JP2011201261A - Method for manufacturing rolled film base material, method for manufacturing pattern forming body using rolled film base material, rolled film base material, and functional layer-containing film base material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a rolled film base material as a principal object by which a rolled film base material free from dimensional shift in inside and outside of the roll can be obtained.SOLUTION: This method for manufacturing a rolled film base material includes a step of: preparing a rolled film base material by winding up a space member-laminated film base material with a space member arranged on a film base material; and a step of preserving the rolled film base material under an atmosphere of prescribed temperature and humidity until the moisture content of the rolled film base material reaches the moisture content under the atmosphere.

Description

  The present invention relates to a method for producing a roll-shaped film substrate used for a pattern forming body that can be used for various applications such as a color filter and a wiring pattern.

  In recent years, liquid crystal display elements have been reduced in thickness and weight and improved in impact resistance. As a base material for constituting color filters, TFT arrays, etc., instead of the conventionally used glass substrate, flexibility has been achieved. Attempts have been made to use a roll-shaped film base material in which a film base material is wound. When a roll-shaped film base material is used for such a base material, there is a problem that it is difficult to obtain a color filter in which, for example, a colored layer and a black matrix are formed on the base material with a desired accuracy. . Specifically, in the process of forming a colored layer and a black matrix on a film substrate unwound from a roll-shaped film substrate, a pattern is formed using a fine processing means such as a photolithography method or an inkjet method. However, there is a problem that a dimensional shift occurs in the roll-shaped film substrate affected by heat, moisture, etc. during the process, and it is difficult to produce a color filter with high accuracy.

  On the other hand, for example, in Patent Document 1, after drying the substrate, the substrate is left in a high-temperature and high-humidity environment to absorb moisture so that the moisture content is within ± 10% of the moisture content in a predetermined temperature-humidity environment. A method of controlling the dimensions of the substrate by performing the above is disclosed.

  However, in this method, since the inside of the roll film substrate is difficult to absorb or dehydrate, it takes a long time to reach the desired moisture content, and the moisture content is uniform between the inside and outside of the roll. However, there is a problem that dimensional deviation occurs in and outside the roll film substrate.

  On the other hand, for example, in Patent Document 2, the time from the heat dehydration of the base material to the start of exposure is managed by the transport means, and the temperature and humidity are adjusted to control the dimensions of the base material with good reproducibility. A method is disclosed.

  However, this method requires precise time management, and there is a problem that the required time differs between the inside and outside of the roll-shaped film substrate.

JP 2003-66423 A JP 2003-177551 A

  This invention is made in view of the said problem, and provides the manufacturing method of the roll-shaped film base material which can obtain the roll-shaped film base material without the dimension shift | offset | difference in winding and unwinding. Main purpose.

  In order to solve the above problems, the present invention comprises a roll-shaped film substrate preparation step of winding a gap member laminated film substrate in which a gap member is disposed on a film substrate, and preparing a roll-shaped film substrate, The roll-shaped film substrate has a storage step of storing the roll-shaped film substrate in the temperature-humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature-humidity atmosphere. A method for producing a film substrate is provided.

  According to the present invention, the roll-shaped film substrate sandwiched with the gap members is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, so that the uniform moisture content can be obtained regardless of whether it is inside or outside the winding. A roll-shaped film substrate having a rate can be obtained.

  In the said invention, it is preferable that the said space | gap member is a porous sheet whose surface roughness (Ra) is 1 micrometer or more. This is because the porous sheet is easily available, and when the Ra is in the above range, a void member having excellent air permeability and moisture permeability can be obtained.

  In the said invention, the temperature and humidity atmosphere of the said storage process are the temperature at the time of forming a pattern on the film base material unwound from the said roll-shaped film base material which reached the moisture content in the said predetermined temperature and humidity atmosphere. It is preferable to be equal to the humidity atmosphere. Film substrate unrolled from a roll-shaped film substrate having a moisture content in a predetermined temperature and humidity atmosphere, in which dimensional deviation of the roll-shaped film substrate due to temperature difference and humidity difference between the storage process and pattern formation is suppressed This is because the pattern can be formed with high dimensional accuracy by forming the pattern with reference to the dimension.

  Moreover, this invention has the pattern formation process which forms a pattern on the film base material unwound from the roll-shaped film base material obtained by the manufacturing method of the roll-shaped film base material mentioned above, It is characterized by the above-mentioned. Provided is a method for manufacturing a pattern forming body.

  According to the present invention, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

  In the said invention, you may have the peeling process which peels a space | gap member from the said film base material before the said pattern formation process or after the said pattern formation process. When the function of the pattern forming body is hindered by the gap member, it is necessary to peel the gap member from the film base material. Even when the function of the pattern forming body is not hindered by the gap member, the pattern forming body can be made thinner by peeling the gap member from the film substrate.

  Moreover, this invention winds the space | gap layer containing film base material which formed the space | gap layer on the film base material, the roll-shaped film base material preparation process of preparing a roll-shaped film base material, and the said roll-shaped film base material And a storage step of storing the roll-shaped film substrate in the temperature-humidity atmosphere until the moisture content reaches a moisture content in a predetermined temperature-humidity atmosphere. I will provide a.

  According to the present invention, the roll-shaped film substrate sandwiched with the void layer is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, so that the uniform moisture content can be obtained regardless of whether it is inside or outside the winding. A roll-shaped film substrate having a rate can be obtained.

  In the said invention, it is preferable that the said space | gap layer is a functional layer which has an uneven | corrugated structure on the surface. Since the void layer has a concavo-convex structure on the surface, a large number of voids can be sandwiched between the roll-shaped film substrates when wound, and the intended pattern forming body is formed by the void layer being a functional layer. It is because a function can be easily added to a pattern formation body by using as a base material.

  In the said invention, it is preferable that the said functional layer has an anti-glare (AG) function and surface roughness (Ra) exists in the range of 50 nm-500 nm. In addition to the advantages described above, when Ra is within the above range, a roll-shaped film substrate containing a layer having a good AG function can be obtained, and the roll-shaped film substrate is unwound from such a roll-shaped film substrate. This is because the occurrence of glare and the reduction in contrast can be suppressed by using the pattern forming body in which the pattern is formed on the film base material as the image display element.

  In the said invention, the temperature and humidity atmosphere of the said storage process are the temperature at the time of forming a pattern on the film base material unwound from the said roll-shaped film base material which reached the moisture content in the said predetermined temperature and humidity atmosphere. It is preferable to be equal to the humidity atmosphere. Film substrate unrolled from a roll-shaped film substrate having a moisture content in a predetermined temperature and humidity atmosphere, in which dimensional deviation of the roll-shaped film substrate due to temperature difference and humidity difference between the storage process and pattern formation is suppressed This is because the pattern can be formed with high dimensional accuracy by forming the pattern with reference to the dimension.

  Moreover, this invention is a pattern formation body which has a pattern formation process which forms a pattern on the film base material unwound from the roll-shaped film base material obtained by the manufacturing method of the roll-shaped film base material mentioned above. A manufacturing method is provided.

  According to the present invention, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

  Moreover, this invention provides the roll-shaped film base material by which the space | gap member laminated | stacked film base material which has arrange | positioned the space | gap member on a film base material is wound.

  According to the present invention, the roll-shaped film substrate is stored in a roll shape that does not cause a difference in moisture content between the inside and outside of the winding, only by storing the moisture content until the moisture content reaches the moisture content under a predetermined temperature and humidity atmosphere. It can be a film substrate.

  Moreover, this invention provides the roll-shaped film base material by which the space | gap layer containing film base material which formed the space | gap layer on the film base material is wound.

  According to the present invention, the roll-shaped film substrate is stored in a roll shape that does not cause a difference in moisture content between the inside and outside of the winding, only by storing the moisture content until the moisture content reaches the moisture content under a predetermined temperature and humidity atmosphere. It can be a film substrate.

  In addition, the present invention provides a functional layer on one surface of the film substrate that imparts air permeability between the roll film substrates when wound, and adds a function to the roll film substrate. The functional layer containing film base material characterized by being made is provided.

  According to the present invention, the functional layer-containing film base material is wound and stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, thereby producing a difference in moisture content between the inside and outside of the winding. And it can be set as the roll-shaped film base material which has a desired function when unwinding and setting it as a film base material.

  In the said invention, the functional pattern may be formed in the other surface of the said film base material. By forming a functional pattern on the surface of the film base material on which the functional layer is not formed, a pattern forming body to which the function of the functional layer is added can be obtained.

  In this invention, there exists an effect that the roll-shaped film base material without the dimension shift | offset | difference in winding and unwinding can be obtained.

It is process drawing which shows an example of the manufacturing method of the roll-shaped film base material of this invention. It is process drawing which shows the other example of the manufacturing method of the roll-shaped film base material of this invention. It is process drawing which shows an example of the manufacturing method of the pattern formation body of this invention. It is a flowchart which shows an example of the manufacturing method of the pattern formation body of this invention. It is process drawing which shows the other example of the manufacturing method of the pattern formation body of this invention. It is a schematic sectional drawing which shows an example of the functional layer containing film base material of this invention.

  Hereinafter, the manufacturing method of the roll-shaped film base material of this invention, the manufacturing method of a pattern formation body, a roll-shaped film base material, and a functional layer containing film base material are demonstrated in detail.

A. First, the manufacturing method of the roll-shaped film base material of this invention is demonstrated. The manufacturing method of the roll-shaped film base material of this invention can be divided roughly into two aspects. Hereinafter, the manufacturing method of the roll-shaped film base material of this invention is divided and demonstrated to a 1st aspect and a 2nd aspect.

1. 1st aspect First, the 1st aspect of the manufacturing method of the roll-shaped film base material of this invention is demonstrated. The manufacturing method of the roll-shaped film base material of the 1st aspect winds the space | gap member laminated | stacked film base material which has arrange | positioned the space | gap member on a film base material, and roll-shaped film base material preparation process which prepares a roll-shaped film base material, And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. It is a manufacturing method.

According to this aspect, by storing the roll-shaped film substrate with the gap member interposed therebetween until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, the difference in moisture content between the inside and outside of the winding is achieved. A roll-shaped film base material having a uniform water content can be obtained without causing the above.
Usually, in a roll-shaped film substrate at room temperature and humidity, the moisture content is different between the inner side and the outer side because the inner side (winding core) is less likely to absorb and dehydrate than the outer side. . On the other hand, as in the present embodiment, by winding a film member having a void member on a film substrate to form a roll film substrate, the air permeability and moisture permeability inside the roll film substrate are wound. Can be improved. By storing in a predetermined temperature / humidity atmosphere in this state, the inside of the winding can reach the moisture content in the predetermined temperature / humidity atmosphere as quickly as the outside of the winding. The moisture content of the inner side and the outer side of the winding can be made equal to such an extent that no dimensional deviation occurs between the outer side and the outer side.

The manufacturing method of the roll-shaped film base material of this aspect is demonstrated referring a figure. FIG. 1 is a schematic cross-sectional view showing an example of a method for producing a roll-shaped film substrate of the first embodiment. First, as shown in FIG. 1 (a), the gap member 2 is disposed on the film base 1 to produce the gap member laminated film base 10, and as shown in FIG. 1 (b), The gap member laminated film substrate 10 is wound to prepare the roll-shaped film substrate 20 (roll-shaped film substrate preparation step). Next, the roll-shaped film base material 20 is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere (storage process). Thereby, the roll-shaped film base material 20 which reached the moisture content in predetermined | prescribed temperature-humidity atmosphere is obtained.
In addition, the roll-shaped film base material 20 which reached the moisture content in predetermined | prescribed temperature / humidity atmosphere may keep the gap member 2 laminated | stacked, and may remove the gap member 2. FIG. Specifically, the roll-shaped film base material 20 is unwound after the storage step, the gap member 2 is peeled off from the film base material 1, and only the film base material 1 is taken up again, whereby the roll-shaped film base material 20 is obtained. Also good.

Thus, the manufacturing method of the roll-shaped film base material of this aspect has a roll-shaped film base material preparation process and a storage process at least, and other arbitrary processes may be used as needed. It is.
Hereinafter, the manufacturing method of the roll-shaped film base material of a 1st aspect is demonstrated for every process.

(1) Roll-shaped film base material preparation process First, the roll-shaped film base material preparation process in this aspect is demonstrated. The roll-shaped film base material preparation step in this embodiment is a step of preparing a roll-shaped film base material by winding a space member laminated film base material in which a space member is arranged on the film base material.

(A) Gap member laminated film base material The gap member laminated film base material in this embodiment is obtained by arranging a gap member on a film base material. By winding the gap member laminated film substrate, a gap can be sandwiched between the roll film substrates, and the air permeability and moisture permeability inside the roll film substrate can be improved by the gaps. it can.

(I) Gap Member The gap member used in this embodiment is a member having a gap due to surface irregularities. The void member is not particularly limited as long as it has flexibility, high air permeability and moisture permeability, and high releasability. For example, moisture permeability such as a porous sheet can be used. A film can be suitably used. This is because it is easily available and has excellent breathability and moisture permeability. Specific examples of the porous sheet include polyethylene porous sheets (Sunmap manufactured by Nitto Denko), microvoided biaxially stretched polypropylene (YUPO manufactured by YUPO Corporation), and nonwoven fabrics.

  Among these, the void member used in this embodiment is preferably a porous sheet, and the surface roughness (Ra) of the porous sheet is preferably 1 μm or more, more preferably 2 μm or more, More preferably, it is 5 μm or more. This is because when Ra is smaller than the above range, the gap member has less gaps, and the air permeability and moisture permeability cannot be increased. In addition, Ra of the porous sheet used for this aspect is 10 micrometers or less normally. In addition, "surface roughness (Ra)" here is "arithmetic mean surface roughness", and is measured based on JIS-B0601.

  The thickness of the gap member used in this embodiment is preferably in the range of 20 μm to 200 μm. This is because if the thickness of the gap member is too thinner than the above range, the gap tends to be collapsed when the film is wound, and if it is too thick, the film cannot be wound.

  The width of the gap member used in this embodiment is preferably within a range of ± 100 mm, and more preferably within a range of ± 40 mm, with respect to the width of the roll-shaped film substrate. If the width of the gap member is too wider than the above range, the protruding portion is wasted, and if it is too narrow than the above range, the roll-shaped film base material is in close contact and air permeability is impaired.

  The gap member used in this embodiment remains sandwiched between the roll-shaped film base materials in the storage step described later, but when forming a pattern on the film base material unwound from the roll-shaped film base material. May be removed from the roll-shaped film substrate or may be in a laminated state.

(Ii) Film base material The film base material used for this aspect is wound and becomes a roll-shaped film base material. If the said film base material is a resin base material which has flexibility, it will not specifically limit, According to the use etc. of the roll-shaped film base material obtained by the manufacturing method of the roll-shaped film base material of this aspect In addition, a base material made of any resin material can be used.
Examples of such a film base material include polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polycarbonate (PC), polyimide (PI), polyetheretherketone (PEEK), polyethylene (PE), and polypropylene. (PP), polyphenylene sulfide (PPS), polyetherimide (PEI), cellulose triacetate (CTA), cyclic polyolefin (COP), polymethyl methacrylate (PMMA), polysulfone (PSF), polyamideimide (PAI), norbornene resin And synthetic resins such as allyl ester resins, among which PEN and PET are preferable.

As the humidity expansion coefficient of the film substrate used in this embodiment, is preferably 2 × ¹⁰ -5 /% RH or less, more preferably less ^{RH 1 × 10 -5 /%,} 5 × More preferably, it is 10 ⁻⁶ /% RH or less. This is because the amount of dimensional change due to changes in humidity is small and handling is easy.

As the linear expansion coefficient of the film substrate used in this embodiment, it is preferably 2 × 10 -5 ^/ ℃ or less, more preferably at most ^{1 × 10 -5 / ℃, 5} × 10 - More preferably, it is ⁶ / ° C. or less. This is because the amount of dimensional change due to temperature change is small and handling is easy.

  In addition, the thickness of the film substrate used in this embodiment is preferably in the range of 1 μm to 1 mm, more preferably in the range of 10 μm to 500 μm, and in the range of 50 μm to 250 μm. Is more preferable. This is because if the thickness of the film base is too thick than the above range, the flexibility is impaired, and it becomes difficult to produce a roll-shaped film and it is easy to break. On the other hand, when it is thinner than the above range, there is no strain and handling in each step becomes difficult.

  Moreover, as a width | variety of the film base material used for this aspect, if a roll-shaped film base material can be prepared by winding in this process, it will not specifically limit, For example, 100 mm-1000 mm It is preferably within the range, and more preferably within the range of 150 mm to 600 mm.

  In addition, the structure which consists of a single layer may be sufficient as the film base material used for this aspect, or it may have the structure by which the several layer was laminated | stacked.

(B) Winding method In this process, the said gap | interval member laminated | multilayer film base material is wound, and a roll-shaped film base material is prepared. As a winding method of the gap member laminated film base material, as long as it can be wound with low tension without crushing the gap of the gap member, it is not particularly limited, using a general known winding machine, The method etc. which wind a space | gap member laminated | multilayer film base material can be mentioned.

  It is preferable that the number of windings of the gap member laminated film base material in this step is appropriately selected according to the use of the roll-shaped film base material manufactured according to this aspect.

(2) Storage process Next, the storage process in this aspect is demonstrated. The storage step in this embodiment is a step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere.

  By storing the roll-shaped film base material in which the gap member is sandwiched in this manner, a roll-shaped film base material having a uniform water content is obtained without causing a difference in water content between the inside and outside of the winding. And the dimensions of the roll film substrate can be stabilized.

  In this step, the moisture content of the roll-shaped film substrate has reached the moisture content in a predetermined temperature and humidity atmosphere. If the moisture content of the roll-shaped film substrate can be measured, for example, microwave online It can be determined by measuring the moisture content using a moisture meter (manufactured by Marukam), an electric resistance type moisture meter (manufactured by Yamazaki Seiki Laboratory Co., Ltd.) or the like.

  In this embodiment, the temperature and humidity atmosphere of this step is a temperature and humidity atmosphere when forming a pattern on a film substrate unwound from a roll-shaped film substrate that has reached a moisture content in a predetermined temperature and humidity atmosphere. It needs to be equal. Film base material unwound from a roll-like film base material having a moisture content in a predetermined temperature and humidity atmosphere without causing dimensional expansion / contraction of the roll-like film base material due to temperature difference and humidity difference between storage process and pattern formation This is because the pattern can be formed with high dimensional accuracy by forming the pattern with reference to the dimension.

Although it will not specifically limit if it is in the range which can obtain | require the dimension of the roll-shaped film base under desired temperature by calculation as a temperature in this process, For example, the range of 20 degreeC-30 degreeC It is preferable that the temperature is equal to that in the subsequent step (for example, an alignment bonding step with the counter substrate). This is because it is not necessary to form the pattern in consideration of the amount of dimensional expansion and contraction of the roll-shaped film substrate due to the temperature difference between the pattern formation and the subsequent process.
Moreover, as humidity in this process, if it is in the range which can obtain | require the dimension of the roll-shaped film base material under desired temperature and humidity by calculation, it will not specifically limit, For example, 30% RH- It is preferable to be within the range of 60% RH, and it is more preferable that the humidity be equal to that in the subsequent process (for example, alignment bonding process with the counter substrate). This is because it is not necessary to form a pattern in consideration of the amount of dimensional expansion / contraction of the roll-shaped film substrate due to the humidity difference between the pattern formation and the subsequent process.

  Moreover, in this aspect, if the moisture content of the roll-shaped film substrate can reach the moisture content in a predetermined temperature and humidity atmosphere, the temperature and humidity atmosphere in this step may be always constant, and this step is performed. Although the temperature and humidity atmosphere in this step may be changed every time, it is preferable that the temperature and humidity atmosphere is always constant from the viewpoint of the pattern forming apparatus. The temperature and humidity atmosphere of this process is always constant, and the film substrate size unrolled from the roll film substrate is maintained by keeping the moisture content of the roll film substrate in a predetermined temperature and humidity atmosphere constant. This is because the number of types of masks during pattern formation can be reduced.

  The storage location in this step is a sealed space, and is not particularly limited as long as the temperature and humidity atmosphere in the sealed space can be managed. For example, a clean room, a desiccator and Examples include storage such as a chamber. Moreover, it is preferable that the inside of the said storage place is a gas atmosphere which does not degrade a roll-shaped film base material.

  In addition, the storage time in this step is not particularly limited as long as the moisture content of the roll-shaped film substrate can reach the moisture content in a predetermined temperature and humidity atmosphere. It is appropriately selected depending on the temperature and humidity atmosphere and the storage location.

2. 2nd aspect Next, the 2nd aspect of the manufacturing method of the roll-shaped film base material of this invention is demonstrated. The manufacturing method of the roll-shaped film base material of a 2nd aspect winds the space | gap layer containing film base material which formed the space | gap layer on the film base material, and the roll-shaped film base material preparation process which prepares a roll-shaped film base material, And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. It is a manufacturing method.

According to this aspect, by storing the roll-shaped film substrate sandwiched with the void layer until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, the difference in moisture content in and outside the winding A roll-shaped film base material having a uniform water content can be obtained without causing the above.
As described above, normally, in a roll-shaped film substrate under normal temperature and humidity, since the inner side of the winding (core) is less likely to absorb and dehydrate than the outer side of the winding, the moisture content is increased between the inner side and the outer side of the winding. There will be a difference. On the other hand, as in this embodiment, by winding a film substrate with a void layer formed into a roll-shaped film substrate, the air permeability and moisture permeability inside the roll-shaped film substrate are wound. Can be improved. As a result, the inside of the winding can be made to reach the moisture content in a predetermined temperature and humidity atmosphere as quickly as the outside of the winding, and the inside of the winding can be made to the extent that no dimensional deviation occurs between the inside and the outside of the roll-shaped film substrate. And the moisture content of the winding outside can be made equal.

  The manufacturing method of the roll-shaped film base material of this aspect is demonstrated referring a figure. FIG. 2: is a schematic sectional drawing which shows an example of the manufacturing method of the roll-shaped film base material of a 2nd aspect. First, as shown in FIG. 2 (a), by forming the void layer 3 on the film substrate 1, the void layer-containing film substrate 11 is prepared, and as shown in FIG. 2 (b), The gap layer-containing film substrate 11 is wound to prepare the roll-shaped film substrate 20 (roll-shaped film substrate preparation step). Next, the roll-shaped film base material 20 is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere (storage process). Thereby, the roll-shaped film base material 20 which reached the moisture content in predetermined | prescribed temperature-humidity atmosphere is obtained.

The manufacturing method of the roll-shaped film base material of this aspect has a roll-shaped film base material preparation process and a storage process at least, and another arbitrary process may be used as needed.
Hereinafter, the manufacturing method of the roll-shaped film base material of a 2nd aspect is demonstrated for every process.

(1) Roll-shaped film base material preparation process First, the roll-shaped film base material preparation process in this aspect is demonstrated. The roll-shaped film base material preparation step in this aspect is a step of winding a gap layer-containing film base material in which a gap layer is formed on the film base material to prepare a roll-shaped film base material.

(A) Void layer-containing film substrate The void layer-containing film substrate in the present embodiment is one in which a void layer is formed on a film substrate. By winding the gap layer-containing film base material, gaps can be sandwiched between the roll-shaped film base materials, and the air permeability and moisture permeability inside the roll-shaped film base material can be improved by the gaps. it can.

(I) Void layer The void layer in this embodiment is a layer formed on a film substrate and having voids. The void layer in this embodiment is not particularly limited as long as it improves the air permeability and moisture permeability of the roll-shaped film substrate.
The material for such a void layer is not particularly limited as long as it does not deteriorate the film substrate, and examples thereof include acrylic resins and polyurethane resins mixed with styrene, acrylic and silica particles. be able to.

  Moreover, as a formation method of the said void layer, the method of apply | coating the material of a void layer on a film base material, the method of bonding together with an adhesive agent etc. can be mentioned, for example.

  The thickness of the void layer formed in this embodiment is preferably in the range of 5 μm to 10 mm.

  In this embodiment, the void layer is preferably a functional layer having a concavo-convex structure on the surface. Since the void layer has a concavo-convex structure on the surface, many voids can be sandwiched between the roll-shaped film substrates when wound, and the intended pattern forming body can be obtained when the void layer is a functional layer. It is because a function can be easily added to a pattern formation body by using as a base material.

  Furthermore, in this embodiment, the functional layer is preferably a layer having an antiglare (AG) function. Suppresses the occurrence of glare and the reduction of contrast by using a pattern forming body with a pattern formed on a film substrate that is unwound from a roll-shaped film substrate containing a layer having an AG function. Because it can be done. Further, the surface roughness (Ra) of the layer having the AG function is preferably in the range of 50 nm to 500 nm, and more preferably in the range of 100 nm to 200 nm. If Ra is smaller than the above range, a functional layer exhibiting a good AG function cannot be obtained, and a sufficient gap layer is reduced and the storage process takes time. On the other hand, if Ra is larger than the above range, the resolution and contrast decrease. In addition, "surface roughness (Ra)" here is "arithmetic mean surface roughness", and is measured based on JIS-B0601.

(Ii) Film base material The film base material in this aspect is the same as that in the first aspect described above, and a description thereof will be omitted here.

(B) Winding method In this process, the said gap | interval layer containing film base material is wound, and a roll-shaped film base material is prepared. As a method for winding the gap layer-containing film base material, as long as it can be wound with low tension without crushing the gap of the gap layer, it is not particularly limited, using a general known winding machine, The method etc. which wind a space | gap layer containing film base material can be mentioned.

  The number of windings of the void layer-containing film base material in this step is preferably selected as appropriate according to the use of the roll-shaped film base material prepared in this step.

(2) Storage process Next, the storage process in this aspect is demonstrated. The storage step in this embodiment is a step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. The details of the storage process in this aspect are the same as those in the first aspect described above, and a description thereof is omitted here.

3. The roll-shaped film base material The use of the roll-shaped film base material obtained by the method for producing a roll-shaped film base material of the present invention will be described later in the section “C. Roll-shaped film base material”. Description is omitted.

B. Next, the manufacturing method of the pattern formation body of this invention is demonstrated. The manufacturing method of the pattern formation body of this invention can be divided roughly into two aspects. Hereinafter, the manufacturing method of the pattern formation body of this invention is divided and demonstrated to a 1st aspect and a 2nd aspect.

1. First Aspect First, a first aspect of the method for producing a pattern forming body of the present invention will be described. The manufacturing method of the pattern formation body of the 1st aspect was obtained by the manufacturing method of the roll-shaped film base material described in the term of "1. 1st aspect" of the above-mentioned "A. Manufacturing method of a roll-shaped film base material". It is a manufacturing method characterized by having the pattern formation process which forms a pattern on the film base material unwound from a roll-shaped film base material.

  According to this aspect, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

  The manufacturing method of the pattern formation body of this aspect is demonstrated, referring a figure. FIG. 3 is a process diagram showing an example of a method for producing the pattern-formed body of the first aspect. First, as shown in FIG. 3 (a), the gap member 2 is arranged on the film base 1 to produce the gap member laminated film base 10, and as shown in FIG. 3 (b), The gap member laminated film base material 10 is wound to prepare a roll-shaped film base material 20. Next, the roll-shaped film base material 20 is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere. Subsequently, as shown in FIG. 3C, a pattern 21 is formed on the film substrate 1 unwound from the roll-shaped film substrate 20 that has reached the moisture content in a predetermined temperature and humidity atmosphere (pattern Forming step), the pattern forming body 30 is obtained.

Thus, the manufacturing method of the pattern formation body of this aspect has a pattern formation process at least, and another arbitrary process may be used as needed.
Hereinafter, the manufacturing method of the pattern formation body of a 1st aspect is demonstrated for every process.

(1) Pattern formation process First, the pattern formation process in this aspect is demonstrated. The pattern formation process in this aspect is a process which forms a pattern on the film base material unwound from the roll-shaped film base material obtained by the manufacturing method of the roll-shaped film base material mentioned above. In addition, the roll-shaped film base material used for this process may have a space | gap member, and does not need to have it.

  The pattern formed in this step is formed as a desired functional part, and is appropriately selected according to the use of the pattern forming body described later. Specific examples of the functional part include a coloring pattern in a color filter and a conductive / insulating pattern in a circuit board.

  In addition, the specific pattern forming method in this step is not particularly limited as long as a pattern forming body in which a desired pattern is formed with high accuracy can be obtained. For example, a photolithography method, an inkjet method, etc. Since generally known methods can be used, description thereof is omitted here.

(2) Peeling process In this aspect, when the roll-shaped film base material used for the manufacturing method of the pattern formation body of this aspect has a space | gap member, it is a film before the said pattern formation process or after the said pattern formation process. You may have the peeling process which peels a space | gap member from a base material. When the function of the pattern forming body is hindered by the gap member, it is necessary to peel the gap member from the film base material. Even when the function of the pattern forming body is not hindered by the gap member, the pattern forming body can be made thinner by peeling the gap member from the film substrate. The method for peeling the gap member is not particularly limited as long as the gap member can be peeled without damaging the film substrate, and the gap member may be destroyed or not destroyed. Good.

(3) Other process The manufacturing method of the pattern formation body of this aspect is the temperature-humidity atmosphere where the moisture content is a predetermined | prescribed water content of the roll-shaped film base material in which the pattern was formed after the said pattern formation process which is an essential process. It can have a storage step of storing until the moisture content below is reached. By applying the above storage process to the roll-shaped film substrate on which the pattern is formed, for each process of stacking the patterns in multiple layers, it is possible to form a layered pattern with high dimensional reproducibility and high overlay accuracy regardless of whether it is inside or outside the winding. You can get a body. The details of the storage step are the same as the storage step described in the above section “A. Method for producing roll-shaped film substrate”, and thus the description thereof is omitted here.

  In this embodiment, as shown in FIG. 4 (a), the pattern forming process may be performed only once, and as shown in FIGS. 4 (b) and 4 (c), the pattern forming process and the storing process are performed. May be repeated. Every time the pattern is overlapped, the pattern forming body is wound up after the pattern forming process, and a storage process is performed on the wound pattern forming body, so that the roll-shaped film base material can be used regardless of the inside or outside of the winding. The dimensions can be controlled, and a pattern forming body with high overlay accuracy can be obtained through the pattern forming step.

(4) Pattern formation body The pattern formation body obtained by the manufacturing method of the pattern formation body of this aspect forms a pattern on the film base material unwound from the roll-shaped film base material in which the space | gap member was pinched | interposed. Is. According to this aspect, it is possible to obtain a pattern forming body in which a high-definition pattern is formed on a film substrate that has been unwound from a roll-shaped film substrate that has no dimensional deviation in and outside the winding. In addition, by applying the storage step to the roll-shaped film substrate for each step of stacking patterns in multiple layers, a layered pattern formed body having high reproducibility of dimensions regardless of the inside and outside of the winding and high overlay accuracy is obtained. be able to.

Examples of the use of the pattern formed body obtained by the method for producing a pattern formed body of this embodiment include a color filter, a TFT array, and a printed board.
As a structure of the said pattern formation body, if it has at least the film base material unwound from a roll-shaped film base material and the desired pattern formed on the said film base material, it will be specifically limited. However, it can be of any configuration depending on the type of the target image display element.

2. Second Aspect Next, a second aspect of the method for producing a pattern forming body of the present invention will be described. The manufacturing method of the pattern formation body of the 2nd aspect was obtained by the manufacturing method of the roll-shaped film base material of the term "2. 2nd aspect" of the above-mentioned "A. Manufacturing method of a roll-shaped film base material". It is a manufacturing method characterized by having the pattern formation process which forms a pattern on the film base material unwound from a roll-shaped film base material.

  According to this aspect, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

  The manufacturing method of the pattern formation body of this aspect is demonstrated, referring a figure. FIG. 5 is a process diagram showing an example of a method for producing the pattern forming body of the second aspect. First, as shown in FIG. 5 (a), a void layer-containing film substrate 11 is produced by forming the void layer 3 on the film substrate 1, and as shown in FIG. 5 (b), The gap layer-containing film substrate 11 is wound to prepare a roll-shaped film substrate 20. Next, the roll-shaped film base material 20 is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere. Subsequently, as shown in FIG. 5C, a pattern 21 is formed on the film substrate 1 unwound from the roll-shaped film substrate 20 that has reached the moisture content in a predetermined temperature and humidity atmosphere (pattern Forming step), the pattern forming body 30 is obtained.

Thus, the manufacturing method of the pattern formation body of this aspect has a pattern formation process at least, and another arbitrary process may be used as needed.
In addition, in this aspect, since the roll-shaped film base material by which the space | gap layer containing film base material which formed the space | gap layer on the film base material is wound is used, it peels unlike the 1st aspect mentioned above. It has no process. Moreover, since the pattern formation process and other processes are the same as those in the first aspect described above, description thereof is omitted here. Hereinafter, the pattern forming body obtained by the manufacturing method of the pattern forming body of the second aspect will be described.

(1) Pattern formation body The pattern formation body obtained by the manufacturing method of the pattern formation body of this aspect forms a pattern on the film base material unwound from the roll-shaped film base material in which the space | gap layer was pinched | interposed. Is. According to this aspect, similarly to the first aspect, pattern formation in which a high-definition pattern is formed on a film base material that is unwound from a roll-shaped film base material that has no dimensional deviation inside and outside the winding. You can get a body. Especially, in this aspect, the pattern formation body which has a desired function can be obtained by making a void layer into a functional layer. In addition, by applying the storage step to the roll-shaped film substrate for each step of stacking patterns in multiple layers, a layered pattern formed body having high reproducibility of dimensions regardless of the inside and outside of the winding and high overlay accuracy is obtained. be able to.

  The use and configuration of the pattern forming body obtained by the method for manufacturing the pattern forming body of the present aspect are the same as those in the first aspect described above, and thus the description thereof is omitted here.

C. Next, the roll-shaped film substrate of the present invention will be described. The roll-shaped film substrate of the present invention can be roughly divided into two embodiments. Hereinafter, the roll-shaped film base material of the present invention will be described by being divided into a first aspect and a second aspect.

1. 1st aspect First, the 1st aspect of the roll-shaped film base material of this invention is demonstrated. The roll-shaped film substrate of the first aspect is characterized in that a gap member laminated film base material in which a gap member is disposed on the film base is wound.

  According to this aspect, since the roll-shaped film base material in which the gap member is arranged on the film base material is wound, the air permeability and moisture permeability on the inner side of the winding can be improved. Only by storing until the moisture content of the film substrate reaches the moisture content in a predetermined temperature and humidity atmosphere, a roll-shaped film substrate that does not cause a difference in moisture content between the inside and outside of the winding can be obtained. Furthermore, by forming the pattern of the functional part on the film base material on which such a roll-shaped film base material is unwound, a high-definition pattern forming body without dimensional deviation can be obtained.

The roll-shaped film base material of the 1st aspect is demonstrated referring a figure. As an example of the roll-shaped film base material of this aspect, the roll-shaped film base material shown by FIG.1 (b) can be mentioned. In FIG.1 (b), the roll-shaped film base material 20 is the thing formed by winding the space | gap member laminated | stacked film base material 10 which has arrange | positioned the space | gap member 2 on the film base material 1. FIG.
In addition, about the structure of the roll-shaped film base material of this aspect, since it is the same as that of the content described in the item of "1. 1st aspect" of the above-mentioned "A. Manufacturing method of a roll-shaped film base material", here The description in is omitted.

  As a use of the roll-shaped film base material of this aspect, it can be used for a substrate for color filter formation, a substrate for wiring pattern formation, and the like.

2. 2nd aspect Next, the 2nd aspect of the roll-shaped film base material of this invention is demonstrated. The roll-shaped film substrate of the second aspect is characterized in that a void layer-containing film substrate in which a void layer is formed on the film substrate is wound.

  According to this aspect, since a roll-shaped film substrate formed by winding a gap layer on a film substrate, the air permeability and moisture permeability on the inner side of the winding can be improved. Only by storing until the moisture content of the film substrate reaches the moisture content in a predetermined temperature and humidity atmosphere, a roll-shaped film substrate that does not cause a difference in moisture content between the inside and outside of the winding can be obtained. Furthermore, by forming the pattern of the functional part on the film base material on which such a roll-shaped film base material is unwound, a high-definition pattern forming body without dimensional deviation can be obtained.

The roll-shaped film base material of the 2nd aspect is demonstrated referring a figure. As an example of the roll-shaped film base material of this aspect, the roll-shaped film base material shown by FIG.2 (b) can be mentioned. In FIG. 2 (b), the roll-shaped film substrate 20 is obtained by winding a void layer-containing film substrate 11 in which a void layer 3 is formed on the film substrate 1.
In addition, about the structure of the roll-shaped film base material of this aspect, since it is the same as the content described in the term of "2. 2nd aspect" of the above-mentioned "A. Manufacturing method of roll-shaped film base material", here The description in is omitted.

  The use of the roll-shaped film substrate of this embodiment is the same as that of the first embodiment described above. However, in this embodiment, when the gap layer is used as a functional layer, it functions when unrolled to form a film substrate. For example, it can be used as a substrate for forming a color filter with an AG function.

D. Next, the functional layer-containing film substrate of the present invention will be described. When the functional layer-containing film base material of the present invention is wound, the functional layer imparts air permeability between the roll-shaped film base materials and adds a function to the roll-shaped film base material. It is formed on one surface.

  According to the present invention, since the functional layer is formed on one surface of the film substrate, the air permeability and moisture permeability inside the roll-shaped film substrate can be improved when wound. . Furthermore, by storing the roll-shaped film substrate formed by winding the functional layer-containing film substrate of the present invention until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, the inside of the roll and the outside of the roll Thus, a roll-shaped film base material having a uniform size without causing a difference in moisture content and having a desired function when unwound to obtain a film base material can be obtained.

Such a functional layer-containing film base material will be described with reference to the drawings. FIG. 6 is a schematic cross-sectional view showing an example of the functional layer-containing film substrate of the present invention. As shown in FIG. 6, the functional layer-containing film substrate 12 is obtained by forming the functional layer 4 on one surface of the film substrate 1. In the present invention, the functional layer 4 is a layer that imparts air permeability between the roll-shaped film substrates when wound, and a layer that adds a function to the roll-shaped film substrate. Features.
Hereinafter, the functional layer-containing film substrate of the present invention will be described for each configuration.

1. Functional Layer First, the functional layer in the present invention will be described. The functional layer in the present invention imparts air permeability between the roll-shaped film substrates when wound, and adds a function to the roll-shaped film substrate. Such a functional layer can be the same as the contents described in the section “2. Second embodiment” of “A. Method for producing roll-shaped film base material”, and thus the description thereof is omitted here. To do.

2. Film Base The film base in the present invention is the same as the content described in the above-mentioned section “A. Method for producing roll-shaped film base”, and thus the description thereof is omitted here.

3. Functional layer containing film base material In this invention, the functional pattern may be formed in the other surface of the said film base material. By forming a functional pattern on the surface of the film base material on which the functional layer is not formed, a pattern forming body to which the function of the functional layer is added can be obtained. Specifically, for example, the functional layer in the functional layer-containing film base material of the present invention has an AG function, and a colored layer or the like is formed on the surface of the functional layer-containing film base material on which the functional layer is not formed. By forming the color filter member, a color filter having an AG function can be obtained.
As a use of the functional layer-containing film substrate of the present invention, for example, it can be used for a color filter forming substrate, a wiring pattern forming substrate, and the like.

  The present invention is not limited to the above embodiment. The above-described embodiment is an exemplification, and the present invention has any configuration that has substantially the same configuration as the technical idea described in the claims of the present invention and exhibits the same function and effect. Are included in the technical scope.

  The following examples illustrate the present invention more specifically.

[Example]
First, as a film substrate, the glass transition point is 155 ° C., and the linear expansion coefficient and the humidity expansion coefficient below the glass transition point are 1.3 × 10 ⁻⁵ / ° C. and 1.1 × 10 ⁻⁵ /%, respectively. It is RH, 300 mm wide x 30 m long x 0.2 mm thick PEN film, and as a gap member, the surface roughness (Ra) is 2.0 μm, and 300 mm wide x 30 m long x 0.2 mm thick porous A quality sheet (sunmap made by Nitto Denko) was prepared. Next, the porous sheet is disposed on the PEN film to form a gap member laminated film base material, and the gap film laminated film base material is wound to form a roll-shaped film base sandwiched with the gap member. The material was obtained.

  Next, the obtained roll-shaped film substrate was stored for one week in an atmosphere of 23 ° C. and 45% RH.

  Subsequently, the roll film substrate was washed with an aqueous system. Thereafter, a resist material (photosensitive material) is applied on the film substrate unrolled from the roll-shaped film substrate to a thickness of 1 μm by a gravure printing method, and the resist material is dried at 100 ° C. for 2 minutes. It was.

  Next, the resist material applied on the film base material was exposed in an atmosphere of 23 ° C. and 45% RH according to a desired pattern.

  Next, the resist material was developed on the film base material. Thereby, the pattern formation body in which the pattern was formed on the film base material was obtained.

[Comparative example]
A pattern-formed body was obtained in the same manner as in Example except that only the film base material was wound without using the gap member to obtain a rolled film base material.

[Evaluation]
The pattern formed bodies obtained in the examples and comparative examples were respectively wound around a sun map made by Nitto Denko as a gap member, stored for one week in an atmosphere of 23 ° C. and 45% RH, and the dimensions of the formed pattern Was measured.

  In the pattern formed body obtained in the example, the dimensional variation in the pattern between the inner side and the outer side of the roll-shaped film substrate was within ± 5 μm / 100 mm. On the other hand, in the pattern forming body obtained in the comparative example, the dimension of the pattern on the inner side of the roll-shaped film substrate was extended by about 35 μm / 100 mm as compared with the dimension of the pattern on the outer side of the winding. This is because, in the examples, there was no difference in moisture content between the inner side and the outer side of the roll-shaped film substrate, whereas in the comparative example, the inner side was patterned with a low moisture content, It is considered that the dimension elongation of the pattern occurred due to moisture absorption by the roll-shaped film substrate inside the winding.

DESCRIPTION OF SYMBOLS 1 ... Film base material 2 ... Gap member 3 ... Gap layer 4 ... Functional layer 10 ... Gap member lamination film base material 11 ... Gap layer content film base material 12 ... Functional layer content film base material 20 ... Roll-shaped film base material 21 ... Pattern 30 ... Pattern forming body

Claims (14)

A roll-shaped film substrate preparation step of winding a void-member laminated film substrate in which a void member is arranged on a film substrate and preparing a roll-shaped film substrate;
And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. Of manufacturing a film-like film substrate.   The method for producing a roll-shaped film substrate according to claim 1, wherein the gap member is a porous sheet having a surface roughness (Ra) of 1 μm or more.   The temperature and humidity atmosphere of the storage step is equal to the temperature and humidity atmosphere when forming a pattern on the film substrate unwound from the roll-shaped film substrate that has reached the moisture content in the predetermined temperature and humidity atmosphere. The manufacturing method of the roll-shaped film base material of Claim 1 or Claim 2 characterized by these.   A pattern is formed on a film substrate that is unwound from a roll-shaped film substrate obtained by the method for producing a roll-shaped film substrate according to any one of claims 1 to 3. A method for producing a pattern forming body, comprising a pattern forming step.   The method for producing a pattern forming body according to claim 4, further comprising a peeling step of peeling the void member from the film base material before or after the pattern forming step. A roll-shaped film substrate preparation step of winding a void-layer-containing film substrate in which a void layer is formed on a film substrate and preparing a roll-shaped film substrate;
And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. Of manufacturing a film-like film substrate.   The method for producing a roll-shaped film substrate according to claim 6, wherein the void layer is a functional layer having an uneven structure on the surface.   The said functional layer has an anti-glare (AG) function, and surface roughness (Ra) exists in the range of 50 nm-500 nm, The manufacturing method of the roll-shaped film base material of Claim 7 characterized by the above-mentioned.   The temperature and humidity atmosphere of the storage step is equal to the temperature and humidity atmosphere when forming a pattern on the film substrate unwound from the roll-shaped film substrate that has reached the moisture content in the predetermined temperature and humidity atmosphere. The manufacturing method of the roll-shaped film base material in any one of Claim 6 to 8 characterized by these.   A pattern is formed on a film substrate unwound from a roll-shaped film substrate obtained by the method for producing a roll-shaped film substrate according to any one of claims 6 to 9. A method for producing a pattern forming body, comprising a pattern forming step.   A roll-shaped film base material comprising a gap member laminated film base material in which a gap member is disposed on a film base material.   A roll-shaped film base material comprising a gap layer-containing film base material in which a void layer is formed on a film base material.   A functional layer that imparts air permeability between the roll-shaped film base materials when wound and adds a function to the roll-shaped film base material is formed on one surface of the film base material A functional layer-containing film substrate.   The functional layer-containing film base material according to claim 13, wherein a functional pattern is formed on the other surface of the film base material.

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