Method for manufacturing electrically conductive adhesive film, electrically conductive adhesive film, and method for manufacturing connector

Abstract

An anisotropic conductive film is capable of preventing a short circuit between terminals even though narrowing of the interval between connecting terminals advances. An electrically conductive support plate supports a base film having one surface with an adhesive layer. An array plate is disposed to face the adhesive layer and has through holes arranged in a pattern corresponding to the array pattern of electrically conductive particles. A spray sprays the electrically conductive particles together with a liquid while applying a voltage to the electrically conductive particles, in which the electrically conductive particles which are charged with an electrical charge are sprayed together with a liquid from the spray while applying a voltage between the spray and the support plate and the electrically conductive particles which have passed through the through holes of the array plate are arranged on the adhesive layer in the array pattern of the through holes.

1 . A method for manufacturing an electrically conductive adhesive film, the method comprising steps of:
 providing an electrically conductive support plate to support a first base film having an adhesive layer formed on a surface;   providing an array plate that is disposed to face the adhesive layer of the first base film supported by the support plate and has a plurality of through holes arranged in a pattern corresponding to an array pattern of electrically conductive particles formed thereon;   providing a spray that is disposed on a side opposite to a side facing the support plate of the array plate and sprays electrically conductive particles together with a liquid while applying a voltage to the electrically conductive particles;   spraying the electrically conductive particles charged with an electrical charge together with a liquid from the spray while applying a voltage between the spray and the support plate supporting a surface on the opposite side to a surface on which the adhesive layer is formed of the first base film; and   arranging the electrically conductive particles which passed through the through holes of the array plate on the adhesive layer in an array pattern of the through holes.   
     
     
         2 . The method for manufacturing an electrically conductive adhesive film according to  claim 1 , wherein a surface of the electrically conductive particles is covered with an insulating material. 
     
     
         3 . The method for manufacturing an electrically conductive adhesive film according to  claim 2 , wherein a thickness of an insulating film to cover the surface of the electrically conductive particles is from 0.1 to 50% of a particle size of the electrically conductive particles. 
     
     
         4 . The method for manufacturing an electrically conductive adhesive film according to  claim 1 , wherein the array plate is prevented from being charged. 
     
     
         5 . The method for manufacturing an electrically conductive adhesive film according to  claim 1 , wherein a size of the through holes formed on the array plate is from 120 to 200% of the size of the electrically conductive particles. 
     
     
         6 . The method for manufacturing an electrically conductive adhesive film according to  claim 1 , wherein the support plate is formed in a roll shape and arrangement of the electrically conductive particles on the adhesive layer is continuously conducted while conveying the base film. 
     
     
         7 . The method for manufacturing an electrically conductive adhesive film according to  claim 1 , wherein a second base film is laminated on the adhesive layer after the electrically conductive particles are arranged on the adhesive layer. 
     
     
         8 . An electrically conductive adhesive film comprising:
 a base film;   a binder resin laminated on the base film; and   electrically conductive particles regularly dispersed and disposed on the binder resin in a predetermined array pattern, wherein electrically conductive particles having abrasions on a surface among the plurality of electrically conductive particles are 0.5% or more and within 30% of a total particle number.   
     
     
         9 . The electrically conductive adhesive film according to  claim 8 , wherein an aggregate of the plurality of the electrically conductive particles is within 15% of a total particle number. 
     
     
         10 . An electrically conductive adhesive film comprising:
 a base film;   a binder resin laminated on the base film; and   electrically conductive particles regularly dispersed and disposed on the binder resin in a predetermined array pattern, wherein electrically conductive particles having abrasions on a surface among the plurality of electrically conductive particles are 0.5% or more and within 30% of a total particle number,   wherein the electrically conductive adhesive film is manufactured using the method for manufacturing an electrically conductive adhesive film according to  claim 1 .   
     
     
         11 . A method for manufacturing a connector obtained by connecting a plurality of terminals arranged in parallel to one another by an anisotropic conductive film having electrically conductive particles arranged therein, wherein
 the anisotropic conductive film is manufactured by steps of:   providing an electrically conductive support plate to support a base film having an adhesive layer formed on a surface;   providing an array plate that is disposed to face the adhesive layer of the base film supported by the support plate and has a plurality of through holes arranged in a pattern corresponding to an array pattern of electrically conductive particles formed thereon;   providing a spray that is disposed above the array plate and sprays electrically conductive particles together with a liquid while applying a voltage to the electrically conductive particles;   spraying the electrically conductive particles charged with an electrical charge together with a liquid from the spray while applying a voltage between the spray and the support plate to support the base film in a state in which the adhesive layer is turned upward; and   arranging the electrically conductive particles which passed through the through holes of the array plate on the adhesive layer in an array pattern of the through holes.