm) of the support layer at the maximum expansion temperature. In addition, the thickness (Da) of the support layer when each support layer is heated under curing condition 1 (heating at 130 ° C. for 2 hours) and the curing condition 2 (at 160 ° C. 1 hour heating) and the thickness (Db) of the support layer was measured. Then, the values of (Da/Dm)×100 and (Db/Dm)×100 were obtained and used as the coefficient of expansion of the support layer at the curing temperature of the curable resin layer.

<Measurement of adhesive strength of thermosetting resin layer>
An adhesive tape (manufactured by Lintec Corporation, product name “PLshin”) was laminated on the surface of the thermosetting resin layer formed on the release film.
Then, the release film was removed, and the exposed surface of the thermosetting resin layer was adhered to the smooth surface of the adherend, a glass plate (3 mm float plate glass manufactured by Yuko Co., Ltd. (JIS R3202 product)). The attachment temperature of the thermosetting resin layer (X1) was 70°C. Then, the glass plate to which each layer was attached was allowed to stand in an environment of 23 ° C. and 50% RH (relative humidity) for 24 hours. The adhesive force at 23° C. was measured at a pulling speed of 300 mm/min according to the method.

The release materials used in the following production examples are as follows.
・ Heavy release film: manufactured by Lintec Corporation, product name “SP-PET382150”, polyethylene terephthalate (PET) film provided with a release agent layer formed from a silicone release agent on one side, thickness: 38 μm
・ Light release film: manufactured by Lintec Corporation, product name "SP-PET381031", a PET film provided with a release agent layer formed from a silicone release agent on one side, thickness: 38 μm

<Evaluation of warpage>
The thermosetting resin layers of the warp-preventing laminates of Examples 1 and 2 were each attached to a 12-inch silicon wafer having a thickness of 100 μm, and epoxy was applied to the surface opposite to the side to which the thermosetting resin layer was attached. The resin composition was applied to a thickness of 30 μm. Then, the layer of the epoxy resin composition and the thermosetting resin layer of each laminate were heated and cured. After curing was completed, the silicon wafer with the cured resin layer was placed on a horizontal table, visually observed, and the presence or absence of warpage was evaluated based on the following criteria.
A: The amount of warp is 3 mm or less.
B: The amount of warpage is greater than 3 mm and less than 15 mm.
C: The amount of warp is 15 mm or more.
As the epoxy resin composition, a mixture of "Epofix Resin" manufactured by Struers and a curing agent "Epofix Hardener" manufactured by Struers was used. In this evaluation, in order to simplify the experimental procedure, a large-diameter silicon wafer was used as the adherend, and an epoxy resin layer was provided on the back side of the adherend to make the condition that warping is likely to occur. By doing so, the evaluation of warpage is made appropriate.

Production example 1
(1) Preparation of curable resin composition Each component of the type and amount shown below (both "active ingredient ratio") is blended, further diluted with methyl ethyl ketone, stirred uniformly, and the solid content concentration (effective A solution of a thermosetting resin composition having a component concentration of 61% by mass was prepared.
・Acrylic polymer: amount = 21 parts by mass Acrylic polymer obtained by copolymerizing 55 parts by mass of n-butyl acrylate, 10 parts by mass of methyl acrylate, 20 parts by mass of glycidyl methacrylate, and 15 parts by mass of 2-hydroxyethyl acrylate Combined (mass average molecular weight: 800,000, glass transition temperature: -28°C), corresponding to component (A1) above.
Epoxy compound (1): Amount = 10 parts by mass Liquid bisphenol A type epoxy resin (manufactured by Nippon Shokubai Co., Ltd., product name “BPA328”, epoxy equivalent = 220 to 240 g/eq), equivalent to component (B1) above.
Epoxy compound (2): Amount = 2.0 parts by mass Solid bisphenol A type epoxy resin (manufactured by Mitsubishi Chemical Corporation, product name “Epikote 1055”, epoxy equivalent = 800 to 900 g / eq), to the above component (B1) Equivalent.
Epoxy compound (3): amount = 5.6 parts by mass dicyclopentadiene type epoxy resin (manufactured by Nippon Kayaku Co., Ltd., product name “XD-1000L”, epoxy equivalent = 274 to 286 g / eq), the above component (B1 ).
・Heat curing agent: Compounding amount = 0.5 parts by mass Dicyandiamide (manufactured by ADEKA, product name “ADEKA HARDNER EH-3636AS”, active hydrogen content = 21 g/eq), equivalent to the above component (B2).
Curing accelerator: Amount = 0.5 parts by mass 2-phenyl-4,5-dihydroxymethylimidazole (manufactured by Shikoku Kasei Kogyo Co., Ltd., product name “Curesol 2PHZ”), equivalent to the component (B3) above.
Silane coupling agent: compounding amount = 0.4 parts by mass Epoxy group-containing oligomer type silane coupling agent (manufactured by Mitsubishi Chemical Corporation, product name: "MSEP2"), equivalent to component (D) above.
Inorganic filler (1): Amount = 6 parts by mass Spherical silica filler (manufactured by Admatechs, product name "SC2050MA", average particle size = 0.5 µm), equivalent to component (E) above.
Inorganic filler (2): Amount = 54 parts by mass Spherical silica filler (Tatsumori, product name: SV-10, average particle size = 8 µm), equivalent to component (E) above.

(2) Formation of thermosetting resin layer A solution of the thermosetting resin composition prepared in (1) above is applied to the release-treated surface of the light release film to form a coating film, and the coating film is formed. It was dried at 120° C. for 2 minutes to form a thermosetting resin layer with a thickness of 25 μm. This is referred to as curable resin layer 1 .
The adhesive strength of the formed thermosetting resin layer 1 was 0.5 N/25 mm.

Production example 2
(1) Preparation of support layer A heat-peelable laminate (manufactured by Nitto Denko, product name “Rivaalpha (NITTO 3195)”) having a structure in which a heat-peelable adhesive layer is provided on a polyester film substrate is supported as it is. used as a layer. This is referred to as support layer 1 . In addition, when producing the later-described warp-preventing laminate, the release liner provided on the surface of the heat-releasable pressure-sensitive adhesive layer was removed before use. The support layer 1 has an adhesive layer containing a substrate and thermally expandable particles, and when heated to an expansion initiation temperature of 170 ° C. or higher, the thermally expandable particles expand, and the surface of the adhesive layer to create a fine uneven shape.

Production example 3
(1) Synthesis of urethane prepolymer In a reaction vessel under a nitrogen atmosphere, isophorone diisocyanate is added to 100 parts by mass (solid content ratio) of a carbonate-type diol having a mass average molecular weight of 1,000. Diisocyanate was blended so that the equivalent ratio of the isocyanate group to the isocyanate group was 1/1, and 160 parts by mass of toluene was added. was reacted for 6 hours or more.
Then, a solution obtained by diluting 1.44 parts by mass of 2-hydroxyethyl methacrylate (2-HEMA) (solid content ratio) in 30 parts by mass of toluene was added, and the mixture was further heated at 80°C until the isocyanate groups at both ends disappeared. After reacting for 6 hours, a urethane prepolymer having a mass average molecular weight of 29,000 was obtained.

(2) Synthesis of acrylic urethane resin In a reaction vessel under a nitrogen atmosphere, 100 parts by mass (solid content ratio) of the urethane prepolymer obtained in Production Example 1, 117 parts by mass (solid content ratio) of methyl methacrylate (MMA), 5.1 parts by mass of 2-hydroxyethyl methacrylate (2-HEMA) (solid content ratio), 1.1 parts by mass of 1-thioglycerol (solid content ratio), and 50 parts by mass of toluene were added and heated to 105°C while stirring. The temperature was raised to
Then, in the reaction vessel, a solution obtained by diluting 2.2 parts by mass (solid content ratio) of a radical initiator (manufactured by Japan Finechem Co., Ltd., product name "ABN-E") with 210 parts by mass of toluene was heated to 105 ° C. It was dripped over 4 hours while maintaining.
After completion of the dropwise addition, the mixture was allowed to react at 105° C. for 6 hours to obtain a solution of an acrylic urethane resin having a mass average molecular weight of 105,000.

(3) Preparation of adhesive composition (1) To 100 parts by mass of the solid content of the following acrylic copolymer (i), which is an adhesive resin, 5.0 parts by mass of the following isocyanate cross-linking agent (i) (solid ratio), diluted with toluene, and uniformly stirred to prepare a pressure-sensitive adhesive composition (1) having a solid content concentration (active ingredient concentration) of 25% by mass.
-Acrylic copolymer (i): 2-ethylhexyl acrylate (2EHA)/2-hydroxyethyl acrylate (HEA) = 80.0/20.0 (mass ratio) having structural units derived from raw material monomers, Acrylic copolymer with a mass average molecular weight of 600,000.
· Isocyanate cross-linking agent (i): manufactured by Tosoh Corporation, product name "Coronate L", solid content concentration: 75% by mass.

(4) Preparation of adhesive composition (2) To 100 parts by mass of the solid content of the following acrylic copolymer (i), which is an adhesive resin, 5.0 parts by mass of the following isocyanate cross-linking agent (i) (solid ratio), diluted with toluene, and uniformly stirred to prepare a pressure-sensitive adhesive composition (2) having a solid content concentration (active ingredient concentration) of 25% by mass.
-Acrylic copolymer (i): 2-ethylhexyl acrylate (2EHA)/2-hydroxyethyl acrylate (HEA) = 80.0/20.0 (mass ratio) having structural units derived from raw material monomers, Acrylic copolymer with a mass average molecular weight of 600,000.
· Isocyanate cross-linking agent (i): manufactured by Tosoh Corporation, product name "Coronate L", solid content concentration: 75% by mass.

(5) Formation of adhesive layer (1) The adhesive composition (1) prepared in Production Example 3 (1) is applied to the surface of the release layer of the light release film to form a coating film. The coating film was dried at 100° C. for 60 seconds to form a pressure-sensitive adhesive layer (1) having a thickness of 5 μm.
(6) Formation of adhesive layer (2) The surface of the release layer of the heavy release film is coated with the adhesive composition (2) prepared in Production Example 3 (2) to form a coating film. The coating film was dried at 100° C. for 60 seconds to form a pressure-sensitive adhesive layer (2) having a thickness of 10 μm.

(7) Preparation of support layer The pressure-sensitive adhesive layer (2) was attached to one side of a polyethylene terephthalate (PET) film (manufactured by Toyobo Co., Ltd., product name "Cosmoshine A4100") having a thickness of 50 µm, which is a base material. .
Then, on the other surface of the PET film, 100 parts by mass of a polyester adhesive (glass transition temperature: -50 ° C., mass average molecular weight: 21,000, OH value: 4 mg KOH / g), 4 parts by mass of HDI nurate crosslinking agent was applied and dried at 100° C. for 1 minute to form an anchor layer having a thickness of 40 μm.
To 100 parts by mass of the solid content of the acrylic urethane resin obtained in Production Example 3 (2), 6.3 parts of an isocyanate cross-linking agent (manufactured by Tosoh Corporation, product name "Coronate L", solid content concentration: 75 mass%). Parts by mass (solid content ratio), 1.4 parts by mass (solid content ratio) of dioctyltin bis(2-ethylhexanoate) as a catalyst, and the above thermally expandable particles (manufactured by Kureha Co., Ltd., product name “S2640” , expansion start temperature (t) = 208 ° C., average particle size (D ₅₀ ) = 24 µm, 90% particle size (D ₉₀ ) = 49 µm), diluted with toluene, stirred uniformly, and the solid content concentration (Effective ingredient concentration) A resin composition having a concentration of 30% by mass was prepared. The content of the thermally expandable particles was 20% by mass with respect to the total amount (100% by mass) of the active ingredients in the resulting resin composition.
The resin composition containing the thermally expandable particles is applied onto the anchor layer to form a coating film, and the coating film is dried by heating at 100° C. for 2 minutes to form a thermally expandable layer having a thickness of 35 μm. formed.
The pressure-sensitive adhesive layer (1) was adhered onto this thermally expandable layer. In this way, a support layer was produced in which the release films were laminated on the front and back surfaces. This is referred to as support layer 2 .
The support layer 2 has a base material containing an adhesive layer and thermally expandable particles. When heated to 208° C. or higher, the thermally expandable particles expand to form fine irregularities on the surface of the support layer. give rise to

Production example 4
The thermally expandable particles are changed to thermally expandable microcapsules manufactured by Nippon Philite Co., Ltd. (product name “Expancel 031-40DU”, expansion start temperature (t) = 80 ° C.), and a resin composition is applied to form a coating film. A support layer was produced in the same procedure as in Production Example 3, except that the drying conditions after drying were changed to 1 minute at an atmospheric temperature of 100°C. This is referred to as support layer 3 .
The support layer 3 has a base material containing an adhesive layer and thermally expandable particles. When heated to 80° C. or higher, the thermally expandable particles expand to form fine irregularities on the surface of the support layer. give rise to

Production example 5
The thermally expandable particles were changed to thermally expandable microcapsules from Nippon Philite Co., Ltd. (product name “Expancel 053-40DU”, expansion start temperature (t) = 100°C), and the resin composition was applied to form a coating film. A support layer was produced in the same procedure as in Production Example 3, except that the subsequent drying conditions were changed to 1 minute at an atmospheric temperature of 100°C. This is referred to as support layer 4 .
The support layer 4 has a base material containing an adhesive layer and thermally expandable particles. When heated to 100° C. or higher, the thermally expandable particles expand to form fine irregularities on the surface of the support layer. give rise to
In Production Examples 4 and 5, when producing the support layer, the drying temperature after coating the resin composition to form a coating film was higher than the expansion start temperature (t) of the thermally expandable particles. However, since the above drying temperature is ambient temperature, no foaming was observed in the formed support layer.

Production example 6
As thermally expandable particles, thermally expandable microcapsules manufactured by Nippon Philite Co., Ltd. (product name “Expancel 920-40DU”, expansion start temperature (t) = 120°C) were used, and a resin composition was applied to form a coating film. A support layer was produced in the same procedure as in Production Example 3, except that the subsequent drying conditions were changed to 1 minute at an atmospheric temperature of 100°C. This is called a support layer 5 .
The support layer 5 has a base material containing an adhesive layer and thermally expandable particles. When heated to 120° C. or higher, the thermally expandable particles expand to form fine irregularities on the surface of the support layer. give rise to

(Example 1)
The release film laminated on the adhesive layer (2) of the support layer 2 prepared in Production Example 3 is removed, and the adhesive surface of the exposed adhesive layer (2) and the curability formed in Production Example 1 The surface of the resin layer 1 is laminated, and the heavy release film/adhesive layer (1)/base material/anchor layer/thermally expandable layer/adhesive layer (2)/thermosetting resin layer/release film are laminated in this order. A warp-preventing laminate with a release film was obtained.

(Example 2)
The release film laminated on the adhesive layer of the support layer 1 of Production Example 2 is removed, and the adhesive surface of the exposed adhesive layer (2) and the surface of the curable resin layer 1 formed in Production Example 1 to obtain a warp-preventing laminate with a release film, in which substrate/adhesive layer/thermosetting resin layer/release film are laminated in this order.

(Comparative example 1)
The release film laminated on the second adhesive layer of the support layer 3 prepared in Production Example 4 is removed, and the exposed adhesive surface of the adhesive layer (2) and the curable resin formed in Production Example 1 The surface of layer 1 is laminated, and the heavy release film/adhesive layer (1)/base material/anchor layer/thermally expandable layer/adhesive layer (2)/thermosetting resin layer/release film are laminated in this order. A warp-preventing laminate with a release film was obtained.

(Comparative example 2)
The release film laminated on the second adhesive layer of the support layer 4 prepared in Production Example 5 is removed, and the exposed adhesive surface of the adhesive layer (2) and the curable resin formed in Production Example 1 The surface of layer 1 is laminated, and the heavy release film/adhesive layer (1)/base material/anchor layer/thermally expandable layer/adhesive layer (2)/thermosetting resin layer/release film are laminated in this order. A warp-preventing laminate with a release film was obtained.

(Comparative Example 3)
The release film laminated on the adhesive layer (2) of the support layer 5 prepared in Production Example 6 is removed, and the adhesive surface of the exposed adhesive layer (2) and the curable surface formed in Production Example 1 The surface of the resin layer 1 is laminated, and the heavy release film/adhesive layer (1)/base material/anchor layer/thermal expansion layer/adhesive layer (2)/thermosetting resin layer/release film are laminated in this order. A warp-preventing laminate with a release film was obtained.

The anti-warp laminates obtained in Examples 1 and 2 and Comparative Examples 1 to 3 were measured and evaluated according to the measurement method and evaluation procedure described above. Table 1 shows the results.

As is clear from the results in Table 1, in Examples 1 and 2, when the curable resin layer was cured at 130° C. for 2 hours, the peelability between the curable resin layer and the support layer was good, and warpage was prevented. The occurrence was also sufficiently suppressed. In Examples 1 and 2, even when the curable resin layer was cured at 160° C. for 1 hour, the peelability between the curable resin layer and the support layer was maintained at a practically acceptable level, and warping was sufficiently suppressed. It had been. In particular, in Example 2, the support layer was foamed to some extent by curing at 160° C., and the peelability of the support layer was slightly lowered. C., and a cured sealant could be obtained in a shorter time.
On the other hand, in Comparative Examples 1 to 3, the releasability between the curable resin layer and the support layer was greatly reduced, and the interface between the support layer and the curable resin layer could not be separated.

(I): Curable resin layer (I′): Cured resin layer (I ^* ): Partially cured curable resin layer (II): Support layer (II′): Expanded support layer (V): Adhesive Layer (V1): (first) adhesive layer (V1-1): first adhesive layer (V2), (V1-2): second adhesive layer (X1), (X1-1), (X1 -2): thermosetting resin layer (X1′): cured thermosetting resin layer (X1-1′): cured thermosetting resin layer (X2): energy ray-curable resin layer (X2′): Cured energy ray-curable resin layer (Y): substrate (Y1): expandable substrate layer (Y1′): expanded expandable substrate layer (Y2): non-expandable substrate layers 1a, 1b, 2a , 2b, 3, 4, 5: warp prevention laminate 50: support 60: object to be sealed (semiconductor chip)
70: mold 71: injection hole 72: molding space 80: sealing material 81: cured sealing material 85: cured sealing body 200: cured sealing body with cured resin layer P: interface

Claims (10)

Having a curable resin layer (I) containing a thermosetting resin layer (X1) and a support layer (II) supporting the curable resin layer (I),
The curable resin layer (I) has an adhesive surface with adhesiveness,
The support layer (II) has a substrate (Y) and an adhesive layer (V), at least one of the substrate (Y) and the adhesive layer (V) contains thermally expandable particles,
The curable resin layer (I), the adhesive layer (V), and the substrate (Y) are arranged in this order, and the adhesive surface of the curable resin layer (I) is the adhesive layer (V) placed opposite to the
The lowest curing temperature (T ₁ ) at which the curing of the curable resin layer (I) is completed within 2 hours to form the curable resin layer (I′) is higher than the foaming start temperature (T ₂ ) of the thermally expandable particles. low temperature,
The difference (T ₂ −T ₁ ) between the minimum curing temperature (T ₁ ) of the curable resin layer (I) and the expansion start temperature (T ₂ ) of the thermally expandable particles is 20° C. to 100° C.,
A warp-preventing laminate of a cured sealing body produced by sealing an object to be sealed on the adhesive surface of the curable resin layer (I). The difference (T ₂ -T ₁ ) between the minimum curing temperature (T ₁ ) of the curable resin layer (I) and the expansion start temperature (T ₂ ) of the thermally expandable particles is 40 °C to 100°C. Item 1. The warp-preventing laminate according to item 1. The curable resin layer (I) has two or more thermosetting resin layers (X1), and the minimum curing temperature (T ₁ ) in the two or more thermosetting resin layers (X1) is the minimum value (T 3. The anti-warp laminate according to claim ₁ , wherein 1a) is lower than the expansion start temperature ( _T2 ) of the thermally expandable particles. The laminate according to any one of claims 1 to 3, wherein the thermosetting resin layer (X1) has a thickness of 1 to 500 µm. The laminate according to any one of claims 1 to 4, wherein the substrate (Y) has an expandable substrate layer (Y1) containing the thermally expandable particles. 6. The laminate according to claim 5, wherein the pressure-sensitive adhesive layer (V) is a non-expanding pressure-sensitive adhesive layer. The substrate (Y) has a non-expandable substrate layer (Y2) and an expandable substrate layer (Y1),
7. The laminate according to claim 5 or 6, wherein the support layer (II) has a non-expandable substrate layer (Y2), an expandable substrate layer (Y1) and an adhesive layer (V) in this order. The curable resin layer (I) has a first layer arranged on the support layer (II) side and a second layer arranged on the adhesive surface side,
The first layer is a thermosetting resin layer (X1-1),
The anti-warp laminate according to any one of claims 1 to 7, wherein the second layer is an energy ray-curable resin layer (X2). A method for producing a cured sealing body using the warp-preventing laminate according to any one of claims 1 to 7,
A step of placing an object to be sealed on a part of the adhesive surface of the curable resin layer (I) of the warp-preventing laminate;
a step of covering the object to be sealed and the adhesive surface of the curable resin layer (I) at least in the periphery of the object to be sealed with a thermosetting sealing material;
The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer, and a cured resin layer is formed. and obtaining a hardened encapsulant. A method for producing a cured sealing body using the warp-preventing laminate according to claim 8,
A step of placing an object to be sealed on a part of the adhesive surface of the curable resin layer (I) of the warp-preventing laminate;
a step of irradiating an energy ray to cure the energy ray-curable resin layer (X2);
a step of covering the object to be sealed and the adhesive surface of the curable resin layer (I) at least in the periphery of the object to be sealed with a thermosetting sealing material;
The sealing material is thermally cured to form a cured sealing body containing the sealing object, and the curable resin layer (I) is also thermally cured to form a cured resin layer (I′), and a step of obtaining a cured sealing body with a cured resin layer.

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