TWI816838B - 感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜及黑矩陣 - Google Patents
感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜及黑矩陣 Download PDFInfo
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- TWI816838B TWI816838B TW108125038A TW108125038A TWI816838B TW I816838 B TWI816838 B TW I816838B TW 108125038 A TW108125038 A TW 108125038A TW 108125038 A TW108125038 A TW 108125038A TW I816838 B TWI816838 B TW I816838B
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- photosensitive resin
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- independently
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- AAEJUTBYDPCTSK-UHFFFAOYSA-N triphenylsulfanium borate Chemical compound [O-]B([O-])[O-].c1ccc(cc1)[S+](c1ccccc1)c1ccccc1.c1ccc(cc1)[S+](c1ccccc1)c1ccccc1.c1ccc(cc1)[S+](c1ccccc1)c1ccccc1 AAEJUTBYDPCTSK-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
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- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
- G03F7/075—Silicon-containing compounds
- G03F7/0757—Macromolecular compounds containing Si-O, Si-C or Si-N bonds
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
- C08L83/14—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers in which at least two but not all the silicon atoms are connected by linkages other than oxygen atoms
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08K3/02—Elements
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0025—Crosslinking or vulcanising agents; including accelerators
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C08L61/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
- C08L61/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- C—CHEMISTRY; METALLURGY
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- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L83/04—Polysiloxanes
- C08L83/06—Polysiloxanes containing silicon bound to oxygen-containing groups
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- C—CHEMISTRY; METALLURGY
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Abstract
本案發明之課題為提供一種具有充分遮光性,且同時具有良好信賴性(密著性、耐裂痕性)、解像性、可撓性之黑色感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜,及黑矩陣。
作為解決手段,為提供一種感光性樹脂組成物,其係包含(A)包含含酸交聯性基之矽氧樹脂之基底樹脂、(B)碳黑,及(C)光酸產生劑。
Description
本發明為關於一種感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜及黑矩陣。
顯示器等之顯示裝置之彩色濾光器部位中,為了維持充分之色純度及對比,期望一種能夠得到具有微細圖型之黑矩陣之感光性樹脂組成物(專利文獻1、2)。
作為前述黑矩陣,有提案摻混碳黑之熱硬化性之丙烯酸樹脂等而成之各種光阻材料(專利文獻3),但近年來,有出現微LED顯示器等更加要求微細加工之顯示裝置,其求對應於此之感光性材料。
為了提升黑矩陣之遮光性,一般來說有提高感光性樹脂組成物中包含之碳黑等遮光成分之含量。然而,若提高遮光成分之含量,則有解像性、可撓性、信賴性(密著性、耐裂痕性)等惡化等問題。
[專利文獻1]特開2001-51112號公報
[專利文獻2]特開2003-161828號公報
[專利文獻3]特開2018-4739號公報
本發明有鑑於前述狀況,目的為提供一種具有充分遮光性,且同時具有良好信賴性(密著性、耐裂痕性)、解像性、可撓性之黑色之感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜及黑矩陣。
本發明者們為了達到前述目的,進行縝密探討之結果發現藉由包含(A)特定矽氧樹脂、(B)碳黑及(C)光酸產生劑之感光性樹脂組成物,能夠達到前述目的,進而完成本發明。
因此,本發明為提供一種下述感光性樹脂組成物、感光性樹脂皮膜、感光性乾薄膜及黑矩陣。
1.一種感光性樹脂組成物,其係包含(A)包含含酸交聯性基之矽氧樹脂之基底樹脂、(B)碳黑,及(C)光酸產生劑。
2.如1之感光性樹脂組成物,其中,前述酸交聯性基為酚性羥基或環氧基。
(式中,Y1為單鍵、亞甲基、丙烷-2,2-二基、1,1,1,3,3,3-六氟丙烷-2,2-二基或茀-9,9-二基,R11及R12分別獨立為氫原子或甲基,R13及R14分別獨立為碳數1~4之烷基或碳數1~4之烷氧基,a1及a2分別獨立為0~7之整數,b1及b2分別獨立為0~2之整數)]。
(式中,Y2為單鍵、亞甲基、丙烷-2,2-二基、1,1,1,3,3,3-六氟丙烷-2,2-二基或茀-9,9-二基,R21及R22分別獨立為氫原子或甲基,R23及R24分別獨立為碳數1~4之烷基或碳數1~4之烷氧基,c1及c2分別獨立為0~7之整數,d1及d2分別獨立為0~2之整數)]。
(式中,R1~R4、X1、X2及m與前述相同)。
(式中,R34為亦可包含酯鍵或醚鍵之碳數1~8之2價烴基))]。
(式中,Z1為2價有機基,R41及R42分別獨立為氫原子或碳數1~8之1價烴基,該1價烴基之氫原子的一部份或全部亦可經鹵原子取代,R43及R44分別獨立為碳數1~8之烷烴二基,Rx1及Rx2分別獨立為單鍵,或分別與Rx3及Rx4閉環而形成環構造之基,Rx3及Rx4分別獨立為氫原子、碳數1~8之1價烴基,或分別與Rx1及Rx2閉環而形成環構造時,為單鍵或碳數1~10之2價烴基)]。
(式中,R51及R52分別獨立為氫原子或甲基,R53及R54各自獨立為碳數1~8之1價烴基,f1及f2分別獨立為0~7之整數,g為0~600之整數)]。
9.如1~8中任一項之感光性樹脂組成物,其中,包含(B)碳黑0.01~60質量%。
10.如1~9中任一項之感光性樹脂組成物,其中,進一步包含(D)交聯劑。
11.如10之感光性樹脂組成物,其中,(D)交聯劑為選自1分子中平均包含2個以上羥甲基及/或烷氧基甲基之三聚氰胺化合物、三聚氰二胺化合物、乙炔脲化合物及脲化合物、經甲醛或甲醛-醇改質之胺基縮合物、1分子中平均具有2個以上羥甲基或烷氧基甲基之酚化合物,及1分子中平均具有2個以上環氧基之環氧化合物中至少1種。
12.如1~11中任一項之感光性樹脂組成物,其中,進
一步包含(E)溶劑。
13.如1~12中任一項之感光性樹脂組成物,其中,進一步包含(F)消化體。
14.一種感光性樹脂皮膜,其係由如1~13中任一項之感光性樹脂組成物所得。
15.一種感光性乾薄膜,其係具備支持薄膜與該支持薄膜上之如14之感光性樹脂皮膜。
16.一種圖型形成方法,其係包含:(i)將如1~13中任一項之感光性樹脂組成物塗布於基板上,於該基板上形成感光性樹脂皮膜之步驟、(ii)將前述感光性樹脂皮膜曝光之步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將非曝光部溶解去除並形成圖型之步驟。
17.一種圖型形成方法,其係包含:(i')使用如15之感光性乾薄膜,於前述基板上形成感光性樹脂皮膜之步驟、(ii)將前述感光性樹脂皮膜曝光之步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將非曝光部溶解去除並形成圖型之步驟。
18.如16或17之圖型形成方法,其中,進一步包含(iv)將藉由顯像所圖型形成之樹脂皮膜於100~250℃之溫度下進行後硬化之步驟。
19.一種黑矩陣,其係具備如14之感光性樹脂皮膜。
由本發明之感光性樹脂組成物所得之感光性樹脂皮膜為黑色且具有充分之遮光性,對基材之密著性等物性也較優異,並具有良好信賴性、顯像性、解像性。因此,由本發明之感光性樹脂組成物所得之感光性樹脂皮膜作為黑矩陣用之材料較有用。
本發明之感光性樹脂組成物為包含(A)包含含酸交聯性基之矽氧樹脂之基底樹脂、(B)碳黑及(C)光酸產生劑。
(A)成分之基底樹脂為包含含酸交聯性基之矽氧樹脂。於此,酸交聯性基意指能夠藉由酸作用,直接或介隔著交聯劑使官能基彼此化學性鍵結之基。本發明中,作為前述酸交聯性基,為酚性羥基、環氧基等較佳,尤其是酚性羥基較佳。
作為(A)成分之基底樹脂之較佳例,有舉出包含下述式(a1)表示之重複單位(以下亦稱作重複單位a1)及下述式(b1)表示之重複單位(以下亦稱作重複單位b1)作為必須單位之矽氧樹脂(惟,不包含後述重複單位a2及b2,以下亦稱作矽氧樹脂A1)。
式(a1)中,R1~R4分別獨立為碳數1~8之1價烴基,為碳數1~6較佳。作為前述1價烴基,有舉出直鏈狀、分枝狀或環狀之烷基、芳基等,作為其具體例,甲基、乙基、丙基、己基及此等之構造異構物、環己基、苯基等。此等中,甲基及苯基以原料之取得容易度來看較佳。
式(a1)中,m為0~600之整數,為0~400較佳,為0~200再較佳。
式(a1)及(b1)中,X1為下述式(X1)表示之2價基。
式(X1)中,Y1為單鍵、亞甲基、丙烷-2,2-二基、1,1,1,3,3,3-六氟丙烷-2,2-二基或茀-9,9-二基,R11及R12分別獨立為氫原子或甲基,R13及R14分別獨立為碳數1~4之烷基或碳數1~4之烷氧基,a1及a2分別獨立為0~7之整數,但為1~5之整數較佳,為1~3之整數再較佳。b1及b2分別獨立為0~2之整數,但為0或1較佳,為0再較佳。
前述烷基亦可為直鏈狀、分枝狀、環狀之任一者,作為其具體例,有舉出甲基、乙基、丙基、丁基、此等之構造異構物等。作為前述烷氧基,亦可為直鏈狀、分枝狀、環狀之任一者,作為其具體例,有舉出甲氧基、乙氧基、丙氧基、丁氧基、此等之構造異構物等。
作為(A)成分之基底樹脂之其他較佳例,有舉出包含下述式(a2)表示之重複單位(以下亦稱作重複單位a2)及下述式(b2)表示之重複單位(以下亦稱作重複單位b2)作為必須單位之矽氧樹脂(惟,不包含重複單位a1及b1。以下亦稱作矽氧樹脂A2)。
式(a2)及(b2)中,R1~R4及m與前述相同。X2為下述式(X2)表示之2價基。
式(X2)中,Y2為單鍵、亞甲基、丙烷-2,2-二基、1,1,1,3,3,3-六氟丙烷-2,2-二基或茀-9,9-二基,R21及R22分別獨立為氫原子或甲基,R23及R24分別獨立為碳數1~4之烷基或碳數1~4之烷氧基,c1及c2分別獨立為0~7之
整數,但為1~5之整數較佳,為1~3之整數再較佳。d1及d2分別獨立為0~2之整數,但為0或1較佳,為0再較佳。作為前述烷基及烷氧基,有舉出與前述相同者。
作為(A)成分之基底樹脂之其他較佳例,有舉出包含重複單位a1及b1以及重複單位a2及b2作為必須單位之矽氧樹脂(以下亦稱作矽氧樹脂A3)。
矽氧樹脂A1~A3亦可進一步包含下述式(a3)表示之重複單位(以下亦稱作重複單位a3)及下述式(b3)表示之重複單位(以下亦稱作重複單位b3)。
式(a3)及(b3)中,R1~R4及m與前述相同X3為下述式(X3)表示之2價基。
式(X3)中,R31及R32分別獨立為氫原子或甲基,e1及e2分別獨立為0~7之整數,但為1~5之整數較佳,為1~3之整數再較佳。
R33為亦可包含酯鍵或醚鍵之碳數1~8之1價烴基,或下述式(X3-1)表示之1價基。
前述1價烴基亦可為直鏈狀、分枝狀、環狀之任一者,作為其具體例,有舉出甲基、乙基、n-丙基等之烷基、苯基等之芳基等。此等之中,為甲基或苯基較佳,為甲基再較佳。且,前述1價烴基之碳原子間亦可介隔著酯鍵或醚鍵。
式(X3-1)中,R34為亦可包含酯鍵或醚鍵之碳數1~8之2價烴基前述2價烴基亦可為直鏈狀、分枝狀、環狀之任一者,作為其具體例,有舉出亞甲基、伸乙基、丙烷-1,2-二基、丙烷-1,3-二基、丙烷-2,2-二基、丁烷-1,2-二基、丁烷-1,3-二基、丁烷-1,4-二基等之碳數1~8之烷烴二基等。此等之中,為亞甲基或伸乙基較佳,為亞甲基再較佳。且,前述2價烴基之碳原子間亦可介隔著酯鍵或醚鍵。
作為R33,為甲基、苯基或環氧丙基較佳,為甲基或環氧丙基再較佳。
矽氧樹脂A1~A3亦可進一步包含下述式(a4)表示之重複單位(以下亦稱作重複單位a4)及下述式(b4)表示之重複單位(以下亦稱作重複單位b4)。
式(a4)及(b4)中,R1~R4及m與前述相同。X4為下述式(X4)表示之2價基。
式(X4)中,Z1為2價有機基,作為Z1,為以下所示者較佳。
(式中,Ra為甲基。z為0或1。Rb分別獨立為氫原子或甲基)
此等之中,作為Z1,為以下所示者再較佳。
(式中,Ra及z與前述相同)
且,Z1表示之2價有機基,其氫原子之一部份或全部亦可經鹵原子取代。作為鹵原子,有舉出氟原子、氯原子、溴原子、碘原子等。
式(X4)中,R41及R42分別獨立為氫原子或碳數1~8之1價烴基,該1價烴基之氫原子的一部份或全部亦可經鹵原子取代,作為前述1價烴基,有舉出作為R1~R4所例示者,或此等氫原子之一部份或全部經鹵原子取代者。
式(X4)中,R43及R44分別獨立為碳數1~8之烷烴二基,作為前述烷烴二基,有舉出亞甲基、伸乙基、丙烷-1,2-二基、丙烷-1,3-二基、丙烷-2,2-二基、丁烷-1,2-二基、丁烷-1,3-二基、丁烷-1,4-二基等。此等之中,為亞甲基較佳。
式(X4)中,Rx1及Rx2分別獨立為單鍵,或分別與Rx3及Rx4閉環而形成環構造之基,Rx3及Rx4分別獨立為氫原子、碳數1~8之1價烴基,或分別與Rx1及Rx2閉環而形成環構造時,為單鍵或碳數1~10之2價烴基。
作為Rx1與Rx3或Rx2與Rx4閉環而得之環構造,有舉出以下所示者,但不限定於此等。且,以下各式中,左側2個鍵結會鍵結於式(X4)中之含氮五員環而形成環構造。
此等之中,為下述式表示之環構造較佳。
尤其是,作為式(X4)表示之2價基,為下述
式(X4-1)表示者較佳。
式(X4-1)中,Z1及R41~R44與前述相同,R45及R46分別獨立為碳數1~8之烷烴二基,作為前述烷烴二基,有舉出亞甲基、伸乙基、丙烷-1,2-二基、丙烷-1,3-二基、丙烷-2,2-二基、丁烷-1,2-二基、丁烷-1,3-二基、丁烷-1,4-二基等,為亞甲基較佳。
式(X4-1)中,R47及R48分別獨立為碳數1~8之1價烴基,該1價烴基之氫原子的一部份或全部亦可經鹵原子取代,作為前述1價烴基,有舉出作為R1~R4所例示者,或此等之氫原子之一部份或全部經鹵原子取代者。h1及h2分別獨立為0或1。
矽氧樹脂A1~A3亦可進一步包含下述式(a5)表示之重複單位(以下亦稱作重複單位a5)及下述式(b5)表示之重複單位(以下亦稱作重複單位b5)。
式(a5)及(b5)中,R1~R4及m與前述相同,X5為下述式(X5)表示之2價基。
式(X5)中,R51及R52分別獨立為氫原子或甲基,R53及R54各自獨立為碳數1~8之1價烴基,f1及f2分別獨立為0~7之整數,但為1~5之整數較佳,為1~3之整數再較佳。g為0~600之整數,但為0~400之整數較佳,為0~200之整數再較佳。作為前述1價烴基,有舉出與R1~R4之說明中所述相同者。
矽氧樹脂A1~A3之機能為賦予薄膜形成能。且,矽氧樹脂A1~A3為在分子中具有環氧基、羥基等之交聯基或產生交聯反應之反應點者。
前述各重複單位亦可隨機鍵結,亦可作為嵌段聚合物鍵結。且,各重複單位中之矽氧烷單位亦可隨機鍵結,亦可包含複數同種矽氧烷單位之嵌段。且,前述矽氧樹脂中,矽氧(矽氧烷單位)含有率為30~80質量%較佳。
矽氧樹脂A1中,重複單位a1、a3、a4、a5、b1、b3、b4及b5之含有比率為滿足0<a1<1.0、0≦a3<1.0、0≦a4<1.0、0≦a5<1.0、0<b1<1.0、0≦b3<1.0、0≦b4<1.0、0≦b5<1.0及0<a1+b1≦1.0較佳,進而,滿足0≦a3+b3<1.0、0≦a4+b4≦0.8、0≦a5+b5≦0.6、0.1≦a1+a3+a4+a5≦0.7及0.3≦b1+b3+b4+b5≦0.9再較佳。且,為a1+a3+a4+a5+b1+b3+b4+b5=1。
矽氧樹脂A2中,重複單位a2、a3、a4、a5、
b2、b3、b4及b5之含有比率滿足0<a2<1.0、0≦a3<1.0、0≦a4<1.0、0≦a5<1.0、0<b2<1.0、0≦b3<1.0、0≦b4<1.0、0≦b5<1.0及0<a2+b2≦1.0較佳,進而,滿足0≦a3+b3<1.0、0≦a4+b4≦0.8、0≦a5+b5≦0.6、0.1≦a2+a3+a4+a5≦0.7及0.3≦b2+b3+b4+b5≦0.9再較佳。且,為a2+a3+a4+a5+b2+b3+b4+b5=1。
矽氧樹脂A3中,重複單位a1、a2、a3、a4、a5、b1、b2、b3、b4及b5之含有比率滿足0<a1<1.0、0<a2<1.0、0≦a3<1.0、0≦a4<1.0、0≦a5<1.0、0<b1<1.0、0<b2<1.0、0≦b3<1.0、0≦b4<1.0、0≦b5<1.0及0<a1+b1+a2+b2≦1.0較佳,進而,滿足0≦a3+b3<1.0、0≦a4+b4≦0.8、0≦a5+b5≦0.6、0.1≦a1+a2+a3+a4+a5≦0.7、及0.3≦b1+b2+b3+b4+b5≦0.9再較佳。且,為a1+a2+a3+a4+a5+b1+b2+b3+b4+b5=1。
矽氧樹脂A1~A3之重量平均分子量(Mw)為3,000~500,000較佳,為5,000~200,000再較佳。且,本發明中,Mw是藉由使用將四氫呋喃作為溶出溶劑之凝膠滲透層析(GPC)所得之聚苯乙烯換算測定值。
矽氧樹脂A1能夠藉由在金屬觸媒存在下,使下述式(1)表示之化合物,與下述式(2)表示之化合物,與下述式(3)表示之化合物,與因應必要選自下述式(5)表示之化合物、下述式(6)表示之化合物及下述式(7)表示之化合物中至少1種進行加成聚合來製造。
矽氧樹脂A2能夠藉由在金屬觸媒存在下,使
下述式(1)表示之化合物,與下述式(2)表示之化合物,與下述式(4)表示之化合物,與因應必要選自下述式(5)表示之化合物、下述式(6)表示之化合物及下述式(7)表示之化合物中至少1種進行加成聚合來製造。
矽氧樹脂A3能夠藉由在金屬觸媒存在下,使下述式(1)表示之化合物,與下述式(2)表示之化合物,與下述式(3)表示之化合物,與下述式(4)表示之化合物,與因應必要選自下述式(5)表示之化合物、下述式(6)表示之化合物及下述式(7)表示之化合物中至少1種進行加成聚合來製造。
(式中,R1~R4及m與前述相同)
(式中,R11~R14、R21~R24、Y1、Y2、a1、a2、b1、b2、c1、c2、d1及d2與前述相同)
(式中,R31~R33、R41~R44、R51~R54、Rx1、Rx2、Rx3、Rx4、Z1、e1、e2、f1、f2及g與前述相同)
作為前述金屬觸媒,能夠使用鉑(包含鉑
黑)、銠、鈀等之鉑族金屬單體;H2PtCl4.xH2O、H2PtCl6.xH2O、NaHPtCl6.xH2O、KHPtCl6.xH2O、Na2PtCl6.xH2O、K2PtCl4.xH2O、PtCl4.xH2O、PtCl2、Na2HPtCl4.xH2O(於此,x為0~6之整數較佳,特別為0或6較佳)等之氯化鉑、氯化鉑酸及氯化鉑酸鹽;乙醇改質氯化鉑酸(例如美國專利第3,220,972號說明書記載);氯化鉑酸與烯烴之錯體(例如美國專利第3,159,601號說明書、美國專利第3,159,662號說明書及美國專利第3,775,452號說明書記載);將鉑黑或鈀等之鉑族金屬擔載於氧化鋁、矽、碳等之載體者;銠-烯烴錯體;氯參(三苯基膦)銠(所謂Wilkinson's觸媒);氯化鉑、氯化鉑酸或氯化鉑酸鹽與含乙烯基之矽氧烷(尤其是含乙烯基之環狀矽氧烷)之錯體等。
前述觸媒之使用量為觸媒量,通常為前述加成聚合反應中使用之溶劑以外之化合物之總質量中,作為鉑族金屬,為0.001~0.1質量%較佳,為0.01~0.1質量%再較佳。
前述加成聚合反應中,因應必要亦可使用溶劑。作為溶劑,例如甲苯、二甲苯等之烴系溶劑較佳。
反應溫度以不失去觸媒活性,且在短時間內能夠結束聚合之觀點來看,為40~150℃較佳,為60~120℃再較佳。聚合時間因所得之樹脂種類及量而異,但聚合系統中為了防止濕氣介入,約為0.5~100小時較佳,為0.5~30小時再較佳。反應結束後,使用溶劑時,藉由將此餾去,
能夠得到矽氧樹脂A。
反應方法並無特別限定,但有舉例如使式(1)表示之化合物,與式(2)表示之化合物,與式(3)表示之化合物及/或式(4)表示之化合物,與選自式(5)表示之化合物、式(6)表示之化合物及式(7)表示之化合物中至少1種反應時,首先混合式(3)及/或(4)表示之化合物,與選自式(5)表示之化合物、式(6)表示之化合物及式(7)表示之化合物中至少1種並加熱後,於前述混合液添加金屬觸媒,接著以0.1~5小時之時間,滴落式(1)及(2)表示之化合物之方法。
各化合物亦可以相對於式(3)表示之化合物及/或式(4)表示之化合物,與選自式(5)表示之化合物、式(6)表示之化合物及式(7)表示之化合物中至少1種中所具有之烯基合計,式(1)及(2)表示之化合物所具有之含氫矽烷基合計,以莫耳比來說,較佳為0.67~1.67,再較佳為0.83~1.25來摻混。
於此,式(1)及(2)表示之化合物之摻混量,以莫耳比來說,亦可較佳為(1):(2)=5:95~20:80、再較佳為10:90~70:30來摻混。
且,將式(3)、(4)、(5)、(6)及(7)表示之化合物之摻混量分別設為N3、N4、N5、N6及N7(莫耳)的話,滿足0≦N3/X≦1.0、0≦N4/X<1.0、0<(N3+N4)/X≦1.0、0≦N5/X<1.0、0≦N6/X≦0.8及0≦N7/X≦0.6較佳。惟,為X=N3+N4+N5+N6+N7。
所得之樹脂之Mw能夠藉由將如o-烯丙基酚之單烯丙基化合物或如三乙基氫矽烷之單氫矽烷或單氫矽氧烷作為分子量調整劑使用來控制。
作為式(1)~(7)表示之化合物,能夠使用市售品,或能夠藉由以往公知之方法來合成。
作為(A)成分之基底樹脂,亦可分別單獨使用矽氧樹脂A1~A3,亦可組合此等來使用。進而,(A)成分之基底樹脂除了矽氧樹脂A1~A3之外,亦可進而包含其他矽氧樹脂。作為其他矽氧樹脂,有舉出選自包含重複單位a3及重複單位b3之矽氧樹脂(以下亦稱作矽氧樹脂B)、包含重複單位a4及重複單位b4之矽氧樹脂(以下亦稱作矽氧樹脂C)以及包含重複單位a5及重複單位b5之矽氧樹脂(以下亦稱作矽氧樹脂D)中至少1種。
(A)成分之基底樹脂包含矽氧樹脂B~D時,矽氧樹脂A1~A3不包含重複單位a3~a5及b3~b5較佳。
矽氧樹脂B中,重複單位a3及b3之含有比率為0<a3<1.0、0<b3<1.0(惟,a3+b3=1.0),但為0.1≦a3≦0.7、0.3≦b3≦0.9(惟,a3+b3=1.0)較佳。矽氧樹脂C中,重複單位a4及b4之含有比率為0<a4<1.0、0<b4<1.0(惟,a4+b4=1.0),但為0.1≦a4≦0.7、0.3≦b4≦0.9(惟,a4+b4=1.0)較佳。矽氧樹脂D中,重複單位a5及b5之含有比率為0<a5<1.0、0<b5<1.0(惟,a5+b5=1.0),但為0.1≦a5≦0.7、0.3≦b5≦0.9(惟,a5+b5=1.0)較佳。
(A)成分之基底樹脂包含矽氧樹脂B~D時,
此等之含量相對於矽氧樹脂A1~A3 100質量份,分別為超過0且100質量份以下較佳。
作為(B)成分之碳黑,為其平均一次粒徑為10~100nm者較佳。且,前述平均一次粒徑為以電子顯微鏡觀察碳黑所求出之算術平均徑。
作為前述碳黑,能夠使用市售品,作為其具體例,有舉出Denka(股)製HS-100;三菱Chemical(股)製三菱(登錄商標)碳黑#2650、#2600、#2350、#2300、#1000、#980、#970、#960、#950、#900、#850、MCF88、MA600、#750B、#650B、#52、#47、#45、#45L、#44、#40、#33、#32、#30、#25、#20、#10、#5、#95、#85、#240、MA77、MA7、MA8、MA11、MA100、MA100R、MA100S、MA230、MA220、MA14、#4000B、#3030B、#3050B、#3230B、#3400B;Diablack(登錄商標)A、Diablack N220M、Diablack N234、Diablack I、Diablack LI、Diablack II、Diablack 339、Diablack SH、Diablack SHA、Diablack LH、Diablack H、Diablack HA、Diablack SF、Diablack N550M、Diablack E、Diablack G、Diablack R、Diablack N760M、Diablack LR;Cancarb公司製Thermax(登錄商標)N990、N991、N907、N908、N990、N991、N908;旭碳(股)製旭#80、旭#70、旭#70L、旭F-200、旭#66、旭#66HN、旭#60H、旭#60U、旭#60、
旭#55、旭#50H、旭#51、旭#50U、旭#50、旭#35、旭#15、Asahi Thermal(登錄商標);Orion Engineered Carbons公司製COLOUR BLACK Fw200、COLOUR BLACK Fw2、COLOUR BLACK Fw2V、COLOUR BLACK Fw1、COLOUR BLACK Fw18、COLOUR BLACK S170、COLOUR BLACK S160、SPECIAL BLACK 6、SPECIAL BLACK5、SSPECIAL BLACK 4、SPECIAL BLACK 4A、PRINTEX U、PRINTEX V、PRINTEX 140U、PRINTEX 140V;山陽色素(股)製SF BLACK AD2065、SF BLACK AD2091、SF BLACK AD2128、SF BLACK AD4179等。
(B)成分之含量在本發明感光性樹脂組成物中,為0.01~60質量%較佳,為10~40質量%再較佳。(B)成分之含量只要在下限值以上,即能夠達到充分支遮光效果且沒有薄膜之剝離性及破壞特性,只要在上限值以下,則樹脂之流動性會變高,充填性較良好,故薄膜形成能會變佳,且信賴性、密著性、解像性良好,故較佳。
作為(C)成分之光酸產生劑,只要是因光照射而分解並產生酸即可,並無特別限定,但藉由照射波長190~500nm之光而產生酸者較佳。(C)光酸產生劑係作為硬化觸媒來使用。作為前述光酸產生劑,有舉例如鎓鹽、重氮甲烷衍生物、乙二肟衍生物、β-酮碸衍生物、二碸衍生物、對硝苄酯磺酸酯衍生物、碸酸酯衍生物、醯亞胺-基-
磺酸酯衍生物、肟磺酸酯衍生物、亞胺基磺酸酯衍生物、三嗪衍生物等。
作為前述鎓鹽,有舉出下述式(C1)表示之鋶鹽或下述式(C2)表示之錪鹽。
式(C1)及(C2)中,R101~R105分別獨立為亦可具有取代基之碳數1~12之烷基、亦可具有取代基之碳數6~12之芳基,或亦可具有取代基之碳數7~12之芳烷基。A-為非求核性對向離子。
前述烷基亦可為直鏈狀、分枝狀、環狀之任一者,作為其具體例,有舉出甲基、乙基、n-丙基、異丙基、環丙基、n-丁基、異丁基、sec-丁基、tert-丁基、環丁基、n-戊基、環戊基、環己基、降基、金剛烷基等。作為前述芳基,有舉出苯基、萘基、聯苯基等。作為前述芳烷基,有舉出苄基、苯乙基等。
作為前述取代基,有舉出氧基、直鏈狀、分枝狀或環狀之碳數1~12之烷氧基、直鏈狀、分枝狀或環狀之碳數1~12之烷基、碳數6~24之芳基、碳數7~25之芳烷基、碳數6~24之芳基氧基、碳數6~24之芳基硫基等。
作為R101~R105,為甲基、乙基、丙基、丁基、環己基、降基、金剛烷基、2-氧基環己基等之亦可具有取代基之烷基;苯基、萘基、聯苯基、o-、m-或p-甲
氧基苯基、乙氧基苯基、m-或p-tert-丁氧基苯基、2-、3-或4-甲基苯基、乙基苯基、4-tert-丁基苯基、4-丁基苯基、二甲基苯基、聯三苯基、聯苯基氧基苯基、聯苯基硫基苯基等之亦可具有取代基之芳基;為苄基、苯乙基等之亦可具有取代基之芳烷基較佳。此等之中,為亦可具有取代基之芳基、亦可具有取代基之芳烷基再較佳。
作為前述非求核性對向離子,有舉出氯化物離子、溴化物離子等之鹵離子;三氟甲磺酸鹽離子、1,1,1-三氟乙烷磺酸鹽離子、九氟丁烷磺酸鹽離子等之氟烷烴磺酸鹽離子;甲苯磺酸鹽離子、苯磺酸鹽離子、4-氟苯磺酸鹽離子、1,2,3,4,5-五氟苯磺酸鹽離子等之芳基磺酸鹽離子;甲磺酸鹽離子、丁烷磺酸鹽離子等之烷烴磺酸鹽離子;三氟甲烷碸醯亞胺離子等之氟烷烴碸醯亞胺離子;參(三氟甲烷磺醯基)甲基化離子等之氟烷烴磺醯基甲基化離子;肆苯基硼酸酯離子、肆(五氟苯基)硼酸鹽離子等之硼酸鹽離子等。
作為前述重氮甲烷衍生物,有舉出下述式(C3)表示之化合物。
式(C3)中,R111及R112分別獨立為碳數1~12之烷基或鹵化烷基、亦可具有取代基之碳數6~12之芳基,或碳數7~12之芳烷基。
前述烷基亦可為直鏈狀、分枝狀、環狀之任
一者,作為其具體例,有舉出與R101~R105之說明中例示者相同者。作為前述鹵化烷基,有舉出三氟甲基、1,1,1-三氟乙基、1,1,1-三氯乙基、九氟丁基等。
作為前述亦可具有取代基之芳基,有舉出苯基;2-、3-或4-甲氧基苯基、2-、3-或4-乙氧基苯基、3-或4-tert-丁氧基苯基等之烷氧基苯基;2-、3-或4-甲基苯基、乙基苯基、4-tert-丁基苯基、4-丁基苯基、二甲基苯基等之烷基苯基;氟苯基、氯苯基、1,2,3,4,5-五氟苯基等之鹵化芳基等。作為前述芳烷基,有舉出苄基、苯乙基等。
作為前述乙二肟衍生物,有舉出下述式(C4)表示之化合物。
式(C4)中,R121~R124分別獨立為碳數1~12之烷基或鹵化烷基、亦可具有取代基之碳數6~12之芳基,或碳數7~12之芳烷基。且,R123及R124亦可互相鍵結,並與鍵結於此等之碳原子一起形成環,形成環時,R123及R124鍵結所形成之基為碳數1~12之直鏈狀或分枝狀之伸烷基。
作為前述烷基、鹵化烷基、亦可具有取代基之芳基及芳烷基,有舉出與作為R111及R112所例示者相同者。作為前述直鏈狀或分枝狀之伸烷基,有舉出亞甲基、伸乙基、伸丙基、伸丁基、伸己基等。
作為前述鎓鹽,具體來說有舉出三氟甲烷碸
酸二苯基錪鎓、三氟甲烷碸酸(p-tert-丁氧基苯基)苯基錪鎓、p-甲苯碸酸二苯基錪鎓、p-甲苯碸酸(p-tert-丁氧基苯基)苯基錪鎓、三氟甲烷碸酸三苯基鋶、三氟甲烷碸酸(p-tert-丁氧基苯基)二苯基鋶、三氟甲烷碸酸雙(p-tert-丁氧基苯基)苯基鋶、三氟甲烷碸酸參(p-tert-丁氧基苯基)鋶、p-甲苯碸酸三苯基鋶、p-甲苯碸酸(p-tert-丁氧基苯基)二苯基鋶、p-甲苯碸酸雙(p-tert-丁氧基苯基)苯基鋶、p-甲苯碸酸參(p-tert-丁氧基苯基)鋶、九氟丁烷碸酸三苯基鋶、丁烷碸酸三苯基鋶、三氟甲烷碸酸三甲基鋶、p-甲苯碸酸三甲基鋶、三氟甲烷碸酸環己基甲基(2-氧基環己基)鋶、p-甲苯碸酸環己基甲基(2-氧基環己基)鋶、三氟甲烷碸酸二甲基苯基鋶、p-甲苯碸酸二甲基苯基鋶、三氟甲烷碸酸二環己基苯基鋶、p-甲苯碸酸二環己基苯基鋶、雙(4-tert-丁基苯基)錪鎓六氟磷酸酯、二苯基(4-硫基苯氧基苯基)鋶六氟銻酸酯、[4-(4-聯苯基硫基)苯基]-4-聯苯基苯基鋶參(三氟甲烷磺醯基)甲基化鹽、肆(氟苯基)硼酸三苯基鋶、肆(氟苯基)硼酸參[4-(4-乙醯基苯基)硫基苯基]鋶、肆(五氟苯基)硼酸三苯基鋶、肆(五氟苯基)硼酸參[4-(4-乙醯基苯基)硫基苯基]鋶等。
作為前述重氮甲烷衍生物,具體來說有舉出雙(苯磺醯基)重氮甲烷、雙(p-甲苯磺醯基)重氮甲烷、雙(二甲苯磺醯基)重氮甲烷、雙(環己基磺醯基)重氮甲烷、雙(環戊基磺醯基)重氮甲烷、雙(n-丁基磺醯基)重氮甲烷、雙(異丁基磺醯基)重氮甲烷、雙(sec-丁基磺醯基)重氮
甲烷、雙(n-丙基磺醯基)重氮甲烷、雙(異丙基磺醯基)重氮甲烷、雙(tert-丁基磺醯基)重氮甲烷、雙(n-戊基磺醯基)重氮甲烷、雙(異戊基磺醯基)重氮甲烷、雙(sec-戊基磺醯基)重氮甲烷、雙(tert-戊基磺醯基)重氮甲烷、1-環己基磺醯基-1-(tert-丁基磺醯基)重氮甲烷、1-環己基磺醯基-1-(tert-戊基磺醯基)重氮甲烷、1-tert-戊基磺醯基-1-(tert-丁基磺醯基)重氮甲烷等。
作為前述乙二肟衍生物,具體來說有舉出雙-o-(p-甲苯磺醯基)-α-二甲基乙二肟、雙-o-(p-甲苯磺醯基)-α-二苯基乙二肟、雙-o-(p-甲苯磺醯基)-α-二環己基乙二肟、雙-o-(p-甲苯磺醯基)-2,3-戊烷二酮乙二肟、雙-(p-甲苯磺醯基)-2-甲基-3,4-戊烷二酮乙二肟、雙-o-(n-丁烷磺醯基)-α-二甲基乙二肟、雙-o-(n-丁烷磺醯基)-α-二苯基乙二肟、雙-o-(n-丁烷磺醯基)-α-二環己基乙二肟、雙-o-(n-丁烷磺醯基)-2,3-戊烷二酮乙二肟、雙-o-(n-丁烷磺醯基)-2-甲基-3,4-戊烷二酮乙二肟、雙-o-(甲烷磺醯基)-α-二甲基乙二肟、雙-o-(三氟甲烷磺醯基)-α-二甲基乙二肟、雙-o-(1,1,1-三氟乙烷磺醯基)-α-二甲基乙二肟、雙-o-(tert-丁烷磺醯基)-α-二甲基乙二肟、雙-o-(全氟辛烷磺醯基)-α-二甲基乙二肟、雙-o-(環己烷磺醯基)-α-二甲基乙二肟、雙-o-(苯磺醯基)-α-二甲基乙二肟、雙-o-(p-氟苯磺醯基)-α-二甲基乙二肟、雙-o-(p-tert-丁基苯磺醯基)-α-二甲基乙二肟、雙-o-(二甲苯磺醯基)-α-二甲基乙二肟、雙-o-(樟腦磺醯基)-α-二甲基乙二肟等。
作為前述β-酮碸衍生物,具體來說有舉出2-環己基羰基-2-(p-甲苯磺醯基)丙烷、2-異丙基羰基-2-(p-甲苯磺醯基)丙烷等。
作為前述二碸衍生物,具體來說有舉出二苯基二碸、二環己基二碸等。
作為前述對硝苄酯磺酸酯衍生物,具體來說有舉出p-甲苯碸酸2,6-二對硝苄酯、p-甲苯碸酸2,4-二對硝苄酯等。
作為前述碸酸酯衍生物,具體來說有舉出1,2,3-參(甲烷磺醯基氧基)苯、1,2,3-參(三氟甲烷磺醯基氧基)苯、1,2,3-參(p-甲苯磺醯基氧基)苯等。
作為前述醯亞胺-基-磺酸酯衍生物,具體來說有舉出鄰苯二甲醯亞胺-基-三氟甲磺酸鹽、鄰苯二甲醯亞胺-基-甲苯磺酸鹽、5-降烯-2,3-二甲醯亞胺-基-三氟甲磺酸鹽、5-降烯-2,3-二甲醯亞胺-基-甲苯磺酸鹽、5-降烯-2,3-二甲醯亞胺-基-n-丁基磺酸酯、n-三氟甲基磺醯基氧基萘基醯亞胺等。
作為前述肟磺酸酯衍生物,具體來說有舉出α-(苯鋶氧基亞胺基)-4-甲基苯基乙腈等。
作為前述亞胺基磺酸酯衍生物,具體來說有舉出(5-(4-甲基苯基)磺醯基氧基亞胺基-5H-噻吩-2-亞基)-(2-甲基苯基)乙腈、(5-(4-(4-甲基苯基磺醯基氧基)苯基磺醯基氧基亞胺基)-5H-噻吩-2-亞基)-(2-甲基苯基)-乙腈等。
且,亦能夠適當地使用2-甲基-2-[(4-甲基苯基)磺醯基]-1-[(4-甲基硫基)苯基]-1-丙烷等。
作為(C)成分之光酸產生劑,尤其為前述鎓鹽較佳,為前述鋶鹽再較佳。
(C)成分之含量以光硬化性之觀點來看,相對於(A)成分100質量份,為0.05~20質量份較佳,為0.05~5質量份再較佳。(C)成分之含量只要在前述範圍,則能夠產生充分之酸且充份地反應交聯反應。
本發明之感光性樹脂組成物亦可進一步包含交聯劑作為(D)成分。前述交聯劑是一種會與(A)成分之式(a1)~(a3)及(b1)~(b3)中之環氧基或羥基引起縮合反應,並能夠容易形成圖型之成分,同時也是一種進一步提升光硬化後樹脂皮膜之強度之乘分。
作為前述交聯劑,為1分子中平均包含2個以上羥甲基及/或烷氧基甲基之三聚氰胺化合物、三聚氰二胺化合物、乙炔脲化合物、脲化合物等之含氮化合物、經甲醛或甲醛-醇所改質之胺基縮合物、1分子中平均具有2個以上羥甲基或烷氧基甲基之酚化合物及1分子中平均具有2個以上環氧基之環氧化合物較佳。此等之化合物能夠單獨使用1種,或組合2種以上來使用。
作為前述三聚氰胺化合物,有舉出下述式(D1)表示者。
式(D1)中,R201~R206分別獨立為羥甲基、碳數2~5之烷氧基甲基或氫原子,但至少1個為羥甲基或烷氧基甲基。作為前述烷氧基甲基,有舉出甲氧基甲基、乙氧基甲基等。
作為式(D1)表示之三聚氰胺化合物,有舉出三甲氧基甲基單羥甲基三聚氰胺、二甲氧基甲基單羥甲基三聚氰胺、三羥甲基三聚氰胺、六羥甲基三聚氰胺、六甲氧基甲基三聚氰胺、六乙氧基甲基三聚氰胺等。
式(D1)表示之三聚氰胺化合物能夠藉由例如首先根據公知方法將三聚氰胺單體以甲醛進行羥甲基化並改質,或將此進一步以乙醇進行烷氧基化並改質所得。且,作為前述乙醇,為低級乙醇,例如碳數1~4之乙醇較佳。
作為前述三聚氰二胺化合物,有舉出四羥甲基三聚氰二胺、四甲氧基甲基三聚氰二胺、四甲氧基乙基三聚氰二胺等。
作為前述乙炔脲化合物,有舉出四羥甲基乙炔脲、肆(甲氧基甲基)乙炔脲等。作為前述脲化合物,有舉出四羥甲基脲、四甲氧基甲基脲、四甲氧基乙基脲、四乙氧基甲基脲、四丙氧基甲基脲等。
作為前述經甲醛或甲醛-醇所改質之胺基縮合物,有舉出經甲醛或甲醛-醇所改質之三聚氰胺縮合物、經甲醛或甲醛-醇所改質之尿素縮合物等。
作為前述改質三聚氰胺縮合物,有舉出使式(D1)表示之化合物或此之多量體(例如二量體、三量體等之寡聚物體)與甲醛進行加成縮合聚合至所期望之分子量所得者。且,作為前述加成縮合聚合方法,能夠採用以往公知之方法。且,式(D1)表示之改質三聚氰胺能夠單獨使用1種,或組合2種以上來使用。
作為經甲醛或甲醛-醇所改質之尿素縮合物,有舉出甲氧基甲基化尿素縮合物、乙氧基甲基化尿素縮合物、丙氧基甲基化尿素縮合物等。
前述改質尿素縮合物能夠藉由例如根據公知之方法,將所期望分子量之尿素縮合物以甲醛進行羥甲基化並改質,或將此進一步以乙醇進行烷氧基化並改質所得。
前述1分子中平均具有2個以上羥甲基或烷氧基甲基之酚化合物,有舉出(2-羥基-5-甲基)-1,3-苯二甲醇、2,2',6,6'-四甲氧基甲基雙酚A等。
作為前述具有2個以上環氧基之環氧化合物,有舉出雙酚A型環氧樹脂、雙酚F型環氧樹脂等之雙酚型環氧樹脂、酚酚醛型環氧樹脂、甲酚酚醛型環氧樹脂等之酚醛型環氧樹脂、三酚烷烴型環氧樹脂、聯苯基型環氧樹脂、二環五二烯改質酚酚醛型環氧樹脂、酚芳烷基型
環氧樹脂、聯苯基芳烷基型環氧樹脂、萘環含有環氧樹脂、環氧丙基酯型環氧樹脂、脂環式環氧樹脂、雜環型環氧樹脂等。
(D)成分之含量相對於(A)成分100質量份,為0~100質量份,但含有時,0.5~100質量份較佳,為0.5~50質量份再較佳,為1~30質量份更較佳。(D)成分之含量只要在0.5質量份以上,則在光照射時能夠得到充分之硬化性,只要在100質量份以下,則感光性樹脂組成物中之(A)成分之比例不會降低,因此硬化物能夠表現充分之本發明效果。(D)成分能夠單獨使用1種,或組合2種以上來使用。
本發明之感光性樹脂組成物亦可進一步包含溶劑作為(E)成分。作為前述溶劑,只要是前述各成分或能夠溶解後述(F)成分及添加劑即可,並無特別限定。藉由摻混溶劑,能夠提升感光性樹脂組成物之塗布性。
作為如此之溶劑,有機溶劑對此等成分之溶解性較優異,故較佳。作為前述有機溶劑,有舉出環己酮、環戊酮、甲基-2-n-戊基酮等之酮類;3-甲氧基丁醇、3-甲基-3-甲氧基丁醇、1-甲氧基-2-丙醇、1-乙氧基-2-丙醇等之醇類;丙二醇單甲基醚、乙二醇單甲基醚、丙二醇單乙基醚、乙二醇單乙基醚、丙二醇二甲基醚、二乙二醇二甲基醚等之醚類;丙二醇單甲基醚乙酸酯(PGMEA)、丙
二醇單乙基醚乙酸酯、乳酸乙酯、丙酮酸乙酯、乙酸丁酯、3-甲氧基丙酸甲酯、3-乙氧基丙酸乙酯、乙酸tert-丁酯、丙酸tert-丁酯、丙二醇單-tert-丁基醚乙酸酯、γ-丁內酯等之酯類等。此等之有機溶劑能夠單獨使用1種,或混合2種以上來使用。尤其是光酸產生劑之溶解性較優異之乳酸乙酯、環己酮、環戊酮、PGMEA、γ-丁內酯及此等之混合溶劑較佳。
(E)成分之含量相對於(A)成分、(B)成分及(C)成分之合計100質量份,為0~5,000質量份,但含有時,以感光性樹脂組成物之相溶性及黏度之觀點來看,為50~2,000質量份較佳,為50~1,000質量份再較佳,為50~100質量份更較佳。
進而,本發明感光性樹脂組成物亦可包含消化體作為(F)成分。作為前述消化體,為因光酸產生劑所產生之酸擴散至感光性樹脂皮膜內時,能夠抑制擴散速度之化合物較適合。藉由摻混前述消化體,能夠提升解析度,抑制曝光後之感度變化,降低基板依存性或環境依存性,提升曝光余裕度或圖型形狀。
作為前述消化體,有舉出1級、2級或3級脂肪族胺類、混成胺類、芳香族胺類、雜環胺類、具有羧基之含氮化合物、具有磺醯基之含氮化合物、具有羥基之含氮化合物、具有羥基苯基之含氮化合物、乙醇性含氮化合
物、醯胺衍生物、醯亞胺衍生物等。
作為前述1級脂肪族胺類,有舉出氨、甲基胺、乙基胺、n-丙基胺、異丙基胺、n-丁基胺、異丁基胺、sec-丁基胺、tert-丁基胺、戊基胺、tert-戊基胺、環戊基胺、己基胺、環己基胺、庚基胺、辛基胺、壬基胺、癸基胺、十二基胺、十六基胺、亞甲基二胺、伸乙基二胺、四伸乙基五胺等。
作為前述2級脂肪族胺類,有舉出二甲基胺、二乙基胺、二-n-丙基胺、二異丙基胺、二-n-丁基胺、二異丁基胺、二-sec-丁基胺、二戊基胺、二環戊基胺、二己基胺、二環己基胺、二庚基胺、二辛基胺、二壬基胺、二癸基胺、二十二基胺、二十六基胺、N,N-二甲基亞甲基二胺、N,N-二甲基伸乙基二胺、N,N-二甲基四伸乙基五胺等。
作為前述3級脂肪族胺類,有舉出三甲基胺、三乙基胺、三-n-丙基胺、三異丙基胺、三-n-丁基胺、三異丁基胺、三-sec-丁基胺、三戊基胺、三環戊基胺、三己基胺、三環己基胺、三庚基胺、三辛基胺、三壬基胺、三癸基胺、三十二基胺、三十六基胺、N,N,N',N'-四甲基亞甲基二胺、N,N,N',N'-四甲基伸乙基二胺、N,N,N',N'-四甲基四伸乙基五胺等。
作為前述混成胺類,有舉出二甲基乙基胺、甲基乙基丙基胺、苄基胺、苯乙基胺、苄基二甲基胺等。
作為前述芳香族胺類及雜環胺類,有舉出苯
胺衍生物(例如苯胺、N-甲基苯胺、N-乙基苯胺、N-丙基苯胺、N,N-二甲基苯胺、2-甲基苯胺、3-甲基苯胺、4-甲基苯胺、乙基苯胺、丙基苯胺、三甲基苯胺、2-硝基苯胺、3-硝基苯胺、4-硝基苯胺、2,4-二硝基苯胺、2,6-二硝基苯胺、3,5-二硝基苯胺、N,N-二甲基甲苯胺等)、二苯基(p-甲苯基)胺、甲基二苯基胺、三苯基胺、伸苯基二胺、萘基胺、二胺基萘、吡咯衍生物(例如吡咯、2H-吡咯、1-甲基吡咯、2,4-二甲基吡咯、2,5-二甲基吡咯、N-甲基吡咯等)、噁唑衍生物(例如噁唑、異噁唑等)、噻唑衍生物(例如噻唑、異噻唑等)、咪唑衍生物(例如咪唑、4-甲基咪唑、4-甲基-2-苯基咪唑等)、吡唑衍生物、呋咱衍生物、二氫吡咯衍生物(例如二氫吡咯、2-甲基-1-二氫吡咯等)、吡咯啶衍生物(例如吡咯啶、N-甲基吡咯啶、吡咯啶酮、N-甲基-2-吡咯烷酮等)、咪唑啉衍生物、咪唑啶衍生物、吡啶衍生物(例如吡啶、甲基吡啶、乙基吡啶、丙基吡啶、丁基吡啶、4-(1-丁基戊基)吡啶、二甲基吡啶、三甲基吡啶、三乙基吡啶、苯基吡啶、3-甲基-2-苯基吡啶、4-tert-丁基吡啶、二苯基吡啶、苄基吡啶、甲氧基吡啶、丁氧基吡啶、二甲氧基吡啶、1-甲基-2-吡啶、4-吡咯啶基吡啶、1-甲基-4-苯基吡啶、2-(1-乙基丙基)吡啶、胺基吡啶、二甲基胺基吡啶等)、噠嗪衍生物、嘧啶衍生物、吡嗪衍生物、吡唑啉衍生物、吡唑啶衍生物、哌啶衍生物、哌嗪衍生物、嗎呋啉衍生物、吲哚衍生物、異吲哚衍生物、1H-吲唑衍生物、吲哚啉衍生物、喹啉衍生物(例如喹
啉、3-喹啉碳化睛等)、異喹啉衍生物、啉衍生物、喹唑啉衍生物、喹啉衍生物、呔衍生物、嘌呤衍生物、喋啶衍生物、咔唑衍生物、啡啶衍生物、吖啶衍生物、啡衍生物、1,10-啡啉衍生物、腺嘌呤衍生物、腺核苷衍生物、鳥嘌呤衍生物、鳥苷衍生物、尿嘧啶衍生物、尿苷衍生物等。
作為具有前述羧基之含氮化合物,有舉出胺基安息香酸、吲哚羧酸、胺基酸衍生物(例如菸鹼酸、丙胺酸、精胺酸、天冬醯胺酸、麩胺酸、甘胺酸、組胺酸、異白胺酸、甘胺酸基甘胺酸、白胺酸、甲硫胺酸、苯基丙胺酸、蘇胺酸、離胺酸、3-胺基吡嗪-2-羧酸、甲氧基丙胺酸等)等。
作為具有前述磺醯基之含氮化合物,有舉出3-吡啶碸酸、p-甲苯碸酸吡啶鹽等。
作為前述具有羥基之含氮化合物、具有羥基苯基之含氮化合物及乙醇性含氮化合物,有舉出2-羥基吡啶、胺基甲酚、2-喹啉二醇、3-吲哚水合甲醇、單乙醇胺、二乙醇胺、三乙醇胺、N-乙基二乙醇胺、N,N-二乙基乙醇胺、三異丙醇胺、2,2'-亞胺基二乙醇、2-胺基乙醇、3-胺基-1-丙醇、4-胺基-1-丁醇、4-(2-羥基乙基)嗎呋啉、2-(2-羥基乙基)吡啶、1-(2-羥基乙基)哌嗪、1-[2-(2-羥基乙氧基)乙基]哌嗪、哌啶乙醇、1-(2-羥基乙基)吡咯啶、1-(2-羥基乙基)-2-吡咯啶酮、3-六氫吡啶基-1,2-丙烷二醇、3-吡咯啶基-1,2-丙烷二醇、8-羥基咯啶、3-喹核
醇、3-托品醇、1-甲基-2-吡咯啶乙醇、1-氮丙啶乙醇、N-(2-羥基乙基)鄰苯二甲醯亞胺、N-(2-羥基乙基)異菸鹼酸醯胺等。
作為前述醯胺衍生物,有舉出甲醯胺、N-甲基甲醯胺、N,N-二甲基甲醯胺、乙醯胺、N-甲基乙醯胺、N,N-二甲基乙醯胺、丙醯胺、苯甲醯胺等。
作為前述醯亞胺衍生物,有舉出鄰苯二甲醯亞胺、琥珀醯亞胺、馬來醯亞胺等。
作為前述消化體,能夠使用下述式(F1)表示者。
【化37】(R 301 ) v -N-(R 302 ) 3-v (F1)
式(F1)中,v為1、2或3。R301為選自下述式(F2)~(F4)表示之取代基中任一種取代基。R302為氫原子或碳數1~20之烷基,亦可包含醚鍵或羥基。且,R301存在2個以上時,2個R301亦可互相鍵結並與此等所鍵結之氮原子一起形成環。且R301存在2個以上時,此等亦可相同或相異,R302存在2個時,此等亦可相同或相異。
式(F2)~(F4)中,R303、R305及R308分別獨立為直鏈狀或分枝狀之碳數1~4之烷烴二基。R304及R307分別獨立為氫原子或碳數1~20之烷基,且亦可包含1個或複數
個羥基、醚鍵、酯鍵及/或內酯環。R306為單鍵或直鏈狀或分枝狀之碳數1~4之烷烴二基。R309為碳數1~20之烷基,且亦可包含1個或複數個羥基、醚鍵、酯鍵及/或內酯環。
作為式(F1)表示之化合物,有舉出參[2-(甲氧基甲氧基)乙基]胺、參[2-(2-甲氧基乙氧基)乙基]胺、參[2-(2-甲氧基乙氧基甲氧基)乙基]胺、參[2-(1-甲氧基乙氧基)乙基]胺、參[2-(1-乙氧基乙氧基)乙基]胺、參[2-(1-乙氧基丙氧基)乙基]胺、參[2-{2-(2-羥基乙氧基)乙氧基}乙基]胺、4,7,13,16,21,24-六氧雜-1,10-二氮雜二環[8.8.8]二十六烷、4,7,13,18-四氧雜-1,10-二氮雜二環[8.5.5]二十烷、1,4,10,13-四氧雜-7,16-二氮雜二環十八烷、1-氮雜-12-冠醚-4、1-氮雜-15-冠醚-5、1-氮雜-18-冠醚-6、參(2-甲醯基氧基乙基)胺、參(2-乙醯氧基乙基)胺、參(2-丙醯基氧基乙基)胺、參(2-丁醯基氧基乙基)胺、參(2-異丁醯基氧基乙基)胺、參(2-戊醯基氧基乙基)胺、參(2-三甲基乙醯基氧基乙基)胺、N,N-雙(2-乙醯氧基乙基)2-(乙醯氧基乙醯氧基)乙基胺、參(2-甲氧基羰基氧基乙基)胺、參(2-tert-丁氧基羰基氧基乙基)胺、參[2-(2-氧基丙氧基)乙基]胺、參[2-(甲氧基羰基甲基)氧基乙基]胺、參[2-(tert-丁氧基羰基甲基氧基)乙基]胺、參[2-(環己基氧基羰基甲基氧基)乙基]胺、參(2-甲氧基羰基乙基)胺、參(2-乙氧基羰基乙基)胺、N,N-雙(2-羥基乙基)-2-(甲氧基羰基)乙基胺、N,N-雙(2-乙醯氧基乙基)-2-(甲氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-(乙氧基羰基)乙基胺、N,N-雙(2-乙醯氧基
乙基)-2-(乙氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-(2-甲氧基乙氧基羰基)乙基胺、N,N-雙(2-乙醯氧基乙基)-2-(2-甲氧基乙氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-(2-羥基乙氧基羰基)乙基胺、N,N-雙(2-乙醯氧基乙基)-2-(2-乙醯氧基乙氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-[(甲氧基羰基)甲氧基羰基]乙基胺、N,N-雙(2-乙醯氧基乙基)-2-[(甲氧基羰基)甲氧基羰基]乙基胺、N,N-雙(2-羥基乙基)-2-(2-氧基丙氧基羰基)乙基胺、N,N-雙(2-乙醯氧基乙基)-2-(2-氧基丙氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-(四氫呋喃甲基氧基羰基)乙基胺、N,N-雙(2-乙醯氧基乙基)-2-(四氫呋喃甲基氧基羰基)乙基胺、N,N-雙(2-羥基乙基)-2-[(2-氧基四氫呋喃-3-基)氧基羰基]乙基胺、N,N-雙(2-乙醯氧基乙基)-2-[(2-氧基四氫呋喃-3-基)氧基羰基]乙基胺、N,N-雙(2-羥基乙基)-2-(4-羥基丁氧基羰基)乙基胺、N,N-雙(2-甲醯基氧基乙基)-2-(4-甲醯基氧基丁氧基羰基)乙基胺、N,N-雙(2-甲醯基氧基乙基)-2-(2-甲醯基氧基乙氧基羰基)乙基胺、N,N-雙(2-甲氧基乙基)-2-(甲氧基羰基)乙基胺、N-(2-羥基乙基)雙[2-(甲氧基羰基)乙基]胺、N-(2-乙醯氧基乙基)雙[2-(甲氧基羰基)乙基]胺、N-(2-羥基乙基)雙[2-(乙氧基羰基)乙基]胺、N-(2-乙醯氧基乙基)雙[2-(乙氧基羰基)乙基]胺、N-(3-羥基-1-丙基)雙[2-(甲氧基羰基)乙基]胺、N-(3-乙醯氧基-1-丙基)雙[2-(甲氧基羰基)乙基]胺、N-(2-甲氧基乙基)雙[2-(甲氧基羰基)乙基]胺、N-丁基雙[2-(甲氧基羰基)乙基]胺、N-丁基雙[2-(2-甲
氧基乙氧基羰基)乙基]胺、N-甲基雙(2-乙醯氧基乙基)胺、N-乙基雙(2-乙醯氧基乙基)胺、N-甲基雙(2-三甲基乙醯基氧基乙基)胺、N-乙基雙[2-(甲氧基羰基氧基)乙基]胺、N-乙基雙[2-(tert-丁氧基羰基氧基)乙基]胺、參(甲氧基羰基甲基)胺、參(乙氧基羰基甲基)胺、N-丁基雙(甲氧基羰基甲基)胺、N-己基雙(甲氧基羰基甲基)胺、及β-(二乙基胺基)-δ-戊內酯,不限定於此等。
(F)成分之含量相對於(A)成分100質量份,為0~3質量份,但含有時,以感度之觀點來看,為0.01~2質量份較佳,為0.05~1質量份再較佳。
本發明感光性樹脂組成物除了前述各成分以外,亦可包含其他添加劑。作為其他添加劑,有舉例如習慣用來使塗布性提升之界面活性劑。
作為前述界面活性劑,為非離子性較佳,例如氟系界面活性劑,具體來說有舉出全氟烷基聚氧基伸乙基乙醇、氟化烷基酯、全氟烷基氧化胺、含氟有機矽氧烷系化合物等。此等能夠使用市售者,有舉例如Fluorad(登錄商標)「FC-430」(3M公司製)、Surflon(登錄商標)「S-141」及「S-145」(AGCSeimi Chemical(股)製)、Unidyne(登錄商標)「DS-401」、「DS-4031」及「DS-451」(Daikin工業(股)製)、Megafac(登錄商標)「F-8151」(DIC(股)製)、「X-70-093」(信越化學工業(股)製)等。此
等之中為Fluorad「FC-430」及「X-70-093」較佳。前述界面活性劑之含量相對於(A)成分100質量份為0.05~1質量份較佳。
本發明感光性樹脂組成物中,亦可包含矽烷偶合劑作為其他添加劑。藉由包含矽烷偶合劑,能夠更加提高由該組成物所得之樹脂皮膜對被接著體之密著性。作為矽烷偶合劑,有舉出環氧基含有矽烷偶合劑、芳香族基含有胺基矽烷偶合劑等。此等能夠單獨使用1種,或組合2種以上來使用。前述矽烷偶合劑之含量並無特別限定,但含有時,在本發明感光性樹脂組成物中,為0.01~5質量%較佳。
本發明之感光性樹脂組成物中亦可包含填料作為其他添加劑。作為填料,為平均粒徑0.01~20μm之矽或矽氧粉末。前述填料之含量並無特別限定,但含有時,本發明之感光性樹脂組成物中,為90質量%以下較佳。
本發明之感光性樹脂組成物並無裂痕,且薄膜特性佳,適合用來作為需要遮光性之黑矩陣用材料。
使用本發明感光性樹脂組成物之圖型形成方法包含:(i)將前述感光性樹脂組成物塗布於基板上,於該基板上形成感光性樹脂皮膜之步驟、(ii)將前述感光性樹脂皮膜曝光之步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將
非曝光部溶解去除並形成圖型之步驟。
步驟(i)為將前述感光性樹脂組成物塗布於基板上,於該基板上形成感光性樹脂皮膜之步驟。作為前述基板,有舉例如矽晶圓、玻璃晶圓、石英晶圓、塑膠製電路基板、陶瓷製電路基板等。
作為塗布方法,只要是公知方法即可,有舉出浸漬法、旋轉塗布法、軋輥塗布法等。塗布量能夠因應目的來適當選擇,但所得之感光性樹脂皮膜之膜厚較佳為0.1~200μm,再較佳為以1~150μm來塗布較佳。
以提升基板面上之膜厚均一性之目的,亦可在塗布感光性樹脂組成物之前,將溶劑滴落於基板(預濕法)。滴落之溶劑能夠因應目的來適當選擇。作為前述溶劑,例如為異丙基醇(IPA)等之醇類、環己酮等之酮類、丙二醇單甲基醚等之二醇類等較佳,但也能夠使用感光性樹脂組成物中所使用之溶劑。
於此,為了有效率地進行光硬化反應,亦可因應必要藉由預備加熱(預烘烤)來將溶劑等揮發。預烘烤能夠例如在40~140℃下進行1分鐘~1小時左右。
接著,(ii)將前述感光性樹脂皮膜曝光。此時,曝光為在波長10~600nm之光下進行較佳,在190~500nm之光下進行再較佳。作為如此波長之光,有舉例如藉由放射線發生裝置所產生之各種波長的光,例如g線、h線、i線等之紫外線光、遠紫外線光(248nm、193nm)等。此等中,為波長248~436nm之光特別佳。曝光量為
10~10,000mJ/cm2較佳。
曝光亦可介隔著光罩來進行。前述光罩亦可為例如劃出所期望之圖型者。且,光罩之材質並無特別限定,但為遮蔽前述波長之光較佳,例如適合使用具備鉻作為遮光膜者,但不限定於此等。
進而為了提升顯像感度,亦可進行曝光後加熱處理(PEB)。PEB為在40~150℃下進行0.5~10分鐘較佳。藉由PEB,曝光部分會交聯形成不溶於顯像液之有機溶劑的不溶化圖型。
(iii)曝光後或PEB後,以顯像液顯像,將非曝光部溶解去除形成圖型。作為顯像液,例如為IPA等之醇類、環己酮等之酮類、丙二醇單甲基醚等之二醇類等之有機溶劑較佳,但也能夠使用感光性樹脂組成物中所使用之溶劑。作為顯像方法,通常之方法有舉例如將有形成圖型之基板浸漬於前述顯像液之方法等。之後,因應必要,進行洗淨、清洗、乾燥等,得到具有所期望圖型之皮膜。
進而,(iv)亦可將形成圖型之皮膜使用烘箱或熱盤,較佳為在100~250℃下,再較佳為在150~220℃下進行後硬化。使用本發明之感光性樹脂組成物的話,即使為200℃前後這種比較低溫之後硬化,也能夠得到各種薄膜特性優異之樹脂皮膜。且,後硬化溫度為100~250℃的話,以能夠提升感光性樹脂組成物之交聯密度,去除殘存之揮發成分,對基板之密著力、耐熱性、強度、電氣特性、接合強度之觀點來看較佳。後硬化時間較佳為10分鐘
~10小時,再較佳為10分鐘~3小時。後硬化後之樹脂皮膜之膜厚通常為1~200μm,較佳為5~50μm。經過此等步驟,能夠得到最後目的之黑矩陣。
本發明之感光性乾薄膜為具備支持薄膜,與該支持薄膜上由感光性樹脂組成物所得之感光性樹脂皮膜者。
前述感光性乾薄膜(支持薄膜及感光性樹脂皮膜)為固體,由於感光性樹脂皮膜不包含溶劑,因此沒有其揮發所造成之氣泡殘留在前述感光性樹脂皮膜之內部及具有凹凸之基板之間之虞。前述感光性樹脂皮膜之膜厚並無特別限定,但為1~200μm較佳,為3~100μm再較佳。
且,前述感光性樹脂皮膜之黏度與流動性有密切關係,前述感光性樹脂皮膜能夠在適當的黏度範圍中發揮適當的流動性,能夠進入狹窄隙縫間的深處,或能夠藉由樹脂軟化來增強與基板之接著性。因此,前述感光性樹脂皮膜之黏度,以前述感光性樹脂皮膜之流動性之觀點來看,在80~120℃中,較佳為10~5,000Pa.s,再較佳為30~2,000Pa.s,更較佳為50~300Pa.s。且,本發明中,黏度為藉由旋轉黏度計之測定值。
本發明之感光性乾薄膜密著於具有凹凸之基板時,感光性樹脂皮膜能夠延著前述凹凸而被覆,且達到較高之平坦性。尤其是本發明之感光性樹脂組成物之特徵為軟化性能,因此能夠達成較高之平坦性。進而,將前述
感光性樹脂皮膜於真空環境下密著於前述基板時,能夠更有效地防止此等間隙之發生。
本發明感光性乾薄膜為藉由將前述感光性樹脂組成物塗布於基材上,使其乾燥後形成感光性樹脂皮膜來製造。作為前述感光性乾薄膜之製造裝置,能夠使用一般用來製造黏著劑製品之薄膜塗布機。作為前述薄膜塗布機,有舉例如點塗布機、點反轉塗布機、多功能塗布機、顏料塗布機、唇式塗布機、唇式反轉塗布機、直接槽輥塗布機、偏移槽輥塗布機、3根底部反轉塗布機、4根底部反轉塗布機等。
將支持薄膜自前述薄膜塗布機之捲出軸捲出,使其通過前述薄膜塗布機之塗布機頭部時,於前述支持薄膜上塗布前述感光性樹脂組成物成特定厚度後,以特定溫度及時間使其通過熱風循環烘箱,藉由於前述支持薄膜上使其乾燥來作為感光性樹脂皮膜,能夠製造感光性乾薄膜。且,因應必要,能夠與將感光性乾薄膜自前述薄膜塗布機的另一捲出軸捲出之保護薄膜一起,以特定壓力使其通過層合輥,將前述支持薄膜上之前述感光性樹脂皮膜與保護薄膜貼合後,藉由捲向前述薄膜塗布機之捲取軸,能夠製造附有保護薄膜之感光性乾薄膜。此時,作為前述溫度,為25~150℃較佳,作為前述時間,為1~100分鐘較佳,作為前述壓力,為0.01~5MPa較佳。
本發明感光性乾薄膜中所使用之支持薄膜亦可為由單一薄膜而成之單層薄膜,亦可為積層複數薄膜之
多層薄膜。作為前述薄膜之材質,有舉出聚乙烯、聚丙烯、聚碳酸酯、聚對苯二甲酸乙二酯等之合成樹脂薄膜。此等之中,為具有適度可撓性、機械性強度及耐熱性之聚對苯二甲酸乙二酯較佳。此等之薄膜亦可進行電暈處理或剝離劑塗布等之各種處理。此等能夠使用市售品,有舉例如Serapiru WZ(RX)、Serapiru BX8(R)(以上、Toray薄膜加工(股)製)、E7302、E7304(以上、東洋紡(股)製)、Purex G31、Purex G71T1(以上、Teijin Dupont薄膜(股)製)、PET38×1-A3、PET38×1-V8、PET38×1-X08(以上、Nippa(股)製)等。
作為前述保護薄膜,能夠使用與前述支持薄膜相同者,但為具有適度可撓性之聚對苯二甲酸乙二酯及聚乙烯較佳。此等能夠使用市售品,作為聚對苯二甲酸乙二酯,有舉出所有例示者,作為聚乙烯,有舉例如GF-8(Tamapoly(股)製)、PE薄膜0型(Nippa(股)製)等。
前述支持薄膜及保護薄膜之厚度,以感光性乾薄膜製造之安定性及對捲芯之容易捲曲,所謂捲曲防止之觀點來看,皆較佳為10~100μm,再較佳為25~50μm。
本發明之使用感光性乾薄膜之圖型形成方法包含(i')將前述感光性乾薄膜(ii)前述感光性樹脂皮膜曝光步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將
非曝光部溶解去除並形成圖型之步驟。
首先,使用(i')感光性乾薄膜於基板上形成感光性樹脂皮膜。亦即,藉由將感光性乾薄膜之感光性樹脂皮膜貼附於基板,於基板上形成感光性樹脂皮膜。且,前述感光性乾薄膜具有保護薄膜時,自感光性乾薄膜剝離保護薄膜後,將感光性乾薄膜之感光性樹脂皮膜貼附於基板。貼附能夠使用例如薄膜貼附裝置來進行。
作為前述薄膜貼附裝置,為真空貼合機較佳。例如將前述感光性乾薄膜之保護薄膜剝離,將露出之前述感光性樹脂皮膜在特定真空度之真空腔室內,使用特定壓力之貼附輥,使其密著於特定溫度之桌上前述基板。且,作為前述溫度,為60~120℃較佳,作為前述壓力,為0~5.0MPa較佳,作為前述真空度,為50~500Pa較佳。
為了有效率地進行前述感光性樹脂皮膜之光硬化反應,及提升感光性樹脂皮膜與基板之密著性,亦可因應必要進行預烘烤。預烘烤能夠例如在40~140℃下進行1分鐘~1小時左右。
貼附於基板之感光性樹脂皮膜與使用前述感光性樹脂組成物之圖型形成方法時相同,(ii)將前述感光性樹脂皮膜曝光之步驟、(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將非曝光部溶解去除並形成圖型之步驟,及因應必要(iv)能夠藉由進行後硬化加熱處理來形成圖型。且,感光性乾薄膜之支持薄膜因應製程,在預烘烤前或PEB前剝離,或以其他方法去除。
藉由本發明感光性樹脂組成物或使用感光性乾薄膜之圖型形成方法,能夠容易進行厚膜且微細之圖型形成。
以下示出合成例、比較合成例、實施例及比較例來更具體說明本發明,但本發明不限定於下述實施例。且,Mw為藉由作為管柱使用TSKgel Super HZM-H(Tosoh(股)製),以流量0.6mL/分鐘、溶出溶劑四氫呋喃、管柱溫度40℃之分析條件,並以單分散聚苯乙烯作為標準之GPC來測定。
下述合成例及比較合成例中,使用之化合物(S-1)~(S-7)如以下所示。
於具備攪拌機、溫度計、氮取代裝置及還流冷卻器之3L燒瓶中添加化合物(S-1)135.5g(0.25莫耳)、化合物(S-3)28.5g(0.05莫耳)及化合物(S-7)86.0g(0.2莫耳)後,添加甲苯2,000g,加熱至70℃。之後,添加氯化鉑酸甲苯溶液(鉑濃度0.5質量%)1.0g,以1小時的時間滴落化合物(S-5)58.2g(0.30莫耳)及化合物(S-6)(y1=40、信越化學工業(股)製)604.0g(0.20莫耳)(含氫矽烷基之合計/烯基之合計=1/1(莫耳比))。滴落結束後,加熱至100℃,熟成6小時後,自反應溶液將甲苯減壓餾去,得到樹脂1。樹脂1是藉由1H-NMR及29Si-NMR(Bruker公司製),分別確認包含重複單位a1、a2、a4、b1、b2及b4者,或確認GPC中各原料之波峰的消失而合成如添加比之聚合物。樹脂1之Mw為42,000,矽氧含有率為69.1質量%。
於具備攪拌機、溫度計、氮取代裝置及還流冷卻器之3L燒瓶中添加化合物(S-2)26.5g(0.10莫耳)、化合物(S-3)57.0g(0.10莫耳)、化合物(S-4)18.6g(0.10莫耳)及化合物(S-7)86.0g(0.20莫耳)後,添加甲苯2,000g,加熱至70℃。之後,添加氯化鉑酸甲苯溶液(鉑濃度0.5質量%)1.0g,以1小時的時間滴落化合物(S-5)58.2g(0.30莫耳)及化合物(S-6)(y1=20、信越化學工業(股)製)317g(0.20莫耳)(含氫矽烷基之合計/烯基之合計=1/1(莫耳比))。滴落結束後,加熱至100℃,熟成6小時後,自反應溶液將甲苯減壓餾去,得到樹脂2。樹脂2是藉由1H-NMR及29Si-NMR(Bruker公司製),分別確認包含重複單位a1、a3、a4、a5、b1、b3、b4及b5者,或確認GPC中各原料之波峰的消失而合成如添加比之聚合物。樹脂2之Mw為40,000,矽氧含有率為56.3質量%。
於具備攪拌機、溫度計、氮取代裝置及還流冷卻器之3L燒瓶中添加化合物(S-2)66.3g(0.25莫耳)、化合物(S-4)9.3g(0.05莫耳)及化合物(S-7)86.0g(0.20莫耳)後,添加甲苯2,000g,加熱至70℃。之後,添加氯化鉑酸甲苯溶液(鉑濃度0.5質量%)1.0g,以1小時的時間滴落化合物(S-5)58.2g(0.30莫耳)及化合物(S-6)(y1=40、信越化學工業(股)
製)604.0g(0.20莫耳)(含氫矽烷基之合計/烯基之合計=1/1(莫耳比))。滴落結束後,加熱至100℃,熟成6小時後,自反應溶液將甲苯減壓餾去,得到樹脂3。樹脂3是藉由1H-NMR及29Si-NMR(Bruker公司製),分別確認包含重複單位a1、a3、a5、b1、b3及b5者,或確認GPC中各原料之波峰的消失而合成如添加比之聚合物。樹脂3之Mw為46,000,矽氧含有率為73.3質量%。
於具備攪拌機、溫度計、氮取代裝置及還流冷卻器之3L燒瓶中添加化合物(S-1)117.6g(0.30莫耳)、化合物(S-4)18.6g(0.10莫耳)及化合物(S-3)57.0g(0.10莫耳)後,添加甲苯2,000g,加熱至70℃。之後,以1小時的時間添加氯化鉑酸甲苯溶液(鉑濃度0.5質量%)1.0g,化合物(S-5)83.4g(0.43莫耳)及化合物(S-6)(y1=40、信越化學工業(股)製)211.4g(0.07莫耳)(含氫矽烷基之合計/烯基之合計=1/1(莫耳比))。滴落結束後,加熱至100℃,熟成6小時後,自反應溶液將甲苯減壓餾去,得到樹脂4。樹脂4是藉由1H-NMR及29Si-NMR(Bruker公司製),分別確認包含重複單位a2、a4、a5、b2、b4及b5者,或確認GPC中各原料之波峰的消失而合成如添加比之聚合物。樹脂4之Mw為50,000,矽氧含有率為43.3質量%。
於具備攪拌機、溫度計、氮取代裝置及還流冷卻器之3L燒瓶中添加化合物(S-1)39.2g(0.10莫耳)、化合物(S-2)26.5g(0.10莫耳)、化合物(S-3)57.0g(0.10莫耳)及化合物(S-7)86.0g(0.20莫耳)後,添加甲苯2,000g,加熱至70℃。之後,添加氯化鉑酸甲苯溶液(鉑濃度0.5質量%)1.0g,以1小時的時間滴落化合物(S-5)97.0g(0.50莫耳)(含氫矽烷基之合計/烯基之合計=1/1(莫耳比))。滴落結束後,加熱至100℃,熟成6小時後,自反應溶液將甲苯減壓餾去,得到樹脂5。樹脂5之Mw為46,000,矽氧含有率為0質量%。
於具備攪拌機、還流冷卻機、惰性氣體導入口及溫度計之燒瓶中添加丙二醇單甲基醚70g、甲苯70g,在氮氣環境下升溫至80℃,一邊將反應溫度保持在80℃±2℃,以4小時的時間均勻地滴落甲基丙烯基酸甲酯90g、甲基丙烯基酸10g及2,2'-偶氮雙(異丁腈)。滴落後,於80℃±2℃連續攪拌6小時,得到丙烯酸樹脂6之溶液。丙烯酸樹脂6之Mw為50,000。
摻混各成分使其成為表1及2記載之組成,之後於常溫下攪拌、混合、溶解,調製實施例1~12及比較例1~11之感光性樹脂組成物。
表1及2中,(B)成分之碳黑如以下所示。
.乙炔黑(Denka(股)製HS-100:平均一次粒徑45nm)
.碳黑(三菱Chemical(股)製MA8:平均一次粒徑24nm)
表1及2中,光酸產生劑PAG-1、交聯劑CL-1及鹼基性化合物AM-1、丙烯酸樹脂7及Irgacure OXE02如以下所示。
丙烯酸樹脂7(ε-己內酯改質二季戊四醇之丙烯酸酸酯):日本化藥(股)製DPCA-20(參照下述式)
Irgacure OXE02(乙醛,1-[9-乙基-6-(2-甲基苯甲醯基)-9H-咔唑-3-基]-,1-(O-乙醯基肟)):BASF公司製
作為薄膜塗布機使用顏料塗布機,作為支持薄膜使用
聚對苯二甲酸乙二酯薄膜(厚度38μm),分別將表1及2記載之感光性樹脂組成物塗布於前述支持薄膜上。接著,藉由使其通過設定為100℃之熱風循環烘箱(長度4m)5分鐘來乾燥,於支持薄膜上形成感光性樹脂皮膜,得到感光性乾薄膜。藉由層合輥以壓力1MPa自前述感光性樹脂皮膜上貼附作為保護薄膜之聚乙烯薄膜(厚度50μm),製作附有保護薄膜之感光性乾薄膜。各感光性樹脂皮膜之膜厚記載於表3及4。且,感光性樹脂皮膜之膜厚能夠藉由光干擾式厚膜測定機來測定。
前述附有保護薄膜之感光性乾薄膜係剝離保護薄膜,使用真空貼合機TEAM-100RF((股)Takatori製),將真空腔室內之真空度設定為80Pa,將支持薄膜上之感光性樹脂皮膜密著於玻璃基板。溫度條件設為100℃。回到常壓後,將前述基板自真空貼合機取出,剝離支持薄膜。接著為了提高與基板之密著性,藉由熱盤於110℃度進行3分鐘預烘烤。為了形成線與間隔(Line and space)圖型及接觸孔圖型,介隔著遮罩以365nm之曝光條件並使用對準型曝光裝置對感光性樹脂皮膜進行曝光。光照射後,以熱盤於120℃下進行3分鐘PEB之後冷卻,將前述基板以PGMEA進行300秒鐘噴霧顯像,形成圖型。
將以前述方法形成圖型之基板上的感光性樹
脂皮膜使用烘箱於190℃下2小時一邊氮沖洗一邊後硬化。之後,藉由掃描式電子顯微鏡(SEM),觀察形成後之50μm、30μm、20μm、10μm、5μm之接觸孔圖型剖面,孔洞貫通薄膜底部之最小孔洞圖型之直徑作為界限解像性。進而自所得之剖面照片來評價50μm之接觸孔圖型之垂直性,垂直之圖型設為◎,稍微反楔形設為○,反楔形設為△,開口不良設為×。
將前述形成圖型之硬化後之實施例1~12及比較例1~11之附有感光性樹脂薄膜之基板使用具備切割刀片之切割鋸條(DAD685,DISCO公司製,轉軸旋轉數為40,000rpm,切斷速度為20mm/sec),得到10mm×10mm方塊之試驗片。將所得之試驗片(每次10片)提供至熱循環試驗(於-25℃下保持10分鐘,於125℃下保持10分鐘,重複1,000循環),確認熱循環試驗之後樹脂薄膜自基板之剝離狀態、裂痕之有無。將全部沒有產生剝離.裂痕者設為良好,將即使只產生1個剝離者亦設為剝離,將即使只產生1個裂痕者亦設為裂痕。
將製作之薄膜捲繞於直徑5mm之主桿,靜置10秒鐘後,恢復薄膜,將此重複10次,確認在薄膜上有無異常。將產生破裂等之情況設為「×」,將沒有變化之情況設為
「○」。
不介隔著遮罩,對於玻璃晶圓上層積所形成之組成物之全面,使用SUSS MicroTec公司之遮罩對準器MA8,照射以高壓水銀燈(波長360nm)作為光源之光後,進行PEB,浸漬於PGMEA。此操作後將殘留之皮膜進一步於190℃之烘箱中加熱2小時,得到硬化皮膜。關於此皮膜,使用分光光度計U-3900H((股)hitachi-hightech製),測定波長450nm之光之透過率。
分別於表3及4表示使用表1及2記載之各感光性樹脂組成物所得之樹脂皮膜之評價結果。
由以上結果能夠表示本發明之感光性樹脂組成物能夠形成具有良好信賴性(密著性、耐裂痕性)、解像性、可撓性,且膜厚雖薄也仍具有充分遮光性之硬化膜。
Claims (18)
- 一種感光性樹脂組成物,其係包含(A)包含含酸交聯性基之矽氧樹脂之基底樹脂(惟,其不包含含有環狀聚矽氧烷結構及陽離子聚合性官能基之聚矽氧烷化合物)、(B)碳黑,及(C)光酸產生劑,前述酸交聯性基為酚性羥基或環氧基。
- 如請求項1之感光性樹脂組成物,其中,(A)矽氧樹脂係包含下述式(a1)表示之重複單位及下述式(b1)表示之重複單位,以及下述式(a2)表示之重複單位及下述式(b2)表示之重複單位之矽氧樹脂,
- 如請求項1~4中任1項之感光性樹脂組成物,其中,包含(B)碳黑0.01~60質量%。
- 如請求項1~4中任1項之感光性樹脂組成物,其中,進一步包含(D)交聯劑。
- 如請求項9之感光性樹脂組成物,其中,(D)交聯劑為選自1分子中平均包含2個以上羥甲基及/或烷氧基甲基之三聚氰胺化合物、三聚氰二胺化合物、乙炔脲化合物及脲化合物、經甲醛或甲醛-醇改質之胺基縮合物、1分子中平均具有2個以上羥甲基或烷氧基甲基之酚化合物,及1分子中平均具有2個以上環氧基之環氧化合物中至少1種。
- 如請求項1~4中任1項之感光性樹脂組成 物,其中,進一步包含(E)溶劑。
- 如請求項1~4中任1項之感光性樹脂組成物,其中,進一步包含(F)消化體。
- 一種感光性樹脂皮膜,其係由如請求項1~12中任1項之感光性樹脂組成物所得。
- 一種感光性乾薄膜,其係具備支持薄膜,與該支持薄膜上之如請求項13之感光性樹脂皮膜。
- 一種圖型形成方法,其係包含:(i)將如請求項1~12中任1項之感光性樹脂組成物塗布於基板上,於該基板上形成感光性樹脂皮膜之步驟、(ii)將前述感光性樹脂皮膜曝光之步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將非曝光部溶解去除並形成圖型之步驟。
- 一種圖型形成方法,其係包含:(i')使用如請求項14之感光性乾薄膜,於前述基板上形成感光性樹脂皮膜之步驟、(ii)將前述感光性樹脂皮膜曝光之步驟,及(iii)將前述曝光之感光性樹脂皮膜以顯像液顯像,將非曝光部溶解去除並形成圖型之步驟。
- 如請求項15或16之圖型形成方法,其中,進一步包含(iv)將藉由顯像所圖型形成之樹脂皮膜於100~250℃之溫度下進行後硬化之步驟。
- 一種黑矩陣,其係具備如請求項13之感光性樹脂皮膜。
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