KR20110021337A - Pattern blancket improved thickness uniformity, and method of manufacturing the same - Google Patents

Abstract

PURPOSE: A patterned blanket and a method for manufacturing the blanket are provided to manage the thickness uniformity of the blanket to be less than 40um using a two-stepped silicon resin coating process for a master mold. CONSTITUTION: An RT607 resin is primarily coated to a pattern master mold and the thickness of the coating is about 100um. A primary leveling process is implemented at room temperature for about 10 minutes. The master mold is 500x600mm of large size. A silicon resin is filled spaces between patterns, and the identical silicon resin is secondarily coated. The thickness of the second coating is about 300um and is hardened for 24hours. A silicon film and a silicon adhesion film are stacked. The films are combined with a polyethylene terephtalate film to obtain a silicon patterned blanket.

Description

PATTERN BLANCKET IMPROVED THICKNESS UNIFORMITY, AND METHOD OF MANUFACTURING THE SAME

The present invention relates to a pattern blanket having improved thickness uniformity of a pattern blanket, and a method of manufacturing the same.

The photolithography process is mainly used for the fabrication of electronic devices, but the photolithography process requires the manufacture of a predetermined pattern mask and the chemical etching and stripping process must be repeated, making the manufacturing process complicated and harmful to the environment. There is a problem of generating a large amount of chemical waste.

A gravure printing method has been proposed as a new pattern formation method to solve the disadvantage of the photolithography process.

Since gravure printing transfers ink onto a substrate using a transfer roll, by using a transfer roll corresponding to the area of a desired display element, a pattern can be formed by one transfer even in the case of a large-area display element. It becomes possible. Such gravure printing not only forms an ink pattern for resist on a substrate, but also various patterns of the display device, for example, a TFT for gate lines and data lines, pixel electrodes, and capacitors connected to the TFT as well as a liquid crystal display device. It can be used to pattern metal patterns.

Typically, the blanket used for gravure pattern printing is produced by providing a silicone resin to a master mold on which a desired pattern is formed and curing it. That is, it is manufactured by the method of bonding a master mold to silicone resin. Thereafter, after coating the primer on the cured silicone resin, the base film is combined and separated from the master mold to finally complete the blanket for gravure pattern printing.

Since silicone blankets used for reverse off-set during flexography are flat blankets with no pattern in the blanket, high-viscosity silicones are comma coated, cap coated, curtain The thickness uniformity may be controlled by coating by a coating method and rapidly curing.

However, as described above in the "Background Art", the blanket used for gravure pattern printing is manufactured by providing a silicone resin to a master mold in which a desired pattern is formed and curing it.

It is difficult to wind the rigid master mold onto the roll due to the property of pouring silicone resin on the master mold to duplicate the pattern, and thus, the comma coating, cap coating, and curtain coating methods are used. Because it can not be used.

Therefore, it is necessary to coat the silicone resin with an applicator on the master mold patterned by wet etching or the like on the Cr glass. Afterwards, the central portion of the blanket is rather thin and forms a thick gradient in the form of thickening of the pattern toward the outer layer without the pattern, that is, the central portion of the large area blanket.

This phenomenon is due to the inherent viscosity of the silicone resin, and it is presumed that the surface of the silicone resin provided to the master mold is not completely leveled by gravity, but appears to bend by the pattern step.

If the cured silicone resin is cured as it is, a blanket with poor thickness uniformity is produced as a result, and the blanket with poor thickness uniformity serves as a major cause of leaving unwanted patterns, particularly residues, in a later printing process. Moreover, in the case of a blanket required for large area fine print patterning, a uniform printing pattern is obtained over the entire area only when the thickness uniformity is excellent over the entire area, so a blanket showing a very good thickness uniformity is required.

The thickness uniformity measurement result of the pattern blanket manufactured as a comparative example in FIG. 1 is shown. As shown in Figure 1, it can be seen that the surface is not uniform in the case of the blanket produced by simply curing the silicone resin coated on the master mold. Since the comparative example was manufactured by a conventional pattern blanket manufacturing method, it may be viewed as a result of blanket manufacturing of the prior art.

Accordingly, an object of the present invention is to provide a blanket for gravure printing, and a method for producing the same, the thickness uniformity is very improved.

The present invention has been made to solve the above problems of the prior art,

A pattern blanket is provided, wherein the thickness uniformity is less than 40 μm.

In the blanket of the present invention, the blanket provides a pattern blanket, characterized in that the large area size.

In addition, in the blanket of the present invention, the use of the blanket provides a pattern blanket, characterized in that for gravure printing.

In addition, in the blanket of the present invention, the blanket includes a surface printing layer and a support layer, the surface printing layer provides a pattern blanket, characterized in that formed by coating a silicone resin two or more times on the pattern master mold. .

In addition, in the method for manufacturing a pattern blanket by applying a silicone resin to the pattern master mold, and curing the pattern, it provides a pattern blanket manufacturing method characterized in that the silicone resin is coated on the master mold two or more times.

In addition, (a) a first coating step of coating the master mold by applying a silicone resin to the master mold for the pattern; And

(B) provides a pattern blanket manufacturing method comprising a second coating step of applying the silicone resin to the master mold again.

In addition, in the manufacturing method of the present invention, from the first coating step to before the second coating step, there is provided a pattern blanket manufacturing method, characterized in that made with a time difference within 10 minutes.

In addition, in the manufacturing method of the present invention, the coating thickness of the silicone resin in the first coating step, the pattern blanket manufacturing method, characterized in that thinner than or equal to the coating thickness of the silicone resin of the second coating step. to provide.

According to the present invention, the silicone resin coating process of the master mold is changed from the conventional one coating to the two coating methods, so that the thickness uniformity is 40 µm. Excellent blankets within range can be provided.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated in detail.

The present invention,

Thickness uniformity is less than 40 micrometers, It is related with the pattern blanket characterized by the above-mentioned.

The thickness uniformity means a thickness deviation value between the maximum thickness value and the minimum thickness value.

Under common knowledge obtained by the present inventors, in the pattern blanket, a thickness uniformity of less than 40 µm is a novel one that has not been developed so far, and is considered to be a blanket with very good thickness uniformity. In particular, this is even more so in the case of large area pattern blankets ('large area size' is a term widely used in the art, but no further explanation is required, but in the present invention, a size of at least 100 mm * 100 mm) Can be defined as). An embodiment of the present invention to be described below was made of a pattern blanket in a large area size, and with reference to this, it will be understood that the present invention helps to improve thickness uniformity in manufacturing a large area pattern blanket.

Moreover, in this invention, it is preferable that the use of the said blanket is for gravure printing.

The blanket includes a surface printing layer and a support layer, and the surface printing layer may be formed by coating silicon resin two or more times on a pattern master mold. The manufacturing method of the said blanket is mentioned later separately.

In addition, the present invention,

In a method of manufacturing a pattern blanket by applying a silicone resin to a pattern master mold and curing the pattern, the present invention relates to a pattern blanket manufacturing method, characterized in that the silicone resin is coated on the master mold two or more times.

The blanket of the present invention is a blanket used for gravure pattern printing, and is manufactured by a method of replicating the pattern after coating a silicone resin with an applicator on a master mold patterned by wet etching. do.

In this case, since the master mold itself has a pattern, when coated with a method of manufacturing an existing flat blanket, a difference in thickness of the blanket occurs due to the step difference of the pattern, so that the thickness uniformity decreases. Improved.

In case of double coating, thickness uniformity can be improved because the thickness of the resin can be adjusted once again by supplying the silicon resin consumed by the step of the pattern once again.

In the present invention, the master mold provides a pattern from which the pattern is replicated from the master mold to the silicon blanket. The duplicated pattern is printed by gravure printing. The master mold may be manufactured by using a conventional pattern forming method without limitation, but is generally manufactured by a wet etching method.

Silicone resin used in the present invention is Any one conventionally used in the manufacture of a pattern blanket can be used without limitation, and examples thereof include Dow sylgard 184, Wacker RT601, wacker RT 607, and the like .

The method of coating the silicone resin uses an applicator coating method, and the method of uniformly controlling the thickness (doctoring method) may use a blade, a baker, a mayer bar, or the like.

The pattern blanket manufacturing method,

(a) a first coating step of coating the master mold by applying a silicone resin to the pattern master mold; And

(b) a second coating step of applying the silicone resin to the master mold again.

(a) first coating with silicone resin on the patterned master mold

The pattern master mold may be patterned by a wet etching method, and the related art description thereof will be omitted.

The pattern master mold is subjected to a silicone resin primary coating. The silicone resin coating coated in this step is for pattern replication of the master mold, and pattern printing is performed using a blanket made of silicone material, and the silicone blanket is formed of ink coating and glass of the pattern ( Used because it is suitable for glass transfer. When only a single coating is performed in this step, the thickness of the blanket is the lowest from the center of the master pattern, and the thickness becomes thicker toward the edge. Thus, the following secondary coating is carried out.

The thickness of the silicone resin during the primary coating is preferably as thin as possible, preferably not to exceed the secondary coating thickness in consideration of the secondary coating thickness. If the thickness of the silicone resin is too thick during the primary coating, it is difficult to match the overall blanket thickness during the secondary coating, and the thickness variation is alleviated by reducing the amount of silicone resin applied during the secondary coating. It may affect the effect.

(b) secondary coating the silicone mold with silicone resin

The secondary coating is performed on the primary coated master mold with silicone resin. When the double coating is performed in this way, the thickness variation due to the pattern layer can be minimized. However, since silicone resin has a rapid increase in viscosity with time, it is preferable to apply a secondary coating within a 10 minute time range when double coating is performed. The thickness of the silicone resin during the secondary coating may be formed to the final product thickness of the desired silicone resin.

Hereinafter, the present invention will be described using examples. The following examples are provided to illustrate the present invention, and the scope of the present invention includes the inventions described in the following claims and their substitutions and modifications within the equivalent ranges, and are not limited to the scope of the present examples. .

Example

Wacker's RT607 resin was first coated on a pattern master mold (Japan, SHIN-EI-SHA order made product) to a thickness of about 100 μm and then first leveled at room temperature for about 10 minutes.

The master mold has a large area size of 500 * 600 mm, and the pattern is a large area size that can produce two pattern blankets of 14.2 inch WXGA class.

After the silicone resin was filled between the patterns, the same coating as the silicone resin was applied again to a thickness of about 300 μm to apply a second coating.

After curing at room temperature for 24 hours, the cured formed silicone film and the silicone adhesive film were laminated and coalesced with a PET film as a support layer, thereby finally preparing a silicone pattern blanket.

Comparative example

Wacker RT607 resin was coated with a silicone resin to a pattern master mold (Japan, SHIN-EI-SHA order made) to a thickness of about 400 μm.

The master mold has a large area size of 500 * 600 mm, and the pattern is a large area size that can produce two pattern blankets of 14.2 inch WXGA class.

After curing at room temperature for 24 hours, the cured formed silicone film and the silicone adhesive film were laminated and coalesced with a PET film as a support layer, thereby finally preparing a silicone pattern blanket.

[Thickness Uniformity Measurement]

The thickness uniformity of the silicon pattern blanket of the said Example and the comparative example was measured. Thickness uniformity was measured by LVDT (linear variable differential transformer, manufactured by Dongdo Tech Co., Ltd.).

Figure 1 shows the thickness distribution according to the position of the blanket produced by the comparative example. The x-axis of the graph represents position, the y-axis represents thickness and the unit is μm. Fig. 1 shows the thickness measurement results of the comparative blanket, and the figure below is a schematic diagram of a master mold manufactured by a large-area wet etching method capable of printing two sheets of 14.2 inch / WXGA level, and the pattern corresponding to each thickness part. The position on the master mold is indicated by the corresponding arrows. Referring to FIG. 1, when the single coating is performed as in the comparative example, it can be seen that the thickness of the blanket is the lowest from the center of the pattern of the master, and the thickness distribution tends to become thicker toward the edge.

Figure 2 shows the thickness distribution according to the position of the blanket manufactured by the embodiment. There is no thickness variation in the entire pattern region, and the thickness distribution as shown in FIG. 2 is evenly shown. When the double coating is performed as in the embodiment, the thickness tendency by the pattern layer can be minimized, and as can be seen in FIG. 2, it can be seen that the difference between the minimum and maximum thickness is only ± 20 μm.

1 is a view showing the thickness distribution according to the position of the blanket produced by the comparative example of the present invention.

Figure 2 is a view showing a different thickness distribution in the position of the blanket produced by the embodiment of the present invention.

Claims (8)

Thickness blanket is less than 40 micrometers, The pattern blanket characterized by the above-mentioned. The pattern blanket of claim 1, wherein the blanket is a large area size. The pattern blanket of claim 1, wherein the blanket is used for gravure printing. The pattern blanket of claim 1, wherein the blanket comprises a surface printing layer and a support layer, wherein the surface printing layer is formed by coating silicon resin two or more times on a pattern master mold. A method of manufacturing a pattern blanket comprising applying a silicone resin to a pattern master mold and curing the pattern mold, wherein the pattern resin is coated on the master mold two or more times. (a) a first coating step of coating the master mold by applying a silicone resin to the pattern master mold; And (B) a pattern blanket manufacturing method comprising a second coating step of applying the silicone resin to the master mold again. The method of claim 6, wherein the pattern blanket manufacturing method comprises a time difference of less than 10 minutes from after the first coating step to before the second coating step. The method of claim 6, wherein the coating thickness of the silicone resin in the first coating step is thinner than or equal to the coating thickness of the silicone resin in the second coating step.

Images