JP5949432B2 - Gas barrier film and method for producing gas barrier film - Google Patents

Description

  The present invention relates to a gas barrier film and a method for producing the gas barrier film. More specifically, a transparent gas barrier film excellent in flexibility used for gas blocking of electronic devices such as liquid crystal, organic electroluminescence (organic EL), solar cells, and electronic paper, and a method for producing the gas barrier film About.

  Electronic devices such as organic electroluminescence (organic EL), solar cells, and electronic paper are easily affected by moisture, oxygen, and other impurities, and high sealing performance of the device is required. In recent years, there has been a demand for using a flexible resin substrate instead of glass because it is light and difficult to break.

  In order to achieve the above object, a gas barrier film having a high gas barrier property even when the film is bent has been proposed (see, for example, Patent Document 1).

  In Patent Document 1, the distribution of oxygen atoms and carbon atoms in the layer thickness direction of the gas barrier layer changes with almost the same period over the entire layer, and accordingly, the elastic modulus periodically varies in the layer thickness direction. A changing region is formed to form a so-called single spring-like gas barrier layer.

  However, many electronic devices are mounted on a moving body such as an automobile, and may be exposed to a vibration environment for a long time during movement. It has been found that when such continuous and various vibrations are applied, the gas barrier film having a region in which the elastic modulus periodically changes in the layer thickness direction deteriorates with time.

JP 2011-073430 A

  The present invention has been made in view of the above problems and situations, and a solution to that problem is a gas barrier film that can sufficiently suppress a decrease in gas barrier properties even when exposed to continuous vibration for a long time. Is to provide. Moreover, it is providing the manufacturing method of the gas barrier film which manufactures the said gas barrier film efficiently with sufficient productivity.

  In order to solve the above-mentioned problems, the present inventor, in the process of examining the cause of the above-mentioned problems, a gas provided with a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of the substrate A carbon distribution curve indicating the ratio of carbon atoms in the layer thickness direction of the gas barrier layer having at least two maximum values having different sizes, and from the surface of the gas barrier layer. In response to the change in the distance, a gas barrier film characterized in that a plurality of maximum values appear aperiodically on the carbon distribution curve has been found, and the present invention has been achieved.

  That is, the said subject which concerns on this invention is solved by the following means.

1. A gas barrier film comprising a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of a substrate, the element in the depth direction by X-ray photoelectron spectroscopy of the gas barrier layer Among the distribution curves of the constituent elements based on the distribution measurement, the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer and carbon relative to the total amount (100 at%) of silicon atoms, oxygen atoms and carbon atoms In the carbon distribution curve showing the relationship with the atomic ratio (referred to as “carbon atomic ratio (at%)”), the difference between the maximum maximum value and the minimum maximum value of the carbon distribution curve is 15-15. has at least two maxima in the range of 35 at%, the carbon distribution curve center line P of the areas a and B when the bisecting the thickness direction of the gas barrier layer caused When it was decided, the not show the symmetrical carbon distribution curve in the region A and B, and the difference of the average values of the carbon atomic ratio in the regions A and B is in the range of 5 to 20 at% Gas barrier film characterized by

2 . A method of manufacturing a gas barrier film for producing a gas barrier film according to paragraph 1, the gas barrier layer, by plasma enhanced chemical vapor deposition of a gas barrier film, which comprises forming on a substrate Production method.

3 . The substrate is conveyed while being brought into contact with each of a pair of film forming rollers, and plasma discharge is performed while supplying a film forming gas containing an organosilicon compound and oxygen between the pair of film forming rollers. 3. The method for producing a gas barrier film according to item 2 , wherein the gas barrier layer is formed on the substrate.

4 . The formation of the gas barrier layer, wherein using a plurality of film-forming gas prepared by changing the concentration of oxygen contained in the film forming gas, and the gas barrier according to paragraph 3, characterized in that a plurality of times A method for producing a film.

  By the above means of the present invention, it is possible to provide a gas barrier film with little deterioration of gas barrier properties even when exposed to continuous vibration for a long time. Moreover, the manufacturing method of the gas barrier film which manufactures the said gas barrier film efficiently with sufficient productivity can be provided.

  The expression mechanism or action mechanism of the effect of the present invention is not clear, but is presumed as follows.

  In the gas barrier layer disclosed in Patent Document 1, the distribution of oxygen atoms and carbon atoms in the layer thickness direction changes with substantially the same period over the entire layer, and is periodically elastic in the layer thickness direction. It has an area where the rate changes. Therefore, since it has one spring-like elastic modulus distribution in the layer thickness direction, resonance may occur when vibration is applied for a long time. At that time, it is presumed that the energy is accumulated in the layer and an unexpected force is applied, and finally the layer is broken to deteriorate the gas barrier property.

  In the present invention, in the distribution of carbon atoms, at least two or more local maxima different in size exist non-periodically, so that it has a structure similar to a structure in which a plurality of springs having different resonance frequencies are connected. Thus, even if one region resonates, the other can absorb the energy, and therefore it is presumed that the layer breakdown does not occur and the deterioration of the gas barrier property is suppressed.

Schematic diagram showing the configuration of the gas barrier film Schematic diagram showing an example in which the maximum value of the carbon distribution curve appears periodically or aperiodically Schematic showing an example of gas barrier film manufacturing equipment Comparative gas barrier layer silicon distribution curve, oxygen distribution curve and carbon distribution curve Silicon distribution curve, oxygen distribution curve and carbon distribution curve of gas barrier layer of Example 1 Silicon distribution curve, oxygen distribution curve and carbon distribution curve of gas barrier layer of Example 2 Silicon distribution curve, oxygen distribution curve and carbon distribution curve of gas barrier layer of Example 3 Silicon distribution curve, oxygen distribution curve and carbon distribution curve of gas barrier layer of Example 4 Schematic diagram of an organic EL panel equipped with the gas barrier film of the present invention

The gas barrier film of the present invention is a gas barrier film comprising a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of a base material, and an X-ray photoelectron for the gas barrier layer Among the distribution curves of each constituent element based on the element distribution measurement in the depth direction by spectroscopy, the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer and the silicon atoms, oxygen atoms and carbon atoms In the carbon distribution curve showing the relationship with the ratio of the amount of carbon atoms to the total amount (100 at%) (referred to as “carbon atom ratio (at%)”), the maximum value of the maximum value and the maximum value of the carbon distribution curve the difference between the minimum has at least two or more maxima in the range of 15～35At%, was the carbon distribution curve bisecting the thickness direction of the gas barrier layer Starting from the center line P of the regions A and B, the carbon distribution curves in the regions A and B do not show a symmetric shape, and the difference between the average values of the carbon atom ratios in the regions A and B Is in the range of 5 to 20 at% . This feature is a technical feature common to the inventions according to claims 1 to 4 .

  Furthermore, the method for producing a gas barrier film of the present invention is preferably a production method in which the gas barrier layer is formed on a substrate by plasma chemical vapor deposition, and in particular, the substrate is formed as a pair of films. The gas barrier layer is formed on the substrate by conveying while contacting each of the rollers and performing plasma discharge while supplying a film forming gas containing an organosilicon compound and oxygen between the pair of film forming rollers. A production method is preferred.

  In addition, the gas barrier layer may be formed by using a plurality of types of film forming gases prepared by changing the concentration of oxygen contained in the film forming gas and a plurality of times. A film can be efficiently produced with high productivity, which is preferable.

The “gas barrier property” as used in the present invention is a water vapor permeability (temperature: 60 ± 0.5 ° C., relative humidity (RH): 90 ± 2%) measured by a method according to JIS K 7129-1992. ) Is 3 × 10 ⁻³ g / m ² · 24 h or less, and the oxygen permeability measured by a method according to JIS K 7126-1987 is 1 × 10 ⁻³ ml / m ² · 24 h · atm or less. Means that.

  Hereinafter, the present invention, its components, and modes and modes for carrying out the present invention will be described in detail. In addition, in this application, "-" is used in the meaning which includes the numerical value described before and behind that as a lower limit and an upper limit.

<Gas barrier layer>
The gas barrier film of the present invention is a gas barrier film comprising a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of a base material, and an X-ray photoelectron for the gas barrier layer Among the distribution curves of each constituent element based on the element distribution measurement in the depth direction by spectroscopy, the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer and the silicon atoms, oxygen atoms and carbon atoms In the carbon distribution curve showing the relationship with the ratio of the amount of carbon atoms to the total amount (100 at%) (referred to as “carbon atom ratio (at%)”), the maximum value of the maximum value and the maximum value of the carbon distribution curve the difference between the minimum has at least two or more maxima in the range of 15～35At%, was the carbon distribution curve bisecting the thickness direction of the gas barrier layer Starting from the center line P of the regions A and B, the carbon distribution curves in the regions A and B do not show a symmetric shape, and the difference between the average values of the carbon atom ratios in the regions A and B Is in the range of 5 to 20 at% .

  In the carbon distribution curve, “total amount of silicon atoms, oxygen atoms and carbon atoms” means the total number of silicon atoms, oxygen atoms and carbon atoms, and “amount of carbon atoms” means the number of carbon atoms. Means. Similarly, the amount of silicon atoms in the silicon distribution curve and the amount of oxygen atoms in the oxygen distribution curve are also synonymous, and the unit is “at% (atomic%)”.

<Configuration of gas barrier film>
Although the structure of the gas barrier film of this invention is not specifically limited, An example is shown to Fig.1 (a). The gas barrier film 1 a is a gas barrier film in which a gas barrier layer 3 is laminated on a substrate 1. In that case, it is preferable to provide the smooth layer 2 between the base material 1 and the gas barrier layer 3 in order to make it difficult to affect the unevenness of the base material surface on the gas barrier layer which is a thin layer.

  Moreover, when applying the gas barrier film of this invention to an electronic device, it is also preferable that it is an aspect which has a some functional layer, for example, as shown in FIG. A smooth layer 2 is provided on the material 1, a gas barrier layer 3 is laminated on the smooth layer 2, and a second gas barrier layer 4 containing, for example, polysilazane is laminated on the gas barrier layer 3. In addition, an embodiment in which an overcoat layer 5 is laminated on the second gas barrier layer 4 can also be mentioned as a preferable example.

<Base material>
Although it does not specifically limit as a base material of the gas barrier film of this invention, It is preferable from a viewpoint of weight reduction that it is a resin base material formed with the organic material which can hold | maintain a gas barrier layer.

  For example, methacrylic acid ester, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polyarylate, polystyrene (PS), aromatic polyamide, polyether ether ketone, polysulfone, polyether sulfone, polyimide, and Examples include resin films such as polyetherimide, and resin films formed by laminating two or more layers of the above resins. In terms of cost and availability, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), and the like are preferably used.

  The thickness of the resin base material is preferably about 5 to 500 μm, more preferably 25 to 250 μm.

  Moreover, it is preferable that the resin base material which concerns on this invention is transparent. Since the resin base material is transparent and the layer formed on the resin base material is also transparent, it becomes possible to make a transparent gas barrier film, so that it can be made a transparent substrate such as an organic EL element. Because it becomes.

  Moreover, the unstretched film may be sufficient as the resin base material using the resin etc. which were mentioned above, and a stretched film may be sufficient as it. A stretched film is preferable from the viewpoint of strength improvement and thermal expansion suppression. Moreover, retardation etc. can also be adjusted by extending | stretching.

The resin base material used in the present invention can be produced by a conventionally known general method. For example, an unstretched resin substrate that is substantially amorphous and not oriented can be produced by melting a resin as a material with an extruder, extruding it with an annular die or a T-die, and quenching. Moreover, an unstretched resin base material that is substantially amorphous and not oriented is obtained by dissolving a resin as a material in a solvent, casting (casting) on an endless metal support, drying, and peeling. It can also be manufactured.
The unstretched resin base material is uniaxially stretched, tenter-type sequential biaxial stretching, tenter-type simultaneous biaxial stretching, tubular-type simultaneous biaxial stretching, and other known methods, such as the resin base material flow (vertical axis) direction, or A stretched resin substrate can be produced by stretching in the direction perpendicular to the flow direction of the resin substrate (horizontal axis). The draw ratio in this case can be appropriately selected according to the resin used as the raw material for the resin base material, but is preferably in the range of 2 to 10 times in the vertical axis direction and the horizontal axis direction.

  Moreover, the resin base material used for this invention may perform a relaxation | loosening process and off-line heat processing at the point of dimensional stability. The relaxation treatment is preferably carried out in the process from the heat setting in the stretching process of the polyester film to the winding in the transversely stretched tenter or after exiting the tenter. The relaxation treatment is preferably performed at a treatment temperature in the range of 80 to 200 ° C, more preferably in the range of 100 to 180 ° C. Although it does not specifically limit as a method of off-line heat processing, For example, the method of conveying by the roller conveyance method by a several roller group, the air conveyance which blows and blows air to a film, etc. (one side of a film surface heated air from several slits) Or, a method of spraying on both surfaces), a method of using radiant heat from an infrared heater, a method of hanging the film under its own weight, and a method of conveying such as winding below. The conveyance tension of the heat treatment is made as low as possible to promote thermal shrinkage, thereby providing a resin substrate with good dimensional stability. The treatment temperature is preferably in the temperature range of Tg + 50 to Tg + 150 ° C. Here, Tg refers to the glass transition temperature (° C.) of the resin.

In the resin base material according to the present invention, the undercoat layer coating solution can be applied inline on one side or both sides in the film forming process. In the present invention, undercoating during the film forming process is referred to as in-line undercoating. Examples of resins used in the undercoat layer coating solution useful in the present invention include polyester resins, acrylic-modified polyester resins, polyurethane resins, acrylic resins, vinyl resins, vinylidene chloride resins, polyethyleneimine vinylidene resins, polyethyleneimine resins, and polyvinyl alcohol resins. , Modified polyvinyl alcohol resin, gelatin and the like, and any of them can be preferably used. A conventionally well-known additive can also be added to these undercoat layers. The undercoat layer can be coated by a known method such as roll coating, gravure coating, knife coating, dip coating or spray coating. The coating amount of the undercoat layer is preferably about 0.01 to ² g / m ² (dry state).

  Hereinafter, the details of the gas barrier layer according to the present invention will be described.

<Gas barrier layer>
The gas barrier film of the present invention is a gas barrier film comprising a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of a base material, and an X-ray photoelectron for the gas barrier layer Among the distribution curves of each constituent element based on the element distribution measurement in the depth direction by spectroscopy, the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer and the silicon atoms, oxygen atoms and carbon atoms In the carbon distribution curve showing the relationship with the ratio of the amount of carbon atoms to the total amount (100 at%) (referred to as “carbon atom ratio (at%)”), the maximum value of the maximum value and the maximum value of the carbon distribution curve Minimum value difference is 15 to 35
When it has at least two or more local maximum values in the range of at% and starts from the center line P of the regions A and B when the carbon distribution curve is equally divided into two in the thickness direction of the gas barrier layer Further, the carbon distribution curves in the regions A and B do not show a symmetric shape, and the difference in the average value of the carbon atom ratios in the regions A and B is in the range of 5 to 20 at%. With such a configuration, a structure similar to a structure in which a plurality of springs having different resonance frequencies are connected in the gas barrier layer is formed, and the gas barrier property is hardly deteriorated even when exposed to continuous vibration for a long time. A barrier film is provided.

  Furthermore, in the gas barrier layer of the present invention, it is preferable that the following condition A is satisfied from the viewpoint of satisfying gas barrier properties, vibration resistance, and flexibility.

[Condition (A)]
The silicon atom ratio, oxygen atom ratio, and carbon atom ratio satisfy the following formula (1) in a distance region of 90% or more of the thickness of the gas barrier layer.

(Carbon atom ratio) <(silicon atom ratio) <(oxygen atom ratio) (1)
Here, the silicon atom ratio means the ratio (at%) of the amount of carbon atoms to the total amount (100 at%) of silicon atoms, oxygen atoms and carbon atoms, and the oxygen atom ratio means silicon atoms, oxygen atoms and carbon. The ratio (at%) of the amount of oxygen atoms to the total amount of atoms (100 at%).
In addition, the gas barrier layer according to the present invention transports the base material in contact with each of a pair of film forming rollers, and performs plasma discharge while supplying a film forming gas between the pair of film forming rollers. A thin film layer formed on the substrate by a vapor phase growth method is preferable.

<Aperiodic appearance of local maximum on carbon distribution curve>
The carbon distribution curve according to the present invention has at least two or more maximum values having different sizes, and a plurality of the maximum values correspond to the change in distance from the surface of the gas barrier layer. Appears non-periodically on the curve.

  FIG. 2 is a schematic diagram showing an example in which the maximum value of the carbon distribution curve appears periodically or aperiodically. The figure is an example, and the present invention is not limited to this.

The carbon distribution curve C in FIG. 2 corresponds to the change in the distance from the surface of the gas barrier layer in the depth direction from the surface (0 nm) of the gas barrier layer to the surface in contact with the substrate (thickness: about 600 nm). In the present application, the peak height of the maximum value and the peak interval of 0 to 300 nm (region A) and 300 to 600 nm (region B) repeatedly appear in a substantially similar pattern. It is defined as “appears periodically” to be in a repeated state. Further, in this application, as shown in FIG. 2, in the two regions A and B when the carbon distribution curve is divided into two equal parts in the thickness direction of the gas barrier layer , the pattern of the maximum value is P with the center line P as a boundary. Appearing in a mirror-like plane symmetry with respect to a distance starting from is also included in “appearing periodically”.
On the other hand, the carbon distribution curve D corresponds to the change in the distance from the surface of the gas barrier layer in the depth direction from the surface (0 nm) of the gas barrier layer to the surface in contact with the substrate (thickness: about 600 nm). The maximum peak height and the peak interval do not repeatedly appear at a constant height and interval, and in this application, the occurrence of such a repeated state is defined as “appears aperiodically”. That is, when “appears aperiodically”, considering the center line P of the regions A and B when the carbon distribution curve is divided into two equal parts in the thickness direction of the gas barrier layer, the regions A and B It can be said that the carbon distribution curve does not show a symmetric shape.
Further, in the carbon distribution curve according to the present invention, “the maximum value appears aperiodically”, the carbon obtained from the carbon distribution curve in the regions A and B when divided into two in the thickness direction of the gas barrier layer. and having an average value of the atomic ratio is different, the absolute value of the difference is Ri der range of 5 to 20 at%, and more preferably in a further range of 10 to 20 at%. By having a difference in the average value of the carbon atom ratio in the regions A and B, the carbon distribution curve according to the present invention forms a structure similar to a structure in which a plurality of springs having different resonance frequencies are connected. It becomes easy to express the effect of the present invention.

<Carbon atom distribution and extreme values>
The gas barrier layer according to the present invention is such that the carbon atom distribution varies substantially continuously with a concentration gradient in a distance region of 90% or more in the layer thickness direction of the gas barrier layer. It is easy to form a structure in which a plurality of springs having different resonance frequencies are connected, which is preferable.

<Definition of real continuity>
In this application, the carbon distribution curve being substantially continuous means that it does not include a portion in which the carbon atom ratio in the carbon distribution curve changes discontinuously. Specifically, the carbon distribution curve is calculated from the etching rate and the etching time. In the relationship between the distance (x, unit: nm) from the surface of the gas barrier layer in the layer thickness direction of at least one of the gas barrier layers and the carbon atom ratio (C, unit: at%), Formula (F1):
(DC / dx) ≦ 0.5 (F1)
This means that the condition represented by

  In such a gas barrier layer, the carbon distribution curve in the layer has at least two maximum values having different sizes, and further has at least three maximum values having different sizes. Is preferred. When the carbon distribution curve has the above maximum value, the flexibility of the obtained gas barrier film is improved, and the gas barrier property is sufficient even when the film is bent. Further, in the case of having at least two or three maximum values having different sizes, the layer thickness of the gas barrier layer at one maximum value and a maximum value adjacent to the maximum value included in the carbon distribution curve. The absolute value of the difference in distance in each direction is preferably 200 nm or less from the viewpoint of flexibility related to flexibility, and more preferably 100 nm or less.

<Definition of maximum and minimum values>
In the present invention, the maximum value is a point where the value of the atomic ratio of an element changes from increasing to decreasing when the distance from the surface of the gas barrier layer is changed, and from the value of the atomic ratio of the element at that point. This also means that the atomic ratio value of the element at a position where the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer is further changed by 20 nm from that point is reduced by 3 at% or more.

Therefore, the maximum value of the carbon distribution curve includes the maximum maximum value and the minimum maximum value. In the present application, the difference between the maximum value and the minimum value of the carbon distribution curve is in the range of 15 to 35 at%. Uchidea is, and more preferably in the range of 20~30at%. By adjusting within the said range, the softness | flexibility of the gas barrier film obtained can be improved and the outstanding vibration resistance can be provided.

  In the present invention, the minimum value is a point where the value of the atomic ratio of the element changes from decreasing to increasing when the distance from the surface of the gas barrier layer is changed, and the value of the atomic ratio of the element at that point Rather, it means that the atomic ratio value of the element at a position where the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer is further changed by 20 nm from that point increases by 3 at% or more.

<Average value of the entire carbon atom ratio layer>
From the viewpoint of flexibility, the carbon atom ratio of the gas barrier layer according to the present invention is preferably in the range of 8 to 20 at% as an average value of the entire layer. More preferably, it is in the range of 10 to 20 at%. By setting it within this range, it is possible to form a gas barrier layer that sufficiently satisfies gas barrier properties and flexibility.

<Relationship between the maximum and minimum values of the maximum oxygen atom ratio>
In the oxygen distribution curve of the gas barrier layer, the absolute value of the difference between the maximum maximum value and the minimum maximum value of the oxygen atom ratio is preferably 5 at% or more. When the absolute value of the difference is 5 at% or more, the gas barrier property when the obtained gas barrier film is bent is sufficient.

<Relationship between maximum value and minimum value of maximum value of silicon atom ratio>
In the present invention, the absolute value of the difference between the maximum maximum value and the minimum maximum value of the silicon atom ratio in the silicon distribution curve of the gas barrier layer is preferably less than 5 at%, and preferably less than 4 at%. More preferably, it is particularly preferably less than 3 at%. When the absolute value is within the above range, the gas barrier property of the obtained gas barrier film and the mechanical strength of the gas barrier layer are sufficient.

<About XPS depth profile>
The silicon distribution curve, oxygen distribution curve, and carbon distribution curve in the thickness direction of the gas barrier layer are obtained by using both X-ray photoelectron spectroscopy (XPS) measurement and rare gas ion sputtering such as argon. Thus, it can be created by so-called XPS depth profile measurement in which surface composition analysis is sequentially performed while exposing the inside of the sample. A distribution curve obtained by such XPS depth profile measurement can be created, for example, with the vertical axis as the atomic ratio (unit: at%) of each element and the horizontal axis as the etching time (sputtering time). In the element distribution curve with the horizontal axis as the etching time in this way, the etching time generally correlates with the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer in the layer thickness direction. , “Distance from the surface of the gas barrier layer in the thickness direction of the gas barrier layer” as calculated from the relationship between the etching rate and the etching time employed in the XPS depth profile measurement Can be adopted. In addition, as a sputtering method employed for such XPS depth profile measurement, a rare gas ion sputtering method using argon (Ar ⁺ ) as an etching ion species is employed, and the etching rate (etching rate) is 0.05 nm / It is preferable to set to sec (SiO ₂ thermal oxide film conversion value).

  In the present invention, from the viewpoint of forming a gas barrier layer having a uniform and excellent gas barrier property over the entire film surface, the gas barrier layer is in the film surface direction (direction parallel to the surface of the gas barrier layer). Is substantially uniform. In the present application, the gas barrier layer is substantially uniform in the film surface direction, and the oxygen distribution curve and the carbon distribution curve are created at any two measurement points on the film surface of the gas barrier layer by XPS depth profile measurement. In this case, the carbon distribution curve obtained at any two measurement points has the same number of extreme values, and the absolute value of the difference between the maximum value and the minimum value of the carbon atomic ratio in each carbon distribution curve. Are the same or different within 5 at%.

  The gas barrier film of the present invention needs to include at least one gas barrier layer that satisfies the above conditions, but may include two or more layers that satisfy such conditions. Furthermore, when two or more such gas barrier layers are provided, the materials of the plurality of gas barrier layers may be the same or different. Further, when two or more such gas barrier layers are provided, such a gas barrier layer may be formed on one surface of the base material, and is formed on both surfaces of the base material. May be. Moreover, as such a plurality of gas barrier layers, a gas barrier layer not necessarily having a gas barrier property may be included.

  In the silicon distribution curve, the oxygen distribution curve, and the carbon distribution curve, the silicon atom ratio, the oxygen atom ratio, and the carbon atom ratio in the distance region where 90% or more of the thickness of the gas barrier layer is equal to the above formula (1 ), The ratio of the amount of silicon atoms to the total amount of silicon atoms, oxygen atoms and carbon atoms in the gas barrier layer is preferably in the range of 25 to 45 at%. A range of 30 to 40 at% is more preferable.

  The ratio of the amount of oxygen atoms to the total amount of silicon atoms, oxygen atoms and carbon atoms in the gas barrier layer is preferably in the range of 33 to 67 at%, and preferably in the range of 45 to 67 at%. More preferred.

  Furthermore, the ratio of the amount of carbon atoms to the total amount of silicon atoms, oxygen atoms and carbon atoms in the gas barrier layer is preferably in the range of 3 to 33 at%, and is preferably in the range of 3 to 25 at%. More preferred.

<Gas barrier layer thickness>
The thickness of the gas barrier layer is preferably in the range of 5 to 3000 nm, more preferably in the range of 10 to 2000 nm, further preferably in the range of 100 to 1000 nm, particularly in the range of 300 to 1000 nm. preferable. When the thickness of the gas barrier layer is within the above range, the gas barrier properties such as oxygen gas barrier properties and water vapor barrier properties are excellent, and no deterioration of the gas barrier properties due to bending is observed.

  When the gas barrier film of the present invention includes a plurality of gas barrier layers, the total value of the thicknesses of the gas barrier layers is usually in the range of 10 to 10,000 nm, and in the range of 10 to 5000 nm. It is more preferable, it is more preferable that it is the range of 100-3000 nm, and it is especially preferable that it is the range of 200-2000 nm. When the total thickness of the gas barrier layers is within the above range, gas barrier properties such as oxygen gas barrier properties and water vapor barrier properties are sufficient, and the gas barrier properties tend not to be lowered by bending.

<Method for producing gas barrier layer>
The gas barrier layer according to the present invention is preferably a layer formed by plasma enhanced chemical vapor deposition. More specifically, as a gas barrier layer formed by such a plasma chemical vapor deposition method, the substrate is conveyed while being in contact with each of a pair of film forming rollers, and a film forming gas is interposed between the pair of film forming rollers. It is preferably a thin film layer formed by plasma chemical vapor deposition by plasma discharge while supplying. Further, when discharging between the pair of film forming rollers in this way, it is preferable to reverse the polarities of the pair of film forming rollers alternately. Further, the film forming gas used in such a plasma chemical vapor deposition method preferably contains an organosilicon compound and oxygen, and the content of oxygen in the film forming gas is the same as that in the film forming gas. It is preferable that the amount is less than or equal to the theoretical oxygen amount necessary for complete oxidation of the entire amount of the organosilicon compound. In the gas barrier film of the present invention, the gas barrier layer is preferably a layer formed by a continuous film forming process.

  Next, the method for producing the gas barrier film of the present invention will be described in detail. The gas barrier film of the present invention can be produced by forming the gas barrier layer on the surface of the substrate. As a method for forming such a gas barrier layer according to the present invention on the surface of the substrate, it is preferable to employ a plasma chemical vapor deposition method (plasma CVD method) from the viewpoint of gas barrier properties, The plasma chemical vapor deposition method may be a Penning discharge plasma type plasma chemical vapor deposition method.

  In order to form a layer in which the carbon atomic ratio has a concentration gradient and continuously changes in the layer as in the gas barrier layer according to the present invention, plasma is generated in the plasma chemical vapor deposition method. In this case, it is preferable to generate a plasma discharge in the space between the plurality of film forming rollers. In the present invention, a pair of film forming rollers is used, and the resin base material is in contact with each of the pair of film forming rollers. It is preferable to transport and generate a plasma by discharging between the pair of film forming rollers. In this way, by using a pair of film forming rollers, conveying the resin base material while contacting the pair of film forming rollers, and performing a plasma discharge between the pair of film forming rollers, By changing the distance between the film discharge rollers and the plasma discharge position, it becomes possible to form a gas barrier layer in which the carbon atom ratio has a concentration gradient and continuously changes in the layer. .

  It is also possible to form a film on the surface part of the resin substrate that exists on the other film forming roller while forming a film on the surface part of the resin substrate that exists on one film formation roller. As a result, the film formation rate can be doubled and a film having the same structure can be formed, so that the extreme value in the carbon distribution curve can be at least doubled, and gas can be efficiently produced. A barrier layer can be formed.

  Moreover, it is preferable that the gas barrier film of this invention forms the said gas barrier layer on the surface of the said base material by the roll to roll system from a viewpoint of productivity.

  An apparatus that can be used when producing a gas barrier film by such a plasma chemical vapor deposition method is not particularly limited, and includes at least a pair of film forming rollers and a plasma power source, and the pair It is preferable that the apparatus is configured to be capable of discharging between the film forming rollers. For example, when the manufacturing apparatus shown in FIG. 3 is used, the roll is used while utilizing the plasma chemical vapor deposition method. It is also possible to manufacture by a to-roll method.

  Hereinafter, the method for producing the gas barrier film of the present invention will be described in more detail with reference to FIG. FIG. 3 is a schematic view showing an example of a production apparatus that can be suitably used for producing the gas barrier film of the present invention.

  The manufacturing apparatus shown in FIG. 3 includes a delivery roller 11, transport rollers 21, 22, 23, 24, film formation rollers 31, 32, a gas supply port 41, a plasma generation power supply 51, a film formation roller 31, and 32, magnetic field generators 61 and 62 installed inside 32, and a winding roller 71 are provided. In such a manufacturing apparatus, a vacuum chamber in which at least film forming rollers 31, 32, a gas supply port 41, a plasma generating power source 51, and magnetic field generators 61, 62 made of permanent magnets are not shown. Is placed inside. Further, in such a manufacturing apparatus, the vacuum chamber is connected to a vacuum pump (not shown), and the pressure in the vacuum chamber can be appropriately adjusted by the vacuum pump.

  In such a manufacturing apparatus, each film-forming roller has a power source for plasma generation so that the pair of film-forming rollers (the film-forming roller 31 and the film-forming roller 32) can function as a pair of counter electrodes. 51 is connected. Therefore, in such a manufacturing apparatus, it is possible to discharge into the space between the film forming roller 31 and the film forming roller 32 by supplying electric power from the plasma generating power source 51, thereby forming the film. Plasma can be generated in the space between the roller 31 and the film forming roller 32. In addition, when using the film-forming roller 31 and the film-forming roller 32 as electrodes as described above, the material and design may be appropriately changed so that the film-forming roller 31 and the film-forming roller 32 can also be used as electrodes. Moreover, in such a manufacturing apparatus, it is preferable to arrange | position a pair of film-forming roller (film-forming rollers 31 and 32) so that the central axis may become substantially parallel on the same plane. By arranging a pair of film forming rollers (film forming rollers 31 and 32) in this way, the film forming rate can be doubled, and a film having the same structure can be formed. Can be at least doubled.

  Further, inside the film forming roller 31 and the film forming roller 32, magnetic field generators 61 and 62 fixed so as not to rotate even when the film forming roller rotates are provided, respectively.

  Furthermore, as the film forming roller 31 and the film forming roller 32, known rollers can be used as appropriate. As such film forming rollers 31 and 32, it is preferable to use ones having the same diameter from the viewpoint of forming a thin film more efficiently. Further, the diameter of the film forming rollers 31 and 32 is preferably in the range of 300 to 1000 mmφ, particularly in the range of 300 to 700 mmφ, from the viewpoint of discharge conditions, chamber space, and the like. When the diameter is larger than 300 mmφ, the plasma discharge space is not reduced, productivity is not deteriorated, and it is possible to prevent the total amount of heat of the plasma discharge from being applied to the film in a short time. On the other hand, it is preferable that the diameter is smaller than 1000 mmφ because practicality can be maintained in terms of device design including uniformity of plasma discharge space.

  Moreover, a well-known roller can be used suitably as the sending-out roller 11 and the conveyance rollers 21, 22, 23, and 24 which are used for such a manufacturing apparatus. The winding roller 71 is not particularly limited as long as it can wind the resin base material 1 on which the gas barrier layer is formed, and a known roller can be used as appropriate.

  As the gas supply port 41, a gas supply port that can supply or discharge a raw material gas at a predetermined speed can be used as appropriate. Furthermore, as the plasma generating power source 51, a known power source for a plasma generating apparatus can be used as appropriate. Such a power source 51 for generating plasma supplies power to the film forming roller 31 and the film forming roller 32 connected thereto, and makes it possible to use these as counter electrodes for discharge. As such a plasma generation power source 51, it is possible to more efficiently carry out the plasma CVD method, so that the polarity of the pair of film forming rollers can be alternately reversed (AC power source or the like) ) Is preferably used. Moreover, as such a plasma generating power source 51, it is possible to more efficiently perform the plasma CVD method, so that the applied power can be in the range of 100 W to 10 kW and the AC frequency is 50 Hz to It is more preferable that the frequency range is 500 kHz. As the magnetic field generators 61 and 62, known magnetic field generators can be used as appropriate.

  Using such a manufacturing apparatus shown in FIG. 3, for example, the type of raw material gas, the power of the electrode drum of the plasma generator, the pressure in the vacuum chamber, the diameter of the film forming roller, and the transport speed of the resin substrate are determined. By appropriately adjusting, the gas barrier film of the present invention can be produced. That is, using the manufacturing apparatus shown in FIG. 3, a plasma discharge is generated between a pair of film forming rollers (film forming rollers 31 and 32) while supplying a film forming gas (such as a source gas) into the vacuum chamber. The film deposition gas (raw material gas or the like) is decomposed by plasma, and the gas barrier layer is formed on the surface of the resin base material 1 on the film formation roller 31 and on the surface of the resin base material 1 on the film formation roller 32. Is formed by plasma CVD. In such film formation, the resin base material 1 is conveyed by the delivery roller 11 and the film formation roller 31, respectively, so that the resin base material 1 is formed by a roll-to-roll continuous film formation process. The gas barrier layer is formed on the surface.

  In the gas barrier layer according to the present invention, the carbon distribution curve indicating the ratio of carbon atoms in the thickness direction of the gas barrier layer has at least two maximum values having different sizes, and the gas barrier layer In order for a plurality of the local maximum values to appear aperiodically on the carbon distribution curve corresponding to the change in the distance from the surface of the gas, the formation of the gas barrier layer by the plasma chemical vapor deposition method, It is preferable to form the film by performing a plurality of times using a plurality of types of film forming gases prepared by changing the concentration of oxygen contained in the film forming gas.

  There are no particular limitations on the oxygen concentration change or the number of times the gas barrier layer is formed by plasma enhanced chemical vapor deposition. The state of carbon atom distribution of the gas barrier layer according to the present invention is measured by the XPS depth profile, and preferably, the mixing ratio of the concentration of the organosilicon compound and oxygen is appropriately adjusted in the range of 1:10 to 1: 2. Preferably it is done. For reference, in the gas barrier layer produced in the example, the carbon maximum value when the mixing ratio of the concentration of the organosilicon compound and oxygen is changed is shown in Table 1 below.

〈原料ガス〉
本発明に係るガスバリアー層の形成に用いる前記成膜ガス中の原料ガスとしては、形成するガスバリアー層の材質に応じて適宜選択して使用することができる。このような原料ガスとしては、例えばケイ素を含有する有機ケイ素化合物を用いることが好ましい。このような有機ケイ素化合物としては、例えば、ヘキサメチルジシロキサン、１,１,３,３−テトラメチルジシロキサン、ビニルトリメチルシラン、メチルトリメチルシラン、ヘキサメチルジシラン、メチルシラン、ジメチルシラン、トリメチルシラン、ジエチルシラン、プロピルシラン、フェニルシラン、ビニルトリエトキシシラン、ビニルトリメトキシシラン、テトラメトキシシラン、テトラエトキシシラン、フェニルトリメトキシシラン、メチルトリエトキシシラン、オクタメチルシクロテトラシロキサン等が挙げられる。これらの有機ケイ素化合物の中でも、成膜での取扱い及び得られるガスバリアー層のガスバリアー性等の特性の観点から、ヘキサメチルジシロキサン、１,１,３,３−テトラメチルジシロキサンが好ましい。また、これらの有機ケイ素化合物は、１種を単独で又は２種以上を組み合わせて使用することができる。

<Raw gas>
The source gas in the film forming gas used for forming the gas barrier layer according to the present invention can be appropriately selected and used depending on the material of the gas barrier layer to be formed. As such a source gas, for example, an organosilicon compound containing silicon is preferably used. Examples of such organosilicon compounds include hexamethyldisiloxane, 1,1,3,3-tetramethyldisiloxane, vinyltrimethylsilane, methyltrimethylsilane, hexamethyldisilane, methylsilane, dimethylsilane, trimethylsilane, diethyl Examples thereof include silane, propylsilane, phenylsilane, vinyltriethoxysilane, vinyltrimethoxysilane, tetramethoxysilane, tetraethoxysilane, phenyltrimethoxysilane, methyltriethoxysilane, and octamethylcyclotetrasiloxane. Among these organosilicon compounds, hexamethyldisiloxane and 1,1,3,3-tetramethyldisiloxane are preferable from the viewpoints of characteristics such as gas barrier properties of the obtained gas barrier layer and handling in film formation. Moreover, these organosilicon compounds can be used individually by 1 type or in combination of 2 or more types.

  In addition to the source gas, a reactive gas may be used as the film forming gas. As such a reactive gas, a gas that reacts with the raw material gas to become an inorganic compound such as an oxide or a nitride can be appropriately selected and used. As a reaction gas for forming an oxide, for example, oxygen or ozone can be used. Moreover, as a reactive gas for forming nitride, nitrogen and ammonia can be used, for example. These reaction gases can be used singly or in combination of two or more. For example, when forming an oxynitride, the reaction gas for forming an oxide and a nitride are formed. Can be used in combination with the reaction gas for

  As the film forming gas, a carrier gas may be used as necessary to supply the source gas into the vacuum chamber. Further, as the film forming gas, a discharge gas may be used as necessary in order to generate plasma discharge. As such carrier gas and discharge gas, known ones can be used as appropriate, for example, rare gases such as helium, argon, neon, xenon, etc .; hydrogen can be used.

  When such a film-forming gas contains a source gas and a reactive gas, the ratio of the source gas and the reactive gas is the reaction gas that is theoretically necessary for completely reacting the source gas and the reactive gas. It is preferable not to make the ratio of the reaction gas excessive rather than the ratio of the amount. If the ratio of the reaction gas is excessive, it is difficult to obtain the gas barrier layer of the present invention. Therefore, in order to obtain the desired performance as a barrier film, when the film-forming gas contains the organosilicon compound and oxygen, the total amount of the organosilicon compound in the film-forming gas is completely reduced. It is preferable that the amount of oxygen be less than or equal to the theoretical oxygen amount necessary for oxidation.

Hereinafter, hexamethyldisiloxane (organosilicon compound: HMDSO: (CH ₃ ) ₆ Si ₂ O :) as a source gas and oxygen (O ₂ ) as a reaction gas will be described as representative examples.

A film-forming gas containing hexamethyldisiloxane (HMDSO, (CH ₃ ) ₆ Si ₂ O) as a source gas and oxygen (O ₂ ) as a reaction gas is reacted by a plasma CVD method to form a silicon-oxygen system In the case of producing a thin film of the following reaction formula (1):
(CH ₃ ) ₆ Si ₂ O + 12O ₂ → 6CO ₂ + 9H ₂ O + 2SiO ₂ (1)
The reaction shown by follows occurs to produce silicon dioxide. In such a reaction, the amount of oxygen required to completely oxidize 1 mol of hexamethyldisiloxane is 12 mol. Therefore, when the film forming gas contains 12 moles or more of oxygen with respect to 1 mole of hexamethyldisiloxane and is completely reacted, a uniform silicon dioxide film is formed. The ratio is controlled to a flow rate equal to or less than the raw material ratio of the complete reaction, which is the theoretical ratio, and the incomplete reaction is performed. That is, the amount of oxygen must be less than the stoichiometric ratio of 12 moles per mole of hexamethyldisiloxane.

In the actual reaction in the plasma CVD chamber, the raw material hexamethyldisiloxane and the reaction gas oxygen are supplied from the gas supply port to the film formation region to form a film, so that the molar amount of oxygen in the reaction gas ( Even if the flow rate is 12 times the molar amount (flow rate) of hexamethyldisiloxane as the raw material, the reaction cannot actually proceed completely. It is considered that the reaction is completed only when a large excess is supplied as compared with the stoichiometric ratio (for example, in order to obtain silicon oxide by complete oxidation by the CVD method, the molar amount (flow rate) of oxygen is changed to the hexamethyldioxide raw material. (It may be about 20 times or more the molar amount (flow rate) of siloxane.) Therefore, the molar amount (flow rate) of oxygen with respect to the molar amount (flow rate) of the raw material hexamethyldisiloxane is preferably an amount of 12 times or less (more preferably 10 times or less) which is the stoichiometric ratio. . By containing hexamethyldisiloxane and oxygen in such a ratio, carbon atoms and hydrogen atoms in hexamethyldisiloxane that have not been completely oxidized are taken into the gas barrier layer to form a desired gas barrier layer. This makes it possible to exhibit excellent barrier properties and flex resistance in the resulting gas barrier film. If the molar amount (flow rate) of oxygen with respect to the molar amount (flow rate) of hexamethyldisiloxane in the film forming gas is too small, unoxidized carbon atoms and hydrogen atoms are excessively taken into the gas barrier layer. In this case, the transparency of the barrier film is lowered, and the barrier film cannot be used for a flexible substrate for a device requiring transparency, such as an organic EL device or an organic thin film solar cell. From such a viewpoint, the lower limit of the molar amount (flow rate) of oxygen relative to the molar amount (flow rate) of hexamethyldisiloxane in the film forming gas is more than 0.1 times the molar amount (flow rate) of hexamethyldisiloxane. Preferably, the amount is more than 0.5 times.
<Degree of vacuum>
Although the pressure (degree of vacuum) in a vacuum chamber can be suitably adjusted according to the kind etc. of source gas, it is preferable to set it as the range of 0.5 Pa-100 Pa.

<Roller film formation>
In such a plasma CVD method, in order to discharge between the film forming rollers 31 and 32, an electrode drum connected to the plasma generating power source 51 (in this embodiment, the electrode drums are installed on the film forming rollers 31 and 32). The electric power to be applied can be adjusted as appropriate according to the type of source gas, the pressure in the vacuum chamber, etc., and cannot be generally stated, but may be in the range of 0.1 to 10 kW. preferable. If the applied power is in such a range, no generation of particles is observed, and the amount of heat generated during film formation is within the control. There is no generation of wrinkles during film formation. In addition, the possibility that the resin base material is melted by heat and a large current discharge is generated between the bare film forming rollers to damage the film forming roller itself.

  Although the conveyance speed (line speed) of the resin base material 1 can be suitably adjusted according to the kind of raw material gas, the pressure in a vacuum chamber, etc., it is preferable to set it as the range of 0.25-100 m / min, A range of 0.5 to 20 m / min is more preferable. When the line speed is within the above range, wrinkles due to the heat of the resin base material are hardly generated, and the thickness of the formed gas barrier layer can be sufficiently controlled.

<Smooth layer>
The smooth layer 2 used in the present invention is a layer containing a carbon-containing polymer, preferably between the base material and the gas barrier layer. The surface of the base material 1 is flattened and minute protrusions on the surface of the base material 1 are obtained. In addition to having the function of preventing irregularities and pinholes from being generated on the gas barrier layer 3 formed on the substrate 1 by means of, etc., the function to improve the adhesion between each layer, the flexibility and the flexibility It is a layer that contributes to

  The smooth layer 2 is a layer containing a polymer containing carbon, and is a layer made of a resin composition mainly composed of a (meth) acrylate having a phosphate ester group and a polyfunctional (meth) acrylate. preferable.

  In particular, when the mass mixing ratio of (meth) acrylate (A) having a phosphate ester group and polyfunctional (meth) acrylate (B) is A / B, the ratio A / B is 3/100 to 30/100. It is preferable that it is the range of these.

<Multifunctional (meth) acrylate>
The polyfunctional (meth) acrylate used in the present invention is mainly polyfunctional (generally bifunctional or higher) acrylate and methacrylate (hereinafter referred to as (meth) acrylic acid, (meth) acrylate, acrylic acid and / or methacrylic acid). Acrylate and / or methacrylate) can be used, but two or more polyfunctional (meth) acrylates or resins having an unsaturated group with a low functional group number can be used in combination.

  Examples of the polyfunctional acrylate include 1,4-butanediol diacrylate, 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, polyethylene glycol diacrylate, hydroxypivalate neopentyl glycol diacrylate, and dicyclopentanyl. Diacrylate, caprolactone-modified dicyclopentenyl diacrylate, ethylene oxide-modified phosphate diacrylate, allylated cyclohexyl diacrylate, isocyanurate diacrylate, trimethylolpropane triacrylate, dipentaerythritol triacrylate, propionic acid-modified dipentaerythritol triacrylate, Pentaerythritol triacrylate, propylene oxide modified trimethylol proppant Acrylate, tris (acryloxyethyl) isocyanurate, dipentaerythritol pentaacrylate, propionic acid modified dipentaerythritol pentaacrylate, dipentaerythritol hexaacrylate, caprolactone modified dipentaerythritol hexaacrylate, and commercially available urethane acrylate and melamine acrylate An acrylate having a larger number of functional groups is preferable because it has a higher surface hardness. You may use these individually or in mixture of 2 or more types. These acrylates may be monomers or prepolymers.

  Examples of the polyfunctional methacrylate include ethylene glycol dimethacrylate, triethylene glycol dimethacrylate, 1.4-butanediol dimethacrylate, neopentyl glycol dimethacrylate, 1.6-hexanediol dimethacrylate, 1.9-nonane. Examples include diol dimethacrylate, 1.10-decanediol dimethacrylate, glycerin dimethacrylate, dimethylol-tricyclodecane dimethacrylate, trimethylolpropane trimethacrylate, ethoxylated trimethylolpropane trimethacrylate, and the like alone or in combination. May be used in combination.

  Moreover, as a polyfunctional methacrylate used for this invention, the methacrylate compound which has 2 or 3 methacryloyl groups is preferable, and the methacrylate compound which has 3 methacryloyl groups is more preferable at the point which is excellent in interlayer adhesiveness.

  Moreover, as the polyfunctional (meth) acrylate used in the present invention, a (meth) acrylate oligomer containing a benzyl group can be preferably used.

  A benzyl group-containing (meth) acrylate oligomer is a compound having a benzyl group and a (meth) acryloyl group. As an example of the production method, a method of synthesizing by reacting a benzyl group-containing polyol, an isocyanate compound, and a hydroxy group-containing (meth) acrylate compound in the absence of a solvent or in an organic solvent can be mentioned.

  Examples of the benzyl group-containing polyol include acryl group-containing acrylic polyols, polyester polyols, and polycarbonate polyols. Examples of commercially available products include Q182 (trade name) manufactured by Mitsui Chemicals. Two or more benzyl group-containing polyols may be used in combination.

  An isocyanate compound is a compound having two or more isocyanate groups. Examples of the isocyanate monomer include tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, isophorone diisocyanate, hexamethylene diisocyanate, and the like. The organic polyisocyanate includes adduct type, isocyanurate type, burette type polyisocyanate synthesized from isocyanate monomer. Two or more isocyanate compounds may be used in combination.

  A hydroxy group-containing (meth) acrylate compound is a compound having a hydroxy group and a (meth) acryloyl group. Specific examples include 2-hydroxy-3-phenoxypropyl acrylate, isocyanuric acid ethylene oxide-modified diacrylate, and pentaerythritol triacrylate. Two or more hydroxy group-containing (meth) acrylate compounds may be used in combination.

  Specific examples of the method for synthesizing a benzyl group-containing (meth) acrylate oligomer from the above-described benzyl group-containing polyol, isocyanate compound, and hydroxy group-containing (meth) acrylate compound include no isocyanate compound and hydroxy group-containing (meth) acrylate compound. In a solvent or an organic solvent, a reaction may be performed until an isocyanate group peak is halved by infrared absorption analysis, and then a benzyl group-containing polyol is added to react until the isocyanate group peak disappears.

  Further, as the polyfunctional (meth) acrylate used in the present invention, those containing both a methacrylate compound having 2 or 3 methacryloyl groups and a benzyl group-containing acrylate oligomer are more preferably used.

  The blending amount of the methacrylate compound having 2 or 3 methacryloyl groups is preferably 0.5 to 50 parts by mass with respect to 100 parts by mass of the benzyl group-containing (meth) acrylate oligomer based on the solid content. In particular, 1 to 30 parts by mass is preferably blended.

<(Meth) acrylate having a phosphate group>
Examples of the (meth) acrylate having a phosphate group used in the present invention include 2- (meth) acryloyloxyethyl) -dihydrophosphate, di- (2- (meth) acryloyloxy) hydrogen phosphate, dipentaerythritol penta ( And (meth) acryloyloxydihydrogen phosphate. In the component, the adhesiveness of the smooth layer to the substrate is improved by the reactivity derived from the phosphate group.

  The (meth) acrylate having a phosphate ester group is preferably blended in an amount of 1 to 30 parts by weight, particularly preferably 3 to 20 parts by weight, based on 100 parts by weight of the polyfunctional (meth) acrylate. . If it is less than 1 part by mass, it does not contribute to the effect of improving the adhesion, and if it exceeds 30 parts by mass, the ester group tends to be hydrolyzed and the water resistance is lowered.

<solvent>
Especially as a solvent used for the coating liquid for forming the smooth layer 2, and used for the coating liquid containing the resin composition which has (meth) acrylate which has a phosphate ester group, and a polyfunctional (meth) acrylate as a main component Although not mentioned, water, alcohol solvents, aromatic hydrocarbon solvents, ether solvents, ketone solvents, ester solvents and the like can be mentioned.

  Examples of alcohol solvents include methanol, ethanol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, tert-butyl alcohol, n-hexyl alcohol, n-octyl alcohol, ethylene glycol, diethylene glycol, and triethylene. Examples include glycol, ethylene glycol monobutyl ether, ethylene glycol monoethyl ether acetate, diethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene monomethyl ether acetate, diacetone alcohol, methyl cellosolve, ethyl cellosolve, propyl cellosolve, and butyl cellosolve.

  Examples of the aromatic hydrocarbon solvent include toluene and xylene.

  Examples of ether solvents include tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and the like.

  Examples of the ketone solvent include cyclohexanone, acetone, methyl ethyl ketone, and methyl isobutyl ketone.

  Examples of the ester solvent include methyl acetate, ethyl acetate, ethoxyethyl acetate and the like.

  In addition to these, solvents such as dichloroethane and acetic acid may be used. These solvents can be used alone or in admixture of two or more.

  The coating liquid for forming the smooth layer preferably contains inorganic fine particles. The inorganic fine particles can suppress curing shrinkage of the coating film and improve the adhesion of the smooth layer to the substrate.

  In order not to lower the transparency of the smooth layer, the primary particle diameter of the inorganic fine particles is preferably less than 100 nm, and particularly preferably less than 50 nm. When the particle diameter exceeds 100 nm, light scattering occurs, and transparency is lowered due to a decrease in transmittance, which is not preferable.

  Inorganic fine particles include silica fine particles such as dry silica and wet silica, metal oxide fine particles such as titanium oxide, zirconium oxide, zinc oxide, tin oxide, cerium oxide, antimony oxide, indium tin mixed oxide and antimony tin mixed oxide. In particular, organic fine particles such as acrylic and styrene are exemplified, and nanodispersed silica fine particles in which silica fine particles of 10 to 50 nm are dispersed in an organic solvent are particularly preferable from the viewpoint of transparency and hardness.

  The inorganic fine particles are preferably blended in an amount of 5 to 50 parts by mass, particularly 10 to 40 parts by mass with respect to 100 parts by mass of the (meth) acrylate having a phosphate ester group and the polyfunctional (meth) acrylate. It is preferable to be blended. If the amount is less than 5 parts by mass, the effect of suppressing the curing shrinkage of the coating film is low and does not contribute to the improvement of adhesion. If it exceeds 50 parts by mass, the total amount of (meth) acrylate and polyfunctional (meth) acrylate having a phosphate ester group in the coating film will decrease, and the adhesion to the substrate and the hardness of the smooth layer will decrease. .

  Moreover, a photopolymerization initiator is blended in the coating liquid for forming the smooth layer in order to cure the resin composition with ultraviolet rays.

  Examples of the photopolymerization initiator include acetophenone, 2,2-diethoxyacetophenone, p-dimethylacetophenone, p-dimethylaminopropiophenone, benzophenone, 2-chlorobenzophenone, benzyl, benzoin, benzoin methyl ether, benzoin ethyl ether, Carbonyl compounds such as benzoin isopropyl ether, sulfur compounds such as thioxanthone, 2-chlorothioxanthone, 2-methylthioxanthone, and tetramethylthiuram disulfide can be used.

  Commercially available products of these photopolymerization initiators include Irgacure 184, 369, 651, 500 (trade name, manufactured by BASF Japan), Lucirin LR8728 (trade name, manufactured by BASF Japan), Darocur 1116, 1173 (trade name, manufactured by Merck), Ubekrill. P36 (trade name manufactured by UCB) and the like.

  The method for applying the coating solution for forming the smooth layer onto the substrate 1 is not particularly limited, and is known spray coating, dipping coating, roll coating, die coating, air knife coating, blade coating, spin coating, reverse coating, gravure. It can be formed by a coating method such as coating or wire bar, or a printing method such as gravure printing, screen printing, offset printing, or ink jet printing.

  The thickness of the smooth layer 2 is preferably in the range of 1 to 20 μm. It is preferable that the thickness of the smooth layer 2 be in the above range since the hardness is sufficient and cracks are not generated.

  Further, the smooth layer 2 may be provided with flexibility by blending an acrylic resin, a urethane resin, a styrene resin, a phenol resin, or a melamine resin as necessary. Further, the smooth layer 2 includes barium hydroxide, magnesium hydroxide, aluminum hydroxide, silicon oxide, titanium oxide, calcium sulfate, barium sulfate, calcium carbonate, basic zinc carbonate, basic lead carbonate, silica sand, clay, talc, In addition to inorganic fillers such as silica compounds and titanium dioxide, coupling agents such as silanes and titanates, bactericides, preservatives, plasticizers, flow regulators, antistatic agents, thickeners, pH adjusters, interfaces You may add compounding materials, such as an activator, a leveling regulator, an antifoamer, a color pigment, and a rust preventive pigment. Moreover, you may add antioxidant and a ultraviolet absorber for the purpose of light resistance improvement.

<Second gas barrier layer>
In the present invention, a coating film of a coating-type polysilazane-containing liquid is provided on the gas barrier layer according to the present invention, and it is formed by irradiating with vacuum ultraviolet light (VUV light) having a wavelength of 200 nm or less. It is preferable to provide a second gas barrier layer. By providing the second gas barrier layer on the gas barrier layer provided by the CVD method, minute defects remaining in the gas barrier layer can be filled with the gas barrier component of polysilazane from above, and further gas Since the barrier property and the flexibility can be improved, it is preferable.
The thickness of the second gas barrier layer is preferably in the range of 1 nm to 500 nm, more preferably in the range of 10 nm to 300 nm. If it is thinner than 1 nm, gas barrier performance cannot be exhibited, and if it is thicker than 500 nm, cracks are likely to occur in a dense silicon oxynitride film.

<Polysilazane>
The “polysilazane” according to the present invention is a polymer having a silicon-nitrogen bond in the structure and is a polymer that is a precursor of silicon oxynitride, and those having the following structure are preferably used.

式中、Ｒ_１、Ｒ_２、Ｒ_３は、各々水素原子、アルキル基、アルケニル基、シクロアルキル基、アリール基、アルキルシリル基、アルキルアミノ基、又はアルコキシ基を表す。

In the formula, each of R ₁ , R ₂ , and R ₃ represents a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, an aryl group, an alkylsilyl group, an alkylamino group, or an alkoxy group.

In the present invention, perhydropolysilazane in which all of R ₁ , R ₂ and R ₃ are hydrogen atoms is particularly preferable from the viewpoint of the denseness as a film of the obtained gas barrier layer.

  Perhydropolysilazane is presumed to have a linear structure and a ring structure centered on a 6-membered ring and an 8-membered ring. Its molecular weight is about 600 to 2000 in terms of number average molecular weight (Mn) (gel Polystyrene conversion by permeation chromatography), which is a liquid or solid substance.

  Polysilazane is commercially available in the form of a solution dissolved in an organic solvent, and a commercially available product can be used as it is as a polysilazane-containing coating solution. Examples of commercially available polysilazane solutions include NN120-20, NAX120-20, and NL120-20 manufactured by AZ Electronic Materials Co., Ltd.

  The second gas barrier layer can be formed by applying a coating liquid containing polysilazane on the gas barrier layer formed by the CVD method and drying it, followed by irradiation with vacuum ultraviolet rays.

  As an organic solvent for preparing a coating liquid containing polysilazane, it is preferable to avoid using an alcohol or water-containing one that easily reacts with polysilazane. For example, hydrocarbon solvents such as aliphatic hydrocarbons, alicyclic hydrocarbons, aromatic hydrocarbons, halogenated hydrocarbon solvents, aliphatic ethers, ethers such as alicyclic ethers can be used, specifically, There are hydrocarbons such as pentane, hexane, cyclohexane, toluene, xylene, solvesso and turben, halogen hydrocarbons such as methylene chloride and trichloroethane, ethers such as dibutyl ether, dioxane and tetrahydrofuran. These organic solvents may be selected according to purposes such as the solubility of polysilazane and the evaporation rate of the solvent, and a plurality of organic solvents may be mixed.

  The concentration of polysilazane in the coating solution containing polysilazane varies depending on the thickness of the gas barrier layer and the pot life of the coating solution, but is preferably about 0.2 to 35% by mass.

  In order to promote the modification to silicon oxynitride, the coating solution is coated with a metal catalyst such as an amine catalyst, a Pt compound such as Pt acetylacetonate, a Pd compound such as propionic acid Pd, or an Rh compound such as Rh acetylacetonate. It can also be added. In the present invention, it is particularly preferable to use an amine catalyst. Specific amine catalysts include N, N-diethylethanolamine, N, N-dimethylethanolamine, triethanolamine, triethylamine, 3-morpholinopropylamine, N, N, N ′, N′-tetramethyl-1 , 3-diaminopropane, N, N, N ′, N′-tetramethyl-1,6-diaminohexane and the like.

  The amount of these catalysts added to the polysilazane is preferably in the range of 0.1 to 10% by mass, more preferably in the range of 0.2 to 5% by mass, and 0.5 to More preferably, it is in the range of 2% by mass. By setting the addition amount of the catalyst within this range, it is possible to avoid excessive silanol formation due to rapid progress of the reaction, reduction in film density, increase in film defects, and the like.

  Any appropriate method can be adopted as a method of applying the coating liquid containing polysilazane. Specific examples include a roll coating method, a flow coating method, an ink jet method, a spray coating method, a printing method, a dip coating method, a cast film forming method, a bar coating method, and a gravure printing method.

  The thickness of the coating film can be appropriately set according to the purpose. For example, the thickness of the coating film is preferably in the range of 50 nm to 2 μm, more preferably in the range of 70 nm to 1.5 μm, and more preferably in the range of 100 nm to 1 μm as the thickness after drying. More preferably.

<Excimer treatment>
In the second gas barrier layer used in the present invention, at least a part of the polysilazane is modified into silicon oxynitride in the step of irradiating the layer containing polysilazane with vacuum ultraviolet rays.

Here, the presumed mechanism in which the coating film containing polysilazane is modified in the vacuum ultraviolet irradiation step and becomes a specific composition of SiO _x N _y will be described by taking perhydropolysilazane as an example.

Perhydropolysilazane can be represented by a composition of “— (SiH ₂ —NH) _n —”. In the case of SiO _x N _y , x = 0 and y = 1. An external oxygen source is required to achieve x> 0. This is because (i) oxygen and moisture contained in the polysilazane coating solution, and (ii) oxygen taken into the coating film from the atmosphere during the coating and drying process. As an outgas from the substrate side by (iii) oxygen, moisture, ozone, singlet oxygen taken into the coating film from the atmosphere in the vacuum ultraviolet irradiation process, (iv) heat applied in the vacuum ultraviolet irradiation process, etc. Oxygen and moisture moving into the coating film, (v) When the vacuum ultraviolet irradiation process is performed in a non-oxidizing atmosphere, when moving from the non-oxidizing atmosphere to the oxidizing atmosphere, Oxygen, moisture, etc. taken into the coating film become oxygen sources.

  On the other hand, for y, the condition under which nitriding proceeds rather than the oxidation of Si is considered to be very special, so basically 1 is the upper limit.

  Also, from the relationship of Si, O, and N bond, x and y are basically in the range of 2x + 3y ≦ 4. In the state of y = 0 where the oxidation has progressed completely, the coating film contains silanol groups, and there are cases where 2 <x <2.5.

  The reaction mechanism presumed to produce silicon oxynitride and further silicon oxide from perhydropolysilazane in the vacuum ultraviolet irradiation step will be described below.

(1) Dehydrogenation and associated Si—N bond formation Si—H bonds and N—H bonds in perhydropolysilazane are relatively easily cleaved by excitation by vacuum ultraviolet irradiation, etc., and in an inert atmosphere, Si— It is considered that they are recombined as N (a dangling bond of Si may be formed). That is, the cured as SiN _y composition without oxidizing. In this case, the polymer main chain is not broken. The breaking of Si—H bonds and N—H bonds is promoted by the presence of a catalyst and heating. The cut H is released out of the membrane as H ₂ .

(2) Formation of Si—O—Si Bonds by Hydrolysis / Dehydration Condensation Si—N bonds in perhydropolysilazane are hydrolyzed by water, and the polymer main chain is cleaved to form Si—OH. Two Si—OHs are dehydrated and condensed to form Si—O—Si bonds and harden. This is a reaction that occurs in the air, but during vacuum ultraviolet irradiation in an inert atmosphere, water vapor generated as outgas from the base material by the heat of irradiation is considered to be the main moisture source. When the moisture is excessive, Si—OH that cannot be dehydrated and condensed remains, and a cured film having a low gas barrier property represented by a composition of SiO2.1 to 2.3 is obtained.

(3) Direct oxidation by singlet oxygen, formation of Si-O-Si bond When a suitable amount of oxygen is present in the atmosphere during irradiation with vacuum ultraviolet rays, singlet oxygen having a very strong oxidizing power is formed. H or N in the perhydropolysilazane is replaced with O to form a Si—O—Si bond and harden. It is thought that recombination of the bond may occur due to cleavage of the polymer main chain.

(4) Oxidation with Si-N bond cleavage by vacuum ultraviolet irradiation / excitation Since the energy of vacuum ultraviolet light is higher than the bond energy of Si-N in perhydropolysilazane, the Si-N bond is cleaved, and oxygen, It is considered that when an oxygen source such as ozone or water is present, it is oxidized to form a Si—O—Si bond or a Si—O—N bond. It is thought that recombination of the bond may occur due to cleavage of the polymer main chain.

  Adjustment of the composition of the silicon oxynitride of the layer subjected to vacuum ultraviolet irradiation on the layer containing polysilazane can be performed by appropriately controlling the oxidation state by appropriately combining the oxidation mechanisms (1) to (4) described above. .

In vacuum ultraviolet irradiation step in the present invention, it is preferable that the illuminance of the vacuum ultraviolet rays in the coating film surface for receiving the polysilazane coating film is in the range of 30~200mW / cm ^2, in the range of 50~160mW / cm ² It is more preferable. When it is 30 mW / cm ² or more, there is no concern that the reforming efficiency is lowered, and when it is 200 mW / cm ² or less, the coating film is not ablated and the substrate is not damaged.

Irradiation energy amount of the VUV in the polysilazane coating film surface is preferably in the range of 200~10000mJ / cm ^2, and more preferably in the range of 500~5000mJ / cm ^2. 200 mJ / cm ² or more, the performed modification sufficiently, cracking and not excessive modification is 10000 mJ / cm ² or less, there is no thermal deformation of the substrate.

  As the vacuum ultraviolet light source, a rare gas excimer lamp is preferably used. Atoms of noble gases such as Xe, Kr, Ar, and Ne are called inert gases because they are not chemically bonded to form molecules.

However, excited atoms of rare gases that have gained energy by discharge or the like can form molecules by combining with other atoms. When the rare gas is xenon,
e + Xe → Xe ^*
Xe ^* + 2Xe → Xe ₂ ^* + Xe
Xe ₂ ^* → Xe + Xe + hν (172 nm)
Thus, when the excited excimer molecule Xe ₂ ^* transitions to the ground state, excimer light of 172 nm is emitted.

  A feature of the excimer lamp is that the radiation is concentrated on one wavelength, and since only the necessary light is not emitted, the efficiency is high. Further, since no extra light is emitted, the temperature of the object can be kept low. Furthermore, since no time is required for starting and restarting, instantaneous lighting and blinking are possible.

  In order to obtain excimer light emission, a method using dielectric barrier discharge is known. Dielectric barrier discharge is a gas space created by placing a gas space between both electrodes via a dielectric such as transparent quartz and applying a high frequency high voltage of several tens of kHz to the electrode. It is a discharge called a thin micro discharge. When the micro discharge streamer reaches the tube wall (derivative), electric charges accumulate on the dielectric surface, and the micro discharge disappears.

  This micro discharge spreads over the entire tube wall, and is a discharge that is repeatedly generated and disappeared. For this reason, flickering of light that can be confirmed with the naked eye occurs. Moreover, since a very high temperature streamer reaches a pipe wall directly locally, there is a possibility that deterioration of the pipe wall is accelerated.

  As a method for efficiently obtaining excimer light emission, electrodeless electric field discharge is possible in addition to dielectric barrier discharge. Electrodeless electric field discharge by capacitive coupling, also called RF discharge. The lamp and electrodes and their arrangement may be basically the same as those of dielectric barrier discharge, but the high frequency applied between the two electrodes is lit at several MHz. Since the electrodeless field discharge can provide a spatially and temporally uniform discharge in this way, a long-life lamp without flickering can be obtained.

  In the case of dielectric barrier discharge, since micro discharge occurs only between the electrodes, the outer electrode covers the entire outer surface and transmits light to extract light to the outside in order to cause discharge in the entire discharge space. Must be a thing.

  For this reason, an electrode in which a fine metal wire is formed in a net shape is used. Since this electrode uses as thin a line as possible so as not to block light, it is easily damaged by ozone generated by vacuum ultraviolet light in an oxygen atmosphere. In order to prevent this, it is necessary to provide an atmosphere of an inert gas such as nitrogen around the lamp, that is, the inside of the irradiation apparatus, and provide a synthetic quartz window to extract the irradiation light. Synthetic quartz windows are not only expensive consumables, but also cause light loss.

  Since the double cylindrical lamp has an outer diameter of about 25 mm, the difference in distance to the irradiation surface cannot be ignored between the position directly below the lamp axis and the side surface of the lamp, resulting in a large difference in illuminance. Therefore, even if the lamps are closely arranged, a uniform illuminance distribution cannot be obtained. If the irradiation device is provided with a synthetic quartz window, the distance in the oxygen atmosphere can be made uniform, and a uniform illuminance distribution can be obtained.

  When electrodeless field discharge is used, it is not necessary to make the external electrodes mesh. The glow discharge spreads over the entire discharge space simply by providing an external electrode on a part of the lamp outer surface. As the external electrode, an electrode that also serves as a light reflector made of an aluminum block is usually used on the back of the lamp. However, since the outer diameter of the lamp is as large as in the case of the dielectric barrier discharge, synthetic quartz is required to obtain a uniform illuminance distribution.

  The biggest feature of the capillary excimer lamp is its simple structure. The quartz tube is closed at both ends, and only gas for excimer light emission is sealed inside.

  The outer diameter of the tube of the thin tube lamp is about 6 nm to 12 mm, and if it is too thick, a high voltage is required for starting.

  As the form of discharge, both dielectric barrier discharge and electrodeless field discharge can be used. The electrode may have a flat surface in contact with the lamp, but if the shape is matched to the curved surface of the lamp, the lamp can be firmly fixed, and the discharge is more stable when the electrode is in close contact with the lamp. Also, if the curved surface is made into a mirror surface with aluminum, it also becomes a light reflector.

  The Xe excimer lamp emits ultraviolet light having a short wavelength of 172 nm at a single wavelength, and thus has excellent luminous efficiency. Since this light has a large oxygen absorption coefficient, it can generate radical oxygen atom species and ozone at a high concentration with a very small amount of oxygen.

  Moreover, it is known that the energy of light having a short wavelength of 172 nm has a high ability to dissociate organic bonds. Due to the high energy of the active oxygen, ozone and ultraviolet radiation, the polysilazane layer can be modified in a short time.

  Therefore, compared with low-pressure mercury lamps with wavelengths of 185 nm and 254 nm and plasma cleaning, it is possible to shorten the process time associated with high throughput, reduce the equipment area, and irradiate organic materials and plastic substrates that are easily damaged by heat. .

  Since the excimer lamp has high light generation efficiency, it can be turned on with low power. In addition, light having a long wavelength that causes a temperature increase due to light is not emitted, and energy is irradiated in the ultraviolet region, that is, in a short wavelength, so that the increase in the surface temperature of the target object is suppressed. For this reason, it is suitable for flexible film materials such as PET that are easily affected by heat.

  Oxygen is required for the reaction at the time of ultraviolet irradiation, but since vacuum ultraviolet rays are absorbed by oxygen, the efficiency in the ultraviolet irradiation process tends to decrease. It is preferable to carry out in a low state. That is, the oxygen concentration during vacuum ultraviolet irradiation is preferably in the range of 10 to 10000 ppm, more preferably in the range of 50 to 5000 ppm, and still more preferably in the range of 1000 to 4500 ppm.

  As a gas that satisfies the irradiation atmosphere used at the time of irradiation with vacuum ultraviolet rays, a dry inert gas is preferable, and a dry nitrogen gas is particularly preferable from the viewpoint of cost. The oxygen concentration can be adjusted by measuring the flow rate of oxygen gas and inert gas introduced into the irradiation chamber and changing the flow rate ratio.

<Overcoat layer>
An overcoat layer may be formed on the second gas barrier layer used in the present invention in order to further improve the flexibility. As the organic substance used for the overcoat layer, an organic resin such as an organic monomer, oligomer or polymer, or an organic-inorganic composite resin layer using a siloxane or silsesquioxane monomer, oligomer or polymer having an organic group is preferably used. Can do. These organic resins or organic-inorganic composite resins preferably have a polymerizable group or a crosslinkable group, contain these organic resins or organic-inorganic composite resins, and contain a polymerization initiator, a crosslinking agent, etc. as necessary. It is preferable to apply a light irradiation treatment or a heat treatment to the layer formed by coating from the organic resin composition coating solution to be cured.

<Electronic device>
The gas barrier film of the present invention is preferably used as a film for an organic element device, and particularly preferably used for an in-vehicle organic element device. Examples of the organic element device include an organic electroluminescence element (hereinafter abbreviated as an organic EL element), an organic photoelectric conversion element, and a liquid crystal element.

<Organic EL panel as an electronic device>
The gas barrier film 1a (1b) of the present invention can be used as a sealing film for sealing solar cells, liquid crystal display elements, organic EL elements and the like.

  An example of an organic EL panel (EL) which is an electronic device using the gas barrier film 1a as a sealing film is shown in FIG.

  As shown in FIG. 9, the organic EL panel (EL) has a gas barrier film 1 a, a transparent electrode 6 such as ITO formed on the gas barrier film 1 a, and a gas barrier film 1 a via the transparent electrode 6. An organic EL element 7 which is the formed electronic device main body, and a counter film 9 disposed via an adhesive layer 8 so as to cover the organic EL element 7 are provided. The transparent electrode 6 may form part of the organic EL element 7.

  A transparent electrode 6 and an organic EL element 7 are formed on the surface of the gas barrier film 1a on the gas barrier layer 3 side.

  In the organic EL panel (EL), the organic EL element 7 is suitably sealed so as not to be exposed to water vapor, and the organic EL element 7 is hardly deteriorated, so that the organic EL panel (EL) is lengthened. It becomes possible to use, and the lifetime of the organic EL panel P is extended.

  The counter film 9 may be a gas barrier film according to the present invention in addition to a metal film such as an aluminum foil. When a gas barrier film is used as the counter film 9, the surface on which the gas barrier layer 3 is formed may be attached to the organic EL element 7 with the adhesive layer 8.

<Organic EL device>
The organic EL element 7 sealed with the gas barrier film 1a in the organic EL panel P will be described.

  Although the preferable specific example of the layer structure of the organic EL element 7 is shown below, this invention is not limited to these.

(1) Anode / light emitting layer / cathode (2) Anode / hole transport layer / light emitting layer / cathode (3) Anode / light emitting layer / electron transport layer / cathode (4) Anode / hole transport layer / light emitting layer / electron Transport layer / cathode (5) Anode / anode buffer layer (hole injection layer) / hole transport layer / light emitting layer / electron transport layer / cathode buffer layer (electron injection layer) / cathode (anode)
As the anode (transparent electrode 6) in the organic EL element 7, an electrode material made of a metal, an alloy, an electrically conductive compound or a mixture thereof having a high work function (4 eV or more) is preferably used. Specific examples of such electrode materials include metals such as Au, and conductive transparent materials such as CuI, indium tin oxide (ITO), SnO ₂ , and ZnO. Alternatively, an amorphous material such as IDIXO (In ₂ O ₃ —ZnO) capable of forming a transparent conductive film may be used.

  The anode may be formed by depositing these electrode materials as a thin film by a method such as vapor deposition or sputtering, and the thin film may be formed into a pattern having a desired shape by a photolithography method. The pattern may be formed through a mask having a desired shape when the electrode material is deposited or sputtered.

  When light emission is taken out from the anode, it is desirable that the transmittance be larger than 10%. The sheet resistance as the anode is preferably several hundred Ω / □ or less. Moreover, although the film thickness of an anode is based also on material, it is normally selected in the range of 10-1000 nm, Preferably it is the range of 10-200 nm.

(cathode)
As the cathode in the organic EL element 7, a material having a low work function (4 eV or less) metal (referred to as an electron injecting metal), an alloy, an electrically conductive compound, and a mixture thereof as an electrode material is used. Specific examples of such electrode materials include sodium, sodium-potassium alloy, magnesium, lithium, magnesium / copper mixture, magnesium / silver mixture, magnesium / aluminum mixture, magnesium / indium mixture, aluminum / aluminum oxide (Al ₂ O ₃ ) Mixtures, indium, lithium / aluminum mixtures, rare earth metals and the like. Among these, from the point of durability against electron injection and oxidation, etc., a mixture of an electron injecting metal and a second metal which is a stable metal having a larger work function than this, for example, a magnesium / silver mixture, Magnesium / aluminum mixtures, magnesium / indium mixtures, aluminum / aluminum oxide (Al ₂ O ₃ ) mixtures, lithium / aluminum mixtures, aluminum and the like are suitable as the cathode.

  The cathode can be produced by forming a thin film of these electrode materials by a method such as vapor deposition or sputtering. The sheet resistance as a cathode is preferably several hundred Ω / □ or less. The film thickness of the cathode is usually selected in the range of 10 nm to 5 μm, preferably in the range of 50 to 200 nm. In order to transmit the emitted light, if either one of the anode or the cathode of the organic EL element 7 is transparent or translucent, the light emission luminance is improved, which is convenient.

  Moreover, after producing the metal mentioned in the description of the cathode with a film thickness in the range of 1 to 20 nm, a transparent transparent or semi-transparent cathode is produced by producing the conductive transparent material mentioned in the explanation of the anode on the metal. By applying this, an element in which both the anode and the cathode are transmissive can be manufactured.

(Injection layer: electron injection layer, hole injection layer)
The injection layer includes an electron injection layer and a hole injection layer, and an electron injection layer and a hole injection layer are provided as necessary, between the anode and the light emitting layer or the hole transport layer, and between the cathode and the light emitting layer or the electron transport. Exist between the layers.

  An injection layer is a layer provided between an electrode and an organic layer in order to reduce drive voltage and improve light emission luminance. “Organic EL element and its forefront of industrialization (issued by NTT Corporation on November 30, 1998) 2), Chapter 2, “Electrode Materials” (pages 123 to 166) in detail, and includes a hole injection layer (anode buffer layer) and an electron injection layer (cathode buffer layer).

  The details of the anode buffer layer (hole injection layer) are also described in JP-A-9-45479, JP-A-9-260062, JP-A-8-288069, and the like. Examples thereof include a phthalocyanine buffer layer typified by phthalocyanine, an oxide buffer layer typified by vanadium oxide, an amorphous carbon buffer layer, and a polymer buffer layer using a conductive polymer such as polyaniline (emeraldine) or polythiophene.

  Details of the cathode buffer layer (electron injection layer) are described in JP-A-6-325871, JP-A-9-17574, JP-A-10-74586, and the like. Specifically, strontium Metal buffer layer typified by aluminum and aluminum, alkali metal compound buffer layer typified by lithium fluoride, alkaline earth metal compound buffer layer typified by magnesium fluoride, oxide buffer layer typified by aluminum oxide, etc. Is mentioned. The buffer layer (injection layer) is preferably a very thin film, and the film thickness is preferably in the range of 0.1 nm to 5 μm, although depending on the material.

(Light emitting layer)
The light-emitting layer in the organic EL element 7 is a layer that emits light by recombination of electrons and holes injected from the electrode (cathode, anode) or electron transport layer or hole transport layer, and the light-emitting portion is the light-emitting layer. The interface between the light emitting layer and the adjacent layer may be used.

  The light emitting layer of the organic EL element 7 preferably contains the following dopant compound (light emitting dopant) and host compound (light emitting host). Thereby, the luminous efficiency can be further increased.

(Luminescent dopant)
There are two types of luminescent dopants: a fluorescent dopant that emits fluorescence and a phosphorescent dopant that emits phosphorescence.

  Representative examples of fluorescent dopants include coumarin dyes, pyran dyes, cyanine dyes, croconium dyes, squalium dyes, oxobenzanthracene dyes, fluorescein dyes, rhodamine dyes, pyrylium dyes, perylene dyes. Stilbene dyes, polythiophene dyes, rare earth complex phosphors, and the like.

  Typical examples of the phosphorescent dopant are preferably complex compounds containing metals of Group 8, Group 9, and Group 10 in the periodic table of elements, more preferably iridium compounds and osmium compounds, and most preferable among them. Is an iridium compound.

  The light emitting dopant may be used by mixing a plurality of kinds of compounds.

(Light emitting host)
A light-emitting host (also simply referred to as a host) means a compound having the largest mixing ratio (mass) in a light-emitting layer composed of two or more compounds. For other compounds, “dopant compound ( Simply referred to as a dopant). " For example, if the light emitting layer is composed of two types of compound A and compound B and the mixing ratio is A: B = 10: 90, compound A is a dopant compound and compound B is a host compound. Further, if the light emitting layer is composed of three types of compound A, compound B and compound C and the mixing ratio is A: B: C = 5: 10: 85, compound A and compound B are dopant compounds, and compound C is a host compound.

  The light emitting host is not particularly limited in terms of structure, but is typically a basic skeleton such as a carbazole derivative, a triarylamine derivative, an aromatic borane derivative, a nitrogen-containing heterocyclic compound, a thiophene derivative, a furan derivative, or an oligoarylene compound. Or a carboline derivative or a diazacarbazole derivative (herein, a diazacarbazole derivative is one in which at least one carbon atom of the hydrocarbon ring constituting the carboline ring of the carboline derivative is substituted with a nitrogen atom) And the like). Of these, carboline derivatives, diazacarbazole derivatives and the like are preferably used.

  The light emitting layer can be formed by depositing the above compound by a known thinning method such as a vacuum deposition method, a spin coating method, a casting method, an LB method, or an ink jet method. Although the film thickness as a light emitting layer does not have a restriction | limiting in particular, Usually, the range of 5 nm-5 micrometers, Preferably it is chosen in the range of 5-200 nm. This light emitting layer may have a single layer structure composed of one or more dopant compounds and host compounds, or may have a multilayer structure composed of a plurality of layers having the same composition or different compositions.

(Hole transport layer)
The hole transport layer is made of a hole transport material having a function of transporting holes, and in a broad sense, a hole injection layer and an electron blocking layer are also included in the hole transport layer. The hole transport layer can be provided as a single layer or a plurality of layers.

  The hole transport material has any of hole injection or transport and electron barrier properties, and may be either organic or inorganic. For example, triazole derivatives, oxadiazole derivatives, imidazole derivatives, polyarylalkane derivatives, pyrazoline derivatives and pyrazolone derivatives, phenylenediamine derivatives, arylamine derivatives, amino-substituted chalcone derivatives, oxazole derivatives, styrylanthracene derivatives, fluorenone derivatives, hydrazone derivatives, Examples thereof include stilbene derivatives, silazane derivatives, aniline copolymers, and conductive polymer oligomers, particularly thiophene oligomers. The above-mentioned materials can be used as the hole transport material, but it is preferable to use a porphyrin compound, an aromatic tertiary amine compound and a styrylamine compound, particularly an aromatic tertiary amine compound. Furthermore, a polymer material in which these materials are introduced into a polymer chain or these materials are used as a polymer main chain can also be used. In addition, inorganic compounds such as p-type-Si and p-type-SiC can also be used as the hole injection material and the hole transport material.

  The hole transport layer can be formed by thinning the hole transport material by a known method such as a vacuum deposition method, a spin coating method, a casting method, a printing method including an ink jet method, or an LB method. it can. Although there is no restriction | limiting in particular about the film thickness of a positive hole transport layer, Usually, about 5 nm-5 micrometers, Preferably it is the range of 5-200 nm. This hole transport layer may have a single layer structure composed of one or more of the above materials.

(Electron transport layer)
The electron transport layer is made of an electron transport material having a function of transporting electrons, and in a broad sense, an electron injection layer and a hole blocking layer are also included in the electron transport layer. The electron transport layer can be provided as a single layer or a plurality of layers.

  The electron transport material only needs to have a function of transmitting electrons injected from the cathode to the light emitting layer, and the material can be selected and used from conventionally known compounds. Examples include nitro-substituted fluorene derivatives, diphenylquinone derivatives, thiopyran dioxide derivatives, carbodiimides, fluorenylidenemethane derivatives, anthraquinodimethane and anthrone derivatives, oxadiazole derivatives, and the like. Furthermore, in the above oxadiazole derivative, a thiadiazole derivative in which the oxygen atom of the oxadiazole ring is substituted with a sulfur atom, and a quinoxaline derivative having a quinoxaline ring known as an electron withdrawing group can also be used as an electron transport material. Furthermore, a polymer material in which these materials are introduced into a polymer chain or these materials are used as a polymer main chain can also be used. In addition, metal complexes of 8-quinolinol derivatives such as tris (8-quinolinol) aluminum (Alq), tris (5,7-dichloro-8-quinolinol) aluminum, tris (5,7-dibromo-8-quinolinol) aluminum Tris (2-methyl-8-quinolinol) aluminum, tris (5-methyl-8-quinolinol) aluminum, bis (8-quinolinol) zinc (Znq), and the like, and the central metals of these metal complexes are In, Mg, Metal complexes replaced with Cu, Ca, Sn, Ga, or Pb can also be used as the electron transport material. In addition, metal-free or metal phthalocyanine, or those having terminal ends substituted with an alkyl group or a sulfonic acid group can be preferably used as the electron transport material. Similarly to the hole injection layer and the hole transport layer, an inorganic semiconductor such as n-type-Si or n-type-SiC can also be used as the electron transport material.

  The electron transport layer can be formed by thinning the electron transport material by a known method such as a vacuum deposition method, a spin coating method, a casting method, a printing method including an ink jet method, or an LB method. Although there is no restriction | limiting in particular about the film thickness of an electron carrying layer, Usually, about 5 nm-5 micrometers, Preferably it is the range of 5-200 nm. The electron transport layer may have a single layer structure composed of one or more of the above materials.

  A method for producing the organic EL element 7 will be described.

  Here, as an example of the organic EL element 7, a method for manufacturing an organic EL element composed of an anode / hole injection layer / hole transport layer / light emitting layer / electron transport layer / electron injection layer / cathode will be described.

  First, a desired electrode material, for example, a thin film made of an anode material is formed on the barrier film 10 so as to have a thickness of 1 μm or less, preferably in the range of 10 to 200 nm. The anode is prepared by the method.

Next, an organic compound thin film of a hole injection layer, a hole transport layer, a light emitting layer, an electron transport layer, and an electron injection layer, which are organic EL element materials, is formed thereon. As a method for forming this organic compound thin film, there are a vapor deposition method, a wet process (spin coating method, casting method, ink jet method, printing method), etc., but a homogeneous film is easily obtained and pinholes are not easily generated. From the point of view, the vacuum deposition method, the spin coating method, the ink jet method and the printing method are particularly preferable. Further, different film forming methods may be applied for each layer. When a vapor deposition method is employed for film formation, the vapor deposition conditions vary depending on the type of compound used, but generally a boat heating temperature range of 50 to 450 ° C., a vacuum degree of 10 ⁻⁶ to 10 ⁻² Pa, a vapor deposition rate. It is desirable to select appropriately in the range of 0.01 to 50 nm / second, the substrate temperature in the range of −50 to 300 ° C., the film thickness in the range of 0.1 nm to 5 μm, and preferably in the range of 5 to 200 nm.

  After these layers are formed, a thin film made of a cathode material is formed thereon by a method such as vapor deposition or sputtering so as to have a thickness of 1 μm or less, preferably in the range of 50 to 200 nm, and a cathode is provided. Thus, a desired organic EL element can be obtained.

  The organic EL element 7 is preferably manufactured from the anode and the hole injection layer to the cathode consistently by a single evacuation, but may be taken out halfway and subjected to different film forming methods. At that time, it is necessary to consider that the work is performed in a dry inert gas atmosphere. In addition, it is also possible to reverse the production order and produce the cathode, the electron injection layer, the electron transport layer, the light emitting layer, the hole transport layer, the hole injection layer, and the anode in this order.

  When a DC voltage is applied to the multicolor display device (organic EL panel 20) including the organic EL element 7 obtained in this manner, the voltage is about 2 to 40 V with the anode being positive and the cathode being negative. Luminescence can be observed by applying. An alternating voltage may be applied. The alternating current waveform to be applied may be arbitrary.

  EXAMPLES Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited thereto. In addition, although the display of "part" or "%" is used in an Example, unless otherwise indicated, "part by mass" or "mass%" is represented.

<Comparative example>
A gas barrier film was produced using the apparatus shown in FIG. That is, a biaxially stretched polyethylene naphthalate film (PEN film, thickness: 100 μm, width: 350 mm, manufactured by Teijin DuPont Films, Inc., trade name “Teonex Q65FA”) was used as a base material, and this was attached to the delivery roller 11. . Next, a magnetic field is applied between the film forming rollers 31 and 32, and electric power is supplied to the film forming rollers 31 and 32, respectively, and electric discharge is performed between the film forming rollers to supply a film forming gas having the following composition. Then, plasma was generated, and a gas barrier layer was formed by plasma CVD under the following conditions.

<Film formation condition 1>
Feed rate of raw material gas (HMDSO: hexamethyldisiloxane): 50 sccm
(Standard Cubic Centimeter per Minute converted to zero degree and 1 atm. The same shall apply hereinafter.)
Supply amount of oxygen gas: 500 sccm
Degree of vacuum in the vacuum chamber: 3Pa
Applied power from the power source for plasma generation: 0.8 kW
Frequency of power source for plasma generation: 70 kHz
Film transport speed: 0.5 m / min
Deposition roller 31 and 32 diameter: 300mmφ

  The thickness of the gas barrier layer in the obtained gas barrier film was 300 nm. The above process was repeated to produce a comparative gas barrier film having a gas barrier layer thickness of 600 nm.

<Example 1>
In the second formation of the gas barrier layer, the oxygen gas supply amount at the time of film formation on the film formation roller 31 and at the time of film formation on the film formation roller 32 is changed as shown below. Produced the gas barrier film of Example 1 in the same manner as in the comparative example.

<Film formation condition 2>
(Conditions at film forming roller 31)
Feed rate of raw material gas (HMDSO: hexamethyldisiloxane): 50 sccm
Supply amount of oxygen gas: 167sccm
(Conditions at film forming roller 32)
Feed rate of raw material gas (HMDSO: hexamethyldisiloxane): 50 sccm
Supply amount of oxygen gas: 500 sccm
<Example 2>
In the second gas barrier layer formation, the oxygen gas supply amount at the time of film formation on the film formation roller 31 is changed as shown below, and the same as in the comparative example is performed. A gas barrier film was prepared.

<Film formation condition 3>
(Conditions at film forming roller 31)
Feed rate of raw material gas (HMDSO: hexamethyldisiloxane): 50 sccm
Supply amount of oxygen gas: 125sccm
<Example 3>
The first gas barrier layer was formed under <Film Formation Condition 2>, and the second gas barrier layer was formed under <Film Formation Condition 4>, and the gas barrier film of Example 3 was produced.

<Film formation condition 4>
Feed rate of raw material gas (HMDSO: hexamethyldisiloxane): 50 sccm
Supply amount of oxygen gas: 167sccm
Degree of vacuum in the vacuum chamber: 3Pa
Applied power from the power source for plasma generation: 0.8 kW
Frequency of power source for plasma generation: 70 kHz
Film conveyance speed: 0.5 m / min.

<Example 4>
The first gas barrier layer was formed under <Film Formation Condition 4> and the second gas barrier layer was formed under <Film Formation Condition 1> to produce a gas barrier film of Example 4.

(XPS depth file)
The gas barrier film obtained above including comparison was subjected to XPS depth profile measurement under the following conditions to obtain a silicon distribution curve, an oxygen distribution curve, and a carbon distribution curve.

Etching ion species: Argon (Ar ⁺ )
Etching rate (SiO ₂ thermal oxide equivalent value): 0.05 nm / sec
Etching interval (SiO ₂ equivalent value): 10 nm
X-ray photoelectron spectrometer: Model “VG Theta Probe”, manufactured by Thermo Fisher Scientific
Irradiation X-ray: Single crystal spectroscopy AlKα
X-ray spot and size: 800 × 400 μm oval.

  Regarding the obtained silicon distribution curve, oxygen distribution curve, and carbon distribution curve, graphs showing the relationship between the atomic ratio and the etching time as well as the relationship between the atomic ratio and the distance (nm) from the surface of the gas barrier layer, respectively. It shows to FIGS. 4-8 in order of the comparative example 1 and Examples 1-Example 4. FIG. The “distance (nm)” described on the horizontal axis of the graphs illustrated in FIGS. 4 to 8 is a value obtained by calculation from the etching time and the etching rate.

<Performance evaluation>
<Vibration resistance barrier>
The above-obtained gas barrier film comparative example 1 and gas barrier film examples 1 to 4 were fixed to a vibration tester (“BF-50UD” manufactured by IDEX Co., Ltd.), and the amplitude was 0.75 mm at room temperature. (Vertical direction) 10 Hz → 55 Hz → 10 Hz was swept in 60 seconds, and this was regarded as one cycle, and the gas barrier properties before and after 24 hours were evaluated.

As the gas barrier property of the gas barrier film, the water vapor permeability was measured by the following method.
(1) Measurement of water vapor permeability Under the conditions of a temperature of 40 ° C., a humidity of 0% RH on the low humidity side, and a humidity of 90% RH on the high humidity side, a water vapor permeability measuring device (model name “GTR Tech− 30XASC ") was used to measure the water vapor permeability of the gas barrier film.
(2) When the evaluation method (1) was below the detection limit, the measurement was performed by the following method.
<< Evaluation of water vapor barrier property (Ca evaluation method) >>
(Water vapor barrier property evaluation sample preparation device)
Vapor deposition device: JE-400, a vacuum vapor deposition device manufactured by JEOL Ltd.
Constant temperature and humidity oven: Yamato Humidic Chamber IG47M
(raw materials)
Metal that reacts with water and corrodes: Calcium (granular)
Water vapor-impermeable metal: Aluminum (φ3-5mm, granular)
(Preparation of water vapor barrier property evaluation sample)
Using a vacuum vapor deposition apparatus (vacuum vapor deposition apparatus JEE-400 manufactured by JEOL Ltd.), metallic calcium was vapor-deposited with a size of 12 mm × 12 mm through the mask on the surface of the gas barrier layer of the produced gas barrier film. At this time, the deposited film thickness was set to 80 nm.
Thereafter, the mask was removed in a vacuum state, and aluminum was vapor-deposited on the entire surface of one side of the sheet to perform temporary sealing. Next, the vacuum state is released, quickly transferred to a dry nitrogen gas atmosphere, and a quartz glass with a thickness of 0.2 mm is bonded to the aluminum deposition surface via an ultraviolet curing resin for sealing (manufactured by Nagase ChemteX). A water vapor barrier property evaluation sample was prepared by irradiating ultraviolet rays to cure and adhere the resin to perform main sealing.
The obtained sample was stored at a high temperature and high humidity of 60 ° C. and 90% RH, and the state in which metallic calcium was corroded with respect to the storage time was observed. Observation is performed every hour for up to 6 hours, every 3 hours for up to 24 hours, every 6 hours for up to 48 hours thereafter, and every 12 hours thereafter, 12 mm x 12 mm metal The area where metallic calcium corroded relative to the calcium deposition area was calculated in%. The time when the area where the metal calcium corrodes becomes 1% is obtained by interpolating from the observation result by a straight line, and the metal calcium vapor deposition area, the amount of water vapor corroding the metal calcium for the area of 1%, and the time required for it. From the relationship, the water vapor permeability of each gas barrier film was calculated.
The measurement results are shown in Table 2.

この結果から、本発明に係る実施例１〜４のガスバリアーフィルムは、長時間に渡って連続した振動にさらした場合においても、ガスバリアー性の低下を十分に抑制することができることが確認された。

From this result, it was confirmed that the gas barrier films of Examples 1 to 4 according to the present invention can sufficiently suppress the deterioration of the gas barrier property even when exposed to continuous vibration for a long time. It was.

DESCRIPTION OF SYMBOLS 1a Gas barrier film 1b Gas barrier film 1 Base material 2 Smooth layer 3 Gas barrier layer 4 2nd gas barrier layer 5 Overcoat layer 6 Transparent electrode 7 Organic EL element (electronic device main body)
8 Adhesive layer 9 Opposite film EL Organic EL panel (electronic device)
DESCRIPTION OF SYMBOLS 11 Sending roller 21, 22, 23, 24 Conveyance roller 31, 32 Film-forming roller 41 Gas supply port 51 Power supply 61 for plasma generation 61, 62 Magnetic field generator 71 Winding roller A Area | region A
B area B
P center line a oxygen distribution curve b silicon distribution curve c carbon distribution curve

Claims (4)

A gas barrier film comprising a gas barrier layer containing silicon, oxygen, and carbon as constituent elements on at least one surface of a substrate, the element in the depth direction by X-ray photoelectron spectroscopy of the gas barrier layer Among the distribution curves of the constituent elements based on the distribution measurement, the distance from the surface of the gas barrier layer in the layer thickness direction of the gas barrier layer and carbon relative to the total amount (100 at%) of silicon atoms, oxygen atoms and carbon atoms In the carbon distribution curve showing the relationship with the atomic ratio (referred to as “carbon atomic ratio (at%)”), the difference between the maximum maximum value and the minimum maximum value of the carbon distribution curve is 15-15. has at least two maxima in the range of 35 at%, the carbon distribution curve center line P of the areas a and B when the bisecting the thickness direction of the gas barrier layer caused When it was decided, the not show the symmetrical carbon distribution curve in the region A and B, and the difference of the average values of the carbon atomic ratio in the regions A and B is in the range of 5 to 20 at% Gas barrier film characterized by A method for producing a gas barrier film according to claim 1 , wherein the gas barrier layer is formed on a substrate by plasma chemical vapor deposition. Production method. The substrate is conveyed while being brought into contact with each of a pair of film forming rollers, and plasma discharge is performed while supplying a film forming gas containing an organosilicon compound and oxygen between the pair of film forming rollers. The method for producing a gas barrier film according to claim 2 , wherein the gas barrier layer is formed. 4. The gas according to claim 3 , wherein the gas barrier layer is formed a plurality of times using a plurality of types of film forming gases prepared by changing a concentration of oxygen contained in the film forming gas. A method for producing a barrier film.

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