JP6384102B2 - Functional element manufacturing method and printing apparatus - Google Patents

Description

  The present invention relates to a functional element manufacturing method and printing apparatus using a relief printing plate.

  By improving the manufacturing technology of electronic devices, a fine functional layer can be formed, which contributes to the spread of small and highly portable devices such as smartphones and tablet terminals.

  Electronic devices are manufactured mainly by a technique called photolithography. In photolithography, a protective layer is formed in a pattern on a functional layer formed on a substrate, and the functional layer exposed at the opening of the protective layer is removed by etching or the like. In other words, photolithography is a method of forming a pattern by removing unnecessary portions, and is a subtractive method. On the other hand, it has been proposed that by using an additive method in which a functional layer is directly formed in a desired pattern, material utilization efficiency can be improved and manufacturing steps can be largely omitted. The main means of the additive method is printing, and therefore attention is focused on a field called printed electronics.

  In printed electronics, it is required to form functional layers such as wiring and semiconductor layers in a predetermined shape on the order of micrometers. That is, a higher resolution than that of a conventional printed material is required. In addition, if the visibility is good by forming beautiful characters and images like conventional printed matter, the required characteristics are not satisfied, and the cross-section and surface shape of the printed functional layer are suitable for electronic devices It is also necessary to be. In order to satisfy these requirements, it is necessary to further improve the printing technology.

  As a technique for enabling micrometer order fine printing, for example, reverse offset printing (Patent Document 1), microcontact printing (Non-Patent Document 1), and the like are known.

  In the reverse offset printing, the ink uniformly applied to the surface of the blanket is transferred to the relief plate, and the ink remaining on the blanket is transferred to the printing substrate. In the reverse offset printing, in order to continuously perform the printing operation, it is necessary that the blanket and the letterpress be in a clean state for each printing. This is because accumulation of residual ink on the blanket and letterpress will lead to pattern defects. In reverse offset printing, the surface of the blanket is reset by completely transferring ink from the blanket surface to the printing substrate. On the other hand, the ink received by the letterpress is not removed, and a separate cleaning process is required. As a method for cleaning the relief plate, for example, a method of wiping off the ink with a solvent, an ink remaining in the relief of the relief plate after the solvent is sprayed to dissolve the ink, and then the ink adhering to the relief portion of the relief plate is scraped with a doctor blade A method of wiping off the solution, a method of removing the ink using an adhesive substrate, and the like have been proposed. However, these cleaning methods require further improvements.

  In microcontact printing, ink is applied to the entire surface of the concavo-convex plate, and the concavo-convex plate and the printing substrate are brought into close contact with each other so that the ink is transferred to the printing substrate only from the convex portions of the concavo-convex plate. In micro contact printing, among the inks applied to the entire surface of the concavo-convex plate, the ink on the concavo-convex plate convex portion is transferred to the printing substrate, and the ink in the concavo-convex plate concave portion remains, so continuous printing is performed. Requires a step of removing the ink in the recesses of the concavo-convex plate.

  As described above, conventional printing methods such as reverse offset printing and microcontact printing are not suitable for continuous printing.

Japanese Patent No. 3689536

Amit Kumar, Hans A. Biebuyck, George M. Whitesides, Langmuir, 1994, 10, p. 1498-1511

  The present invention has been made in view of the above problems, and a main object of the present invention is to provide a functional element manufacturing method and printing apparatus capable of continuous high-definition printing.

  In order to achieve the above object, the present invention includes a relief printing plate preparation step for preparing a relief printing plate having a pattern-like convex portion containing a first resin, and a second resin layer containing a second resin. A blanket preparing step for preparing a blanket, a transfer layer forming step for applying a functional layer-forming coating solution on the second resin layer of the blanket and drying to form a transfer layer, and the second for the blanket A primary transfer step of bringing the resin layer and the convex portion of the relief printing plate into contact via the transfer layer, and transferring the transfer layer of the blanket to only the convex portion of the relief printing plate; and the relief printing plate The transfer layer of the convex portion is completely transferred to the functional layer forming base material, a secondary transfer step for forming the functional layer, and the transfer layer remaining on the blanket is completely transferred to the cleaning base material. And the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or is more hydrophilic than the second resin layer. An element manufacturing method is provided.

  In the present invention, high-definition printing is possible and continuous printing is possible by performing a primary transfer step, a secondary transfer step, and a removal step using a relief printing plate having a pattern-like convex portion. .

  In the said invention, it is preferable that the said 1st resin and the said 2nd resin are silicone rubber. This is because the transferability of the transfer layer obtained by drying the functional layer forming coating solution can be improved.

  Moreover, this invention has the 2nd resin layer which is arrange | positioned so that contact with the said relief printing plate and a roll-shaped relief printing plate which has a pattern-shaped convex part containing 1st resin, and contains 2nd resin. A roll-shaped blanket, a coating machine that applies ink onto the second resin layer of the blanket, and a printing mounting member that is disposed so as to be in contact with the relief printing plate and mounts a printing substrate. And a roll-shaped cleaning mounting member that is disposed so as to be in contact with the blanket and mounts a long cleaning substrate, a first roll that feeds the long cleaning substrate, and the long A cleaning unit having a second roll for winding the cleaning substrate, and the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or the second resin. Parent than layer To provide a printing apparatus characterized by a high resistance.

  In the present invention, by using a relief printing plate having a pattern-like convex part and providing a cleaning unit, high-definition printing is possible and continuous printing is possible.

  In the said invention, it is preferable that the said 1st resin and the said 2nd resin are silicone rubber. This is because the transferability of the ink layer obtained by drying the ink can be improved.

  In the present invention, it is possible to provide a method for manufacturing a functional element and a printing apparatus capable of high-definition printing and capable of continuous printing.

It is process drawing which shows an example of the manufacturing method of the functional element of this invention. It is process drawing which shows an example of the manufacturing method of the functional element of this invention. It is process drawing which shows the other example of the manufacturing method of the functional element of this invention. It is a schematic diagram which shows an example of the printing apparatus of this invention. It is a schematic diagram which shows the other example of the printing apparatus of this invention.

  Hereinafter, a method for producing a functional element and a printing apparatus of the present invention will be described in detail.

A. Manufacturing method of functional element The manufacturing method of the functional element of the present invention includes a relief printing plate preparation step of preparing a relief printing plate having a pattern-like convex portion containing a first resin, and a second resin containing a second resin. A blanket preparing step of preparing a blanket having two resin layers, a transfer layer forming step of applying a functional layer forming coating solution on the second resin layer of the blanket and drying to form a transfer layer; and A primary transfer step of bringing the second resin layer of the blanket and the convex portion of the relief printing plate into contact with each other via the transfer layer, and transferring the transfer layer of the blanket only to the convex portion of the relief printing plate; A secondary transfer step in which the transfer layer of the convex portion of the relief printing plate is completely transferred to a functional layer forming base material to form a functional layer; and the transfer layer remaining on the blanket is used as a cleaning base material. In A removal step of complete transfer, wherein the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or is more hydrophilic than the second resin layer. And

Here, “complete transfer” means that the transfer rate of the solid content of the transfer layer is 95% or more and 100% or less.
The “transfer layer” means a dried functional layer forming coating solution.

“Hydrophilicity” is indicated by the contact angle of water at 25 ° C., and the smaller the contact angle, the higher the hydrophilicity, and the larger the contact angle, the lower the hydrophilicity.
“The convex portion has the same hydrophilicity as the second resin layer” means that the contact angle of water at 25 ° C. to the convex portion is the same as the contact angle of water at 25 ° C. to the second resin layer. “The convex portion has higher hydrophilicity than the second resin layer” means that the contact angle of water at 25 ° C. with respect to the convex portion is smaller than the contact angle of water at 25 ° C. with respect to the second resin layer.

  1 (a) to 1 (d) and FIGS. 2 (a) to 2 (d) are process diagrams showing an example of a method for producing a functional element of the present invention. First, as illustrated in FIG. 1A, a relief printing plate preparation for preparing a relief printing plate 1 in which a first resin layer 3 having a patterned convex portion 4 on the surface is formed on a first support 2 is prepared. Perform the process. In addition, a blanket preparation step of preparing the blanket 10 in which the second resin layer 12 is formed on the second support 11 is performed. The convex portion 4 of the relief printing plate 1 has the same hydrophilicity as the second resin layer 12 of the blanket 10 or has a higher hydrophilicity than the second resin layer 12. Next, as illustrated in FIG. 1B, a transfer layer forming step of forming a transfer layer 21 by applying a functional layer forming coating solution to the entire surface of the second resin layer 12 of the blanket 10 and drying it. Do. Next, as illustrated in FIGS. 1C to 1D, the second resin layer 12 of the blanket 10 and the convex portion 4 of the relief printing plate 1 are brought into contact with each other via the transfer layer 21 to transfer the transfer layer of the blanket 10. A primary transfer process for completely transferring 21 to only the convex portions 4 of the relief printing plate 1 is performed. Next, as illustrated in FIGS. 2A to 2B, the transfer layer 21 transferred to the convex portion 4 of the relief printing plate 1 is completely transferred to the functional layer forming substrate 22 to form a functional layer. A secondary transfer process is performed. Next, as illustrated in FIGS. 2C to 2D, a removal step of completely transferring the transfer layer 21 remaining on the second resin layer 12 of the blanket 10 to the cleaning substrate 23 is performed.

Here, when the hydrophilicity of the two substrates is different, complete transfer of the ink occurs from the substrate having low hydrophilicity to the substrate having high hydrophilicity due to the difference in hydrophilicity.
In the adhesion science, the theory of Weak Boundary Layer is known. In the following, the weak boundary layer may be abbreviated as WBL. The theory of WBL is that bond failure occurs at any time in the weak layer, ie WBL, near the interface of either phase that is bonded, and there can be no pure interface failure. Moreover, it is estimated that WBL is formed when a low molecular component and an additive segregate on the surface.

In the present invention, the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or has a higher hydrophilicity than the second resin layer. In the present invention, when the functional layer forming coating solution is applied onto the second resin layer of the blanket, WBL is formed at the interface between the second resin layer of the blanket and the functional layer forming coating solution. it is conceivable that. Therefore, when the hydrophilicity of the convex part of the relief printing plate is higher than the hydrophilicity of the second resin layer of the blanket, the primary transfer process transfers only to the convex part of the relief printing plate due to the difference in hydrophilicity and WBL. The layer can be fully transferred. In addition, when the hydrophilicity of the convex part of the relief printing plate is equal to the hydrophilicity of the second resin layer of the blanket, the transfer layer is completely transferred only to the convex part of the relief printing plate by the WBL in the primary transfer step. Can do.
In general, from the viewpoint of transferability, the hydrophilicity of the functional layer-forming substrate is set to be higher than the hydrophilicity of the convex portions of the relief printing plate. Therefore, due to the difference in hydrophilicity, the transfer layer can be completely transferred to the functional layer forming substrate in the secondary transfer step.
Similarly, from the viewpoint of transferability, the hydrophilicity of the cleaning substrate is usually set to be higher than the hydrophilicity of the second resin layer of the blanket. Therefore, due to the difference in hydrophilicity and WBL, the transfer layer can be completely transferred to the cleaning substrate in the removal step.
As described above, in the present invention, the transfer layer can be completely transferred using not only the difference in hydrophilicity but also WBL. In the present invention, continuous printing becomes possible by performing such a primary transfer step, a secondary transfer step, and a removal step. Moreover, in a relief printing plate, high-definition printing is attained by making the pattern shape of a convex part into a fine pattern shape. Therefore, in the present invention, continuous high-definition printing is possible.

  Further, the transfer layer transferred to the cleaning substrate can be recovered without being discarded and reused as a functional layer forming coating solution. Therefore, an unnecessary transfer layer remaining on the blanket can be recovered without waste, and a functional element can be manufactured at low cost.

Conventionally, flexographic printing is known as one of printing methods. In flexographic printing, ink uniformly applied to the surface of an anilox roll is transferred to a relief printing plate, and the ink transferred to the relief printing plate is transferred to a printing substrate. Generally, metal rolls and ceramic rolls are used for anilox rolls. In flexographic printing, ink is not dried after it is applied to an anilox roll, and the ink is completely transferred from the anilox roll to the relief printing plate. Instead, the ink is separated into an anilox roll and a relief printing plate, so-called crying. In flexo printing, high-definition printing is said to be difficult.
On the other hand, in the present invention, the transfer layer is completely transferred in the primary transfer step, the secondary transfer step, and the removal step, and continuous high-definition printing is possible.

  Further, in the conventional reverse offset printing, the ink remaining on the blanket is transferred to the printing substrate, whereas in the present invention, the transfer layer remaining on the blanket is transferred to the cleaning substrate. In the present invention, due to the difference in hydrophilicity and WBL, the transfer layer can be completely transferred to the cleaning substrate in the removal step, and the transfer layer of the blanket can be easily removed.

  Hereafter, each process in the manufacturing method of the functional element of this invention is demonstrated.

1. Letterpress printing plate preparation step The letterpress printing plate preparation step in the present invention is a step of preparing a letterpress printing plate having a pattern of convex portions containing the first resin. The convex portion of the relief printing plate has the same hydrophilicity as a second resin layer of a blanket described later, or is more hydrophilic than the second resin layer.

  It does not specifically limit as 1st resin used for a convex part, The general resin used for a relief printing plate can be applied. Usually, a resin having a three-dimensional crosslinked structure is used. In the convex part comprised from resin which has a three-dimensional crosslinked structure, the solvent in the transfer layer transcribe | transferred by the convex part can be penetrate | infiltrated in a convex part. Since the solvent in the transfer layer permeates into the convex part of the relief printing plate after the transfer layer is transferred to the convex part of the relief printing plate until it is transferred to the functional layer forming substrate, Along with the evaporation of the solvent, the viscosity of the transfer layer gradually increases, and the cohesive force of the transfer layer on the convex surface of the relief printing plate can be increased. Therefore, when transferring the transfer layer from the relief printing plate to the functional layer forming substrate, the transfer layer can be completely transferred.

  Moreover, it is preferable that a convex part has elasticity. Due to the elasticity of the convex part, when transferring the transfer layer from the convex part of the relief printing plate to the functional layer forming substrate, pressure can be uniformly applied to the surface of the convex part of the relief printing plate. Since the degree of adhesion between the convex portions of the relief printing plate and the functional layer-forming substrate can be increased, the transferability of the transfer layer can be improved.

  Examples of the first resin used for such convex portions include elastomers and rubbers. Specific examples include silicone rubber, polyurethane, polyester, acrylonitrile butadiene rubber, chloroprene rubber, polyepichlorohydrin rubber, epichlorohydrin ethylene oxide copolymer rubber, butadiene rubber, and ethylene propylene diene copolymer rubber.

  Among these, the first resin is preferably silicone rubber. This is because silicone rubber is excellent in the releasability of the transfer layer and can improve the transfer property of the transfer layer from the relief printing plate to the functional layer-forming substrate.

  Examples of the material of the silicone rubber include polydimethylsiloxane and a copolymer thereof, fluorine group-containing polydimethylsiloxane and a copolymer thereof, polyvinylmethylsiloxane, and polyphenylmethylsiloxane.

  The relief printing plate only needs to have a pattern-like convex portion, and may be, for example, a single member made of the first resin, and has a pattern-like convex portion on the surface of the first support. The 1st resin layer which it has may be formed. Examples of the first support include a glass substrate, a resin substrate, a ceramic substrate, and a metal substrate.

  The hydrophilicity of the convex portion of the relief printing plate may be the same as the hydrophilicity of the second resin layer of the blanket described later or higher than the hydrophilicity of the second resin layer. The contact angle of water at 0 ° C. may be equal to or less than the contact angle of the second resin layer of the blanket. More specifically, the convex portion preferably has a contact angle with respect to water at 25 ° C. in the range of 50 ° or more and 110 ° or less, and particularly in the range of 60 ° or more and 110 ° or less, particularly 70 ° or more and 110 ° It is preferable to be within the following range. If the convex portion is too hydrophilic, a functional layer-forming substrate having a higher hydrophilicity than the convex portion is used in the secondary transfer step described later, so the surface of the functional layer-forming substrate suitable for the secondary transfer step The state is limited.

  The contact angle is measured by, for example, dropping 1 microliter of liquid onto the layer to be measured, observing the shape of the dropped liquid droplet from the side, and measuring the angle formed by the liquid droplet and the layer surface. can do. The contact angle can be measured using, for example, a contact angle measuring device manufactured by Imoto Seisakusho or a contact angle meter DM-901 manufactured by Kyowa Interface Science.

  Further, the difference in the contact angle between the convex portion of the relief printing plate and the second resin layer of the blanket is the hydrophilicity of the convex portion of the relief printing plate and the functional layer forming substrate in the secondary transfer step as described above. Considering the relationship, it is better not to be too large, and it is preferably in the range of 0 ° to 30 °.

  In the convex part, the surface of the convex part may be hydrophilized in order to adjust hydrophilicity. The hydrophilization method is not particularly limited as long as it is a method capable of imparting hydrophilicity to the convex surface, and examples thereof include UV-ozone treatment, vacuum ultraviolet light irradiation, and plasma irradiation.

In the present invention, the pattern shape of the convex portion becomes the pattern shape of the functional layer. The pattern shape of the convex portion is appropriately selected according to the type and application of the functional element, and can be an arbitrary shape.
Further, the width and height of the convex portion can be set to the width and height of a general convex portion in a relief printing plate, and are appropriately adjusted according to the type and application of the functional element. For example, the width of the convex portion can be set within a range of 2 μm to 10 mm, and particularly preferably within a range of 5 μm to 500 μm. In the present invention, high-definition printing is possible, and specifically, printing is possible if the width of the convex portion is up to about 2 μm. Moreover, the height of a convex part can be set in the range of 1 micrometer-1 mm, and it is preferable to exist in the range of 2 micrometers-200 micrometers especially.

  The shape of the relief printing plate may be a plate shape or a roll shape. When the relief printing plate and the blanket are in a roll shape, continuous printing can be performed by a roll-to-roll method.

  The method for preparing the relief printing plate can be the same as the method for producing a general relief printing plate. Commercially available relief printing plates can also be used.

2. Blanket preparation process The blanket preparation process in this invention is a process of preparing the blanket which has the 2nd resin layer containing 2nd resin. The second resin layer of the blanket has the same hydrophilicity as the convex portion of the relief printing plate or has a lower hydrophilicity than the convex portion. The surface of the blanket on the second resin layer side is flat.

  It does not specifically limit as 2nd resin used for a 2nd resin layer, The general resin used for a blanket can be applied. Usually, a resin having a three-dimensional crosslinked structure is used. In the 2nd resin layer comprised from resin which has a three-dimensional crosslinked structure, the solvent in the coating liquid for functional layer formation apply | coated on the 2nd resin layer can be penetrated into the 2nd resin layer. The functional layer forming coating solution or functional layer is applied after the functional layer forming coating solution is applied on the second resin layer of the blanket until it is transferred to the convex portion of the relief printing plate or the substrate for cleaning. Since the solvent in the transfer layer after drying the forming coating solution penetrates into the second resin layer, the functional layer is formed together with the evaporation of the solvent in the functional layer forming coating solution or the transfer layer. The viscosity of the coating liquid or transfer layer gradually increases, and the cohesive force of the transfer layer on the surface of the second resin layer of the blanket can be increased. Therefore, when the transfer layer is transferred from the blanket to the relief printing plate or the cleaning substrate, the transfer layer can be completely transferred.

  The second resin layer preferably has elasticity. Due to the elasticity of the second resin layer, when the transfer layer is transferred from the second resin layer of the blanket to the convex portion of the relief printing plate or the cleaning substrate, pressure can be uniformly applied to the surface of the blanket. Further, since the degree of adhesion between the blanket and the relief printing plate or the substrate for cleaning can be increased, the transferability of the transfer layer can be improved.

The second resin used for such a second resin layer can be the same as the first resin.
Among these, the second resin is preferably silicone rubber. This is because silicone rubber is excellent in the releasability of the transfer layer and can improve the transfer property of the transfer layer from the blanket to the relief printing plate or the cleaning substrate.

  The blanket may be a single layer composed of the second resin layer, or may be one in which the second resin layer is formed on the second support. Examples of the second support include a glass substrate, a resin substrate, a ceramic substrate, and a metal substrate.

The hydrophilicity of the second resin layer of the blanket may be the same as or lower than the hydrophilicity of the convex portion of the relief printing plate. Specifically, the hydrophilicity of the second resin layer is 25 ° C. The contact angle of water should just be more than the said contact angle of the convex part of the said relief printing plate. More specifically, the second resin layer preferably has a contact angle with respect to water at 25 ° C. in the range of 70 ° or more and 120 ° or less, particularly in the range of 80 ° or more and 110 ° or less, particularly 90 ° or more. It is preferably within a range of 110 ° or less.
The method for measuring the contact angle is as described above.

  The shape of the blanket may be a plate shape or a roll shape. When the relief printing plate and the blanket are in a roll shape, continuous printing can be performed by a roll-to-roll method.

  A blanket manufacturing method can be the same as a general blanket manufacturing method. A commercially available blanket can also be used.

3. Transfer Layer Forming Step The transfer layer forming step in the present invention is a step of forming a transfer layer by applying a functional layer forming coating solution onto the second resin layer of the blanket and drying it.

  Here, “function” means optical selective absorption, reflection, polarization, light selective transmission, nonlinear optical properties, luminescence such as fluorescence or phosphorescence, photochromic optical, etc .; hard magnetism, soft magnetism, Nonmagnetic, magnetic such as magnetic permeability; electrical or electronic such as conductivity, insulation, piezoelectricity, pyroelectricity, dielectricity; adsorptive, desorption, catalytic, water absorption, ionic conductivity, redox Chemical properties such as heat resistance, electrochemical properties, electrochromic properties; mechanical properties such as wear resistance; thermal properties such as heat transfer properties, heat insulation properties, infrared radiation properties; biofunctional properties such as biocompatibility and antithrombotic properties It means various functions.

The functional layer forming coating solution contains a functional material and a solvent.
The functional material is appropriately selected according to the type and application of the functional element. For example, semiconductor materials, light emitting materials, hole injecting materials, conductive materials such as metal nanocolloids, and coloring materials , Resin materials, proteins, cells, biological materials such as DNA, and the like.

  The solvent should be permeable and volatile to the first resin used for the convex portions of the relief printing plate and the second resin used for the second resin layer of the blanket. preferable. By using such a solvent, the transferability of the transfer layer can be improved. About permeability and volatility, what is described, for example in Unexamined-Japanese-Patent No. 2011-187179 and international publication 2008/111484 pamphlet can be referred.

  As a method of applying the functional layer forming coating solution on the second resin layer of the blanket, any method can be used as long as the functional layer forming coating solution can be applied to the entire surface of the second resin layer with a uniform thickness. The method is not particularly limited, and can be appropriately selected from general methods such as spin coating, die coating, and bar coating.

  Moreover, after apply | coating the coating liquid for functional layer formation, it is made to dry. The cohesive force of the functional layer forming coating solution is increased by drying, and the transfer layer obtained by drying the functional layer forming coating solution can be completely transferred. When the functional layer forming coating solution contains a volatile solvent, it can be naturally dried. Further, the functional layer forming coating solution may be dried by heating, blowing, or the like.

4). Primary transfer step In the primary transfer step in the present invention, the second resin layer of the blanket and the convex portion of the relief printing plate are brought into contact with each other via the transfer layer, and the transfer layer of the blanket is brought into contact with the relief printing plate. This is a step of completely transferring only the convex portion.
The pressure for bringing the blanket and the relief printing plate into contact with each other is appropriately adjusted so that the transfer layer adheres only to the projections of the relief printing plate.

5. Secondary transfer step The secondary transfer step in the present invention is a step of completely transferring the transfer layer of the convex portion of the relief printing plate to a functional layer forming substrate to form a functional layer.

As the hydrophilicity of the surface of the functional layer forming substrate, it is sufficient that the hydrophilicity of the convex portion of the relief printing plate is higher. Specifically, the contact angle of 25 ° C. water on the functional layer forming substrate surface is What is necessary is just to be smaller than the said contact angle of the convex part of a relief printing plate. More specifically, the functional layer-forming substrate preferably has a contact angle with respect to water at 25 ° C. of 5 ° or more and 95 ° or less, particularly 60 ° or more and 90 ° or less, particularly 60. It is preferable that the angle is in the range of not less than 80 ° and not more than 80 °.
The method for measuring the contact angle is as described above.

  Further, the difference in the contact angle between the convex part of the relief printing plate and the functional layer forming substrate is preferably as large as possible, specifically preferably 5 ° or more, more preferably 10 ° or more, and particularly preferably 20 ° or more. It is preferable.

  The functional layer forming substrate may be a single wafer or a long sheet. In the case of a long functional layer-forming substrate, continuous printing is possible by a roll-to-roll method.

The pressure at which the relief printing plate and the functional layer forming substrate are brought into contact with each other is appropriately adjusted.
The thickness of the transfer layer is appropriately selected according to the type and application of the functional element.
Further, when forming the functional layer, after transferring the transfer layer to the functional layer forming substrate, a treatment such as heating or light irradiation may be performed as necessary.

6). Removal Step The removal step in the present invention is a step of completely transferring the transfer layer remaining on the blanket to the cleaning substrate.

The hydrophilicity of the surface of the cleaning substrate may be higher than the hydrophilicity of the second resin layer of the blanket. Specifically, the contact angle of 25 ° C. water on the surface of the cleaning substrate is the second of the blanket. What is necessary is just to be smaller than the said contact angle of a resin layer. More specifically, the cleaning substrate preferably has a contact angle with respect to water at 25 ° C. in the range of 2 ° to 100 °, more preferably in the range of 10 ° to 80 °, particularly 10 ° or more. It is preferably within a range of 50 ° or less.
The method for measuring the contact angle is as described above.

  The difference in the contact angle between the second resin layer of the blanket and the substrate for cleaning is preferably as large as possible, specifically 10 ° or more, more preferably 30 ° or more, particularly 50 ° or more. preferable.

  The cleaning substrate may be a single wafer or may be long. In the case of a long cleaning substrate, continuous printing is possible by a roll-to-roll method.

The pressure for bringing the blanket and the cleaning substrate into contact with each other is appropriately adjusted.
The transfer layer transferred to the cleaning substrate can be recovered and reused as a functional layer forming coating solution.

7). Applications Examples of the use of the functional element manufacturing method of the present invention include formation of electrodes, semiconductor layers, gate insulating layers and interlayer insulating layers in semiconductor elements such as transistors and diodes, formation of pixel electrodes on TFT substrates, and solar cells. Back electrode formation in organic EL elements, back electrode formation in organic EL elements, formation of non-volatile memory electrodes and polymer layers, formation of pressure sensor electrodes and polymer layers, formation of wiring on wiring boards, colored layers and light shielding in color filters Part formation, biochip production, and the like. In particular, the method for producing a functional element of the present invention can be suitably used for producing an electronic device that requires a fine pattern.

B. Other Embodiments of Functional Element Manufacturing Method In the present invention, the functional layer forming substrate and the cleaning substrate can be interchanged in the functional element manufacturing method described above. That is, the functional element manufacturing method of the present embodiment includes a relief printing plate preparation step of preparing a relief printing plate having a pattern-like convex portion containing a first resin, and a second resin layer containing a second resin. A blanket preparation step for preparing a blanket, a transfer layer forming step for applying a functional layer forming coating solution on the second resin layer of the blanket and drying to form a transfer layer, and the blanket above A primary transfer step of bringing the second resin layer and the convex portion of the relief printing plate into contact with each other via the transfer layer, and transferring the transfer layer of the blanket only to the convex portion of the relief printing plate; and the blanket The transfer layer remaining on the substrate is completely transferred to the functional layer forming substrate to form a secondary transfer step for forming the functional layer, and the transfer layer on the convex portion of the relief printing plate is completely transferred to the cleaning substrate. The convex part of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or higher hydrophilicity than the second resin layer. .

  1 (a) to 1 (d) and FIGS. 3 (a) to 3 (d) are process diagrams showing an example of a method for manufacturing a functional element of this embodiment. 1A to 1D are described in the above “A. Functional element manufacturing method”, description thereof is omitted here. Next, as illustrated in FIGS. 3A to 3B, the transfer layer 21 remaining on the second resin layer 12 of the blanket 10 is completely transferred to the functional layer forming substrate 22 to form a functional layer. A secondary transfer process is performed. Further, as illustrated in FIGS. 3C to 3D, a removal step of completely transferring the transfer layer 21 transferred to the convex portion 4 of the relief printing plate 1 to the cleaning substrate 23 is performed.

  Also in this embodiment, high-definition printing is possible and continuous printing is possible as in the above-described method for manufacturing a functional element. In this case, continuous printing is possible in reverse offset printing.

  Note that the relief printing plate preparation step, blanket preparation step, primary transfer step, and application are the same as those in the method for manufacturing a functional element described above, and thus description thereof is omitted here. Hereinafter, other steps in the method for producing the functional element of the present embodiment will be described.

1. Secondary transfer step The secondary transfer step in this embodiment is a step of completely transferring the transfer layer remaining on the blanket to a functional layer forming substrate to form a functional layer.

  As the hydrophilicity of the surface of the functional layer forming substrate, it is sufficient that the hydrophilicity of the second resin layer of the blanket is higher. Specifically, the contact angle of 25 ° C. water on the functional layer forming substrate surface is as follows: What is necessary is just to be smaller than the said contact angle of the 2nd resin layer of a blanket. The specific contact angle of the functional layer forming substrate surface can be the same as the contact angle of the cleaning substrate surface described in “A. Functional element manufacturing method”. Explanation here is omitted.

  The functional layer forming substrate may be a single wafer or a long sheet. In the case of a long functional layer-forming substrate, continuous printing is possible by a roll-to-roll method.

The pressure when the blanket and the functional layer forming substrate are brought into contact with each other is appropriately adjusted.
The thickness of the transfer layer is appropriately selected according to the type and application of the functional element.
Further, when forming the functional layer, after transferring the transfer layer to the functional layer forming substrate, a treatment such as heating or light irradiation may be performed as necessary.

2. Removal Step The removal step in the present invention is a step of completely transferring the transfer layer of the convex portion of the relief printing plate to a cleaning substrate.

  The hydrophilicity of the surface of the substrate for cleaning should be higher than the hydrophilicity of the convex portion of the relief printing plate. Specifically, the contact angle of water at 25 ° C. of the surface of the substrate for cleaning is that of the relief printing plate. What is necessary is just to be smaller than the said contact angle of a convex part. The specific contact angle on the surface of the cleaning substrate can be the same as the contact angle on the surface of the functional layer forming substrate described in “A. Functional element manufacturing method”. Explanation here is omitted.

  The cleaning substrate may be a single wafer or may be long. In the case of a long cleaning substrate, continuous printing is possible by a roll-to-roll method.

The pressure at which the relief printing plate and the cleaning substrate are brought into contact with each other is appropriately adjusted.
The transfer layer transferred to the cleaning substrate can be recovered and reused as a functional layer forming coating solution.

C. Printing device The printing device of the present invention is a roll-shaped relief printing plate having a pattern-like convex portion containing a first resin, and a second resin containing a second resin, which is disposed so as to be in contact with the relief printing plate. A roll blanket having a resin layer, a coating machine for applying ink onto the second resin layer of the blanket, and a printing on which a printing substrate is placed so as to be in contact with the relief printing plate A mounting member, a roll-shaped cleaning mounting member that is disposed so as to be in contact with the blanket and mounts a long cleaning substrate, and a first roll that sends out the long cleaning substrate; And a cleaning unit having a second roll for winding the long cleaning substrate, and whether the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket. Second above It is characterized by being more hydrophilic than the resin layer.

  FIG. 4 is a schematic diagram illustrating an example of the printing apparatus of the present invention. The printing apparatus 40 illustrated in FIG. 4 includes a roll-shaped relief printing plate 1, a roll-shaped blanket 10 disposed so as to be able to contact the relief printing plate 1, and a coating machine 41 that applies ink 42 a to the blanket 10. A printing placement member 43 that is placed in contact with the relief printing plate 1 and on which the printing base material 44 is placed; and a long cleaning base 49 that is placed in contact with the blanket 10. A cleaning unit 48 including a roll-shaped cleaning mounting member 45 to be mounted. The relief printing plate 1 includes a first support 2 and a first resin layer 3 formed on the first support 2 and having a pattern-like convex portion 4 on the surface. The blanket 10 includes a second support body 11 and a second resin layer 12 formed on the second support body 11, and the surface on the second resin layer 12 side is a flat curved surface. The convex portion 4 of the relief printing plate 1 has the same hydrophilicity as the second resin layer 12 of the blanket 10 or has a higher hydrophilicity than the second resin layer 12. The cleaning unit 48 includes a roll-shaped cleaning mounting member 45, a first roll 46 that sends out a long cleaning substrate 49, and a second roll 47 that winds up the long cleaning substrate 49. doing.

In this printing apparatus 40, first, the ink 42a is apply | coated on the 2nd resin layer 12 of the blanket 10 with the coating machine 41, and it is made to dry, and the ink layer 42b is formed. Next, the second resin layer 12 of the blanket 10 and the convex portion 4 of the relief printing plate 1 are brought into contact with each other through the ink layer 42 b, and the ink layer 42 b of the blanket 10 is transferred only to the convex portion 4 of the relief printing plate 1. Next, the ink layer 42 b transferred to the convex portion 4 of the relief printing plate 1 is transferred to the printing substrate 44. Further, the ink layer 42 b remaining on the blanket 10 is transferred to a long cleaning substrate 49.
Here, “ink layer” means a dried ink.

  In the present invention, a cleaning unit is provided, and as described in the above “A. Functional element manufacturing method”, transfer of the ink layer from the second resin layer of the blanket to the convex portion of the relief printing plate, When transferring the ink layer from the convex part of the relief printing plate to the printing substrate and transferring the ink layer from the second resin layer of the blanket to the cleaning substrate, not only the difference in hydrophilicity but also WBL is used. Since the ink layer can be completely transferred, continuous printing is possible. Moreover, in a relief printing plate, high-definition printing is attained by making the pattern shape of a convex part into a fine pattern shape. Therefore, in the present invention, continuous high-definition printing is possible.

Further, since the cleaning mounting member is in a roll shape, the ink layer remaining on the blanket can be continuously removed by a roll-to-roll method.
Furthermore, since the cleaning unit is provided, the contact surface with the blanket can be kept clean in the long cleaning substrate placed on the cleaning placement member. Can be prevented from reattaching. Therefore, the occurrence of pattern defects can be suppressed and high-definition printing can be performed.

  Further, the ink layer transferred to the cleaning substrate can be recovered without being discarded and reused as ink. Therefore, an unnecessary ink layer transferred from the blanket to the printing plate can be recovered without waste, and the cost can be reduced.

  Hereinafter, each configuration in the printing apparatus of the present invention will be described.

1. Letterpress printing plate The letterpress printing plate used for this invention has a pattern-shaped convex part containing 1st resin, and is a roll-shaped thing. Further, the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or is more hydrophilic than the second resin layer.
The letterpress printing plate was described in detail in the above-mentioned “A. Functional element manufacturing method 1. Letterpress printing plate preparation process”, and thus the description thereof is omitted here.

2. Blanket The blanket used in the present invention is disposed so as to be in contact with the relief printing plate, has a second resin layer containing a second resin, and has a roll shape. Moreover, the 2nd resin layer of a blanket has the same hydrophilicity as the convex part of the said relief printing plate, or hydrophilicity is lower than a convex part.
The blanket has been described in detail in the above “A. Functional element manufacturing method 2. Blanket preparation step”, and the description thereof is omitted here.
The blanket should just be arrange | positioned so that a relief printing plate may be contact | abutted, and the arrangement | positioning is adjusted suitably.

3. Coating machine The coating machine used for this invention applies an ink on the said 2nd resin layer of the said blanket.
The coating machine is not particularly limited as long as the ink can be applied to the entire surface of the second resin layer of the blanket with a uniform thickness. For example, a general spin coater, die coater, bar coater, etc. Can be appropriately selected from various coating machines.

4). Printing placement member The printing placement member in the present invention is disposed so as to be able to contact the relief printing plate, and places a printing substrate.
The shape of the printing mounting member may be a plate shape or a roll shape. Among these, a roll shape is preferable. When the printing mounting member is in the form of a roll, continuous printing is possible by a roll-to-roll method, which is advantageous for printing on a printing substrate having a large area.
The printing mounting member only needs to be arranged so as to be able to contact the relief printing plate, and the arrangement is appropriately selected according to the shape of the printing mounting member.

5. Cleaning unit The cleaning unit according to the present invention is disposed so as to be in contact with the blanket, and includes a roll-shaped cleaning mounting member on which a long cleaning substrate is mounted, and a long cleaning substrate that sends out the long cleaning substrate. 1 roll and the 2nd roll which winds up the long base material for cleaning.
The cleaning mounting member may be arranged so as to be able to contact the blanket, and the arrangement thereof is adjusted as appropriate.

D. Other Embodiments of Printing Apparatus In the present invention, the printing mounting member and the cleaning unit can be replaced in the above-described printing apparatus. That is, the printing apparatus of this embodiment is arranged so as to be in contact with the relief printing plate having a roll-like relief printing plate having a pattern-like convex portion containing the first resin, and the second resin containing the second resin. A roll blanket having two resin layers, a coating machine that applies ink onto the second resin layer of the blanket, and a printing substrate that is disposed so as to be in contact with the blanket and on which a printing substrate is placed A mounting member, a roll-shaped cleaning mounting member that is disposed so as to be in contact with the relief printing plate and on which a long cleaning substrate is mounted, and a first roll that feeds out the long cleaning substrate And a cleaning unit having a second roll for winding the long cleaning substrate, and the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket. Or above Than the second resin layer is characterized in that the higher the hydrophilicity.

  FIG. 5 is a schematic diagram illustrating an example of a printing apparatus according to the present embodiment. A printing apparatus 40 illustrated in FIG. 5 includes a roll-shaped relief printing plate 1, a roll-shaped blanket 10 disposed so as to be in contact with the relief printing plate 1, and a coating machine 41 that applies ink 42 a to the blanket 10. A printing placement member 43 placed on the blanket 10 so as to be in contact with the blanket 10, and a printing cleaning member 49 placed on the relief printing plate 1 so as to be in contact with the printing plate 1. A cleaning unit 48 including a roll-shaped cleaning mounting member 45 to be mounted. The relief printing plate 1 includes a first support 2 and a first resin layer 3 formed on the first support 2 and having a pattern-like convex portion 4 on the surface. The blanket 10 includes a second support body 11 and a second resin layer 12 formed on the second support body 11, and the surface on the second resin layer 12 side is a flat curved surface. The convex portion 4 of the relief printing plate 1 has the same hydrophilicity as the second resin layer 12 of the blanket 10 or has a higher hydrophilicity than the second resin layer 12. The cleaning unit 48 includes a roll-shaped cleaning mounting member 45, a first roll 46 that sends out a long cleaning substrate 49, and a second roll 47 that winds up the long cleaning substrate 49. doing.

  In this printing apparatus 40, first, the ink 42a is apply | coated on the 2nd resin layer 12 of the blanket 10 with the coating machine 41, and it is made to dry, and the ink layer 42b is formed. Next, the second resin layer 12 of the blanket 10 and the convex portion 4 of the relief printing plate 1 are brought into contact with each other through the ink layer 42 b, and the ink layer 42 b of the blanket 10 is transferred only to the convex portion 4 of the relief printing plate 1. Next, the ink layer 42 b remaining on the blanket 10 is transferred to the printing substrate 44. Further, the ink layer 42 b transferred to the convex portion 4 of the relief printing plate 1 is transferred to a long cleaning substrate 49.

  Also in this embodiment, high-definition printing is possible and continuous printing is possible as in the above-described printing apparatus. In this case, continuous printing is possible in reverse offset printing.

  The printing apparatus is the same as the above-described printing apparatus except that the printing mounting member can contact the roll-shaped blanket and the roll-shaped cleaning mounting member can contact the roll-shaped relief printing plate. Therefore, explanation here is omitted.

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

  The following examples illustrate the present invention in more detail.

[Example 1]
(Blanket production)
The surface of PEN film Q65FA manufactured by Teijin DuPont was washed by vacuum ultraviolet light treatment using a light irradiation device UER616908-172 manufactured by Ushio Electric. Next, uncured silicone rubber KE106 manufactured by Shin-Etsu Silicone Co., Ltd. was spin-coated on the PEN film using a spin coater MS-300 manufactured by Mikasa Co., Ltd., and 160 ° C. for 1 hour using an oven DE410 manufactured by Yamato Scientific Co. The blanket which baked and has a silicone rubber layer was produced. It was 0.75 ± 0.01 mm when the thickness of the silicone rubber layer was measured with a caliper CD67-S PS manufactured by Mitutoyo Corporation. Further, when the pure water contact angle on the surface of the silicone rubber layer was measured using a contact angle meter DM-901 manufactured by Kyowa Interface Science Co., Ltd., it was 107 ± 3 °.

(Preparation of letterpress printing plate)
A glass relief plate manufactured by Topic Co., Ltd. having a printed pattern including a pattern used for forming wirings and TFTs as recesses was prepared, and a release agent Durasurf manufactured by Harves was processed on the surface of the glass relief plate. Next, uncured silicone rubber KE106 manufactured by Shin-Etsu Silicone Co., Ltd. was applied to the surface of the glass relief plate having concave portions, and a PEN film Q65FA manufactured by Teijin DuPont Co., Ltd. was covered on the coated surface after a 3 mm spacer was installed. In this state, after leaving at room temperature for 10 hours, when the PEN film is peeled off from the glass relief plate, the silicone rubber layer is peeled off in close contact with the PEN film side, and on the surface of the silicone rubber layer, a protrusion corresponding to the depression of the glass relief plate Formed. The PEN film to which the silicone rubber layer was adhered was further baked at 160 ° C. for 1 hour using an oven DE410 manufactured by Yamato Kagaku Co., Ltd., thereby producing a relief printing plate having a silicone rubber layer. When the contact angle meter DM-901 manufactured by Kyowa Interface Science Co., Ltd. was used to measure the pure water contact angle of the surface of the silicone rubber layer having no irregularities, it was 105 ± 2 °.

(Preparation of substrate for cleaning)
The surface of the PEN film Q65FA manufactured by Teijin DuPont was subjected to vacuum ultraviolet light treatment using a light irradiation device UER616908-172 manufactured by Ushio Electric Co., Ltd., and the surface was washed and hydrophilicized at the same time. When the pure water contact angle on the surface of the PEN film was measured using a contact angle meter DM-901 manufactured by Kyowa Interface Science Co., Ltd., it was 17 ± 6 °.

(printing)
A plate glass OA-10G manufactured by Nippon Electric Glass Co., Ltd. was prepared as a functional layer forming substrate. When the contact angle meter DM-901 manufactured by Kyowa Interface Science Co., Ltd. was used to measure the pure water contact angle on the surface of the functional layer-forming substrate, it was 68 ± 2 °.

The above-mentioned blanket, relief printing plate, and functional layer forming base material were set in a printing machine Suma Labo III manufactured by Comlatech. Use DIC's silver paste GOAGT as ink, spread the ink on the blanket with a doctor blade, let it dry at room temperature for 30 seconds, then contact the blanket and letterpress printing plate with the operation of the printing machine, and remove the ink from the blanket Transferred to a relief printing plate. In this transfer, the transfer of ink from the blanket to the relief printing plate was a complete transfer. Continuously, when the relief printing plate and the functional layer forming substrate are brought into contact with each other by the operation of the printing machine, the ink is completely transferred from the relief printing plate to the functional layer forming substrate. A pattern of silver paste was formed on the surface. On the other hand, the ink was not left on the relief printing plate and it was in a clean state.
Next, when the above-mentioned cleaning substrate is pressed against the blanket using a hand roller micro catch made by Kazuki Roller Mfg. Co., the ink is completely transferred from the blanket to the cleaning substrate, and the blanket is in a clean state. became. Since both the blanket and the relief printing plate were in a clean state, the next printing could be performed in the same manner.

  Next, the functional layer-forming substrate on which the pattern of the silver paste is formed is baked at 160 ° C. for 1 hour using an oven DE410 manufactured by Yamato Scientific Co., Ltd., so that the ink is baked, and the silver wiring and the TFT pattern are formed. Been formed.

[Example 2]
The blanket, relief printing plate, cleaning substrate and functional layer forming substrate were the same as those in Example 1.

(printing)
The above-mentioned blanket, relief printing plate, and functional layer forming base material were set in a printing machine Suma Labo III manufactured by Comlatech. Use DIC's silver paste GOAGT as ink, spread the ink on the blanket with a doctor blade, let it dry at room temperature for 30 seconds, then contact the blanket and letterpress printing plate with the operation of the printing machine, and remove the ink from the blanket Transferred to a relief printing plate. In this transfer, the transfer of ink from the blanket to the relief printing plate was a complete transfer. When the blanket and the functional layer forming substrate are continuously brought into contact with each other by the operation of the printing machine, the ink is completely transferred from the blanket to the functional layer forming substrate, and the silver paste is applied to the surface of the functional layer forming substrate. A pattern was formed. On the other hand, no ink remained on the blanket and it was in a clean state.
Next, when the above-mentioned cleaning substrate is pressed against the relief printing plate using a hand roller micro catch manufactured by Kazuki Roller Mfg. Co., the ink is completely transferred from the relief printing plate to the cleaning substrate, and the relief printing is performed. The plate was clean. Since both the blanket and the relief printing plate were in a clean state, the next printing could be performed in the same manner.

  Next, the functional layer-forming substrate on which the pattern of the silver paste is formed is baked at 160 ° C. for 1 hour using an oven DE410 manufactured by Yamato Scientific Co., Ltd., so that the ink is baked, and the silver wiring and the TFT pattern are formed. Been formed.

DESCRIPTION OF SYMBOLS 1 ... Letterpress printing plate 2 ... 1st support body 3 ... 1st resin layer 4 ... Convex part 10 ... Blanket 11 ... 2nd support body 12 ... 2nd resin layer 21 ... Transfer layer 22 ... Base material for functional layer formation 23 ... Cleaning substrate 40 ... Printing device 41 ... Coating machine 42a ... Ink 42b ... Ink layer 43 ... Printing mounting member 44 ... Printing substrate 45 ... Cleaning mounting member 46 ... First roll 47 ... Second roll 48… Cleaning unit 49… Cleaning substrate

Claims (4)

A letterpress printing plate preparation step of preparing a letterpress printing plate having a pattern of convex portions containing the first resin;
A blanket preparation step of preparing a blanket having a second resin layer containing a second resin;
A transfer layer forming step of applying a functional layer forming coating solution on the second resin layer of the blanket and drying to form a transfer layer;
A primary transfer step in which the second resin layer of the blanket and the convex portion of the relief printing plate are brought into contact with each other via the transfer layer, and the transfer layer of the blanket is completely transferred only to the convex portion of the relief printing plate. When,
A secondary transfer step of completely transferring the transfer layer of the convex portion of the relief printing plate to a functional layer-forming substrate and forming a functional layer;
A removal step of completely transferring the transfer layer remaining on the blanket to a substrate for cleaning, wherein the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket. the hydrophilic than the second resin layer is rather high or,
The contact angle with respect to 25 ° C. water of the convex portion of the relief printing plate is in the range of 60 ° to 110 °, and the contact angle with respect to 25 ° C. water of the surface of the cleaning substrate is 2 ° to 50 °. The manufacturing method of the functional element characterized by being in the following ranges .   The method for manufacturing a functional element according to claim 1, wherein the first resin and the second resin are silicone rubber. A roll-shaped relief printing plate having a pattern-like convex portion containing the first resin;
A roll-shaped blanket having a second resin layer containing a second resin, disposed so as to be in contact with the relief printing plate;
A coating machine for applying ink onto the second resin layer of the blanket;
A placement member for printing placed on the relief printing plate so as to be in contact with each other, and placing a substrate for printing; and
A roll-shaped cleaning mounting member that is disposed so as to be in contact with the blanket and mounts a long cleaning substrate, a first roll that feeds out the long cleaning substrate, and the long cleaning A cleaning unit having a second roll that winds up the base material for printing, and the convex portion of the relief printing plate has the same hydrophilicity as the second resin layer of the blanket or more than the second resin layer. also rather high hydrophilic,
The contact angle with respect to 25 ° C. water of the convex portion of the relief printing plate is in the range of 60 ° to 110 °, and the contact angle with respect to 25 ° C. water of the surface of the cleaning substrate is 2 ° to 50 °. A printing apparatus having the following range .   The printing apparatus according to claim 3, wherein the first resin and the second resin are silicone rubber.

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