WO2012046808A1 - 陽極酸化膜の製造方法 - Google Patents
陽極酸化膜の製造方法 Download PDFInfo
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- WO2012046808A1 WO2012046808A1 PCT/JP2011/073109 JP2011073109W WO2012046808A1 WO 2012046808 A1 WO2012046808 A1 WO 2012046808A1 JP 2011073109 W JP2011073109 W JP 2011073109W WO 2012046808 A1 WO2012046808 A1 WO 2012046808A1
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
- C25D1/08—Perforated or foraminous objects, e.g. sieves
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/0005—Separation of the coating from the substrate
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/18—Metallic material, boron or silicon on other inorganic substrates
- C23C14/185—Metallic material, boron or silicon on other inorganic substrates by cathodic sputtering
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/58—After-treatment
- C23C14/5846—Reactive treatment
- C23C14/5853—Oxidation
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
- C25D11/12—Anodising more than once, e.g. in different baths
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
- C25D11/18—After-treatment, e.g. pore-sealing
- C25D11/24—Chemical after-treatment
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
- C25D11/06—Anodisation of aluminium or alloys based thereon characterised by the electrolytes used
- C25D11/10—Anodisation of aluminium or alloys based thereon characterised by the electrolytes used containing organic acids
Definitions
- the present invention relates to a method for producing an anodized film, and more particularly to a method for producing a self-supporting anodized film having a porous alumina layer.
- the self-supporting film means a film that can maintain the form of the film without being supported by the base material.
- This method utilizes the principle of a so-called moth-eye structure, and the refractive index for light incident on the substrate is determined from the refractive index of the incident medium along the depth direction of the irregularities, to the refractive index of the substrate.
- the reflection in the wavelength region where the reflection is desired to be prevented is suppressed by continuously changing the wavelength.
- the moth-eye structure has an advantage that it can exhibit an antireflection effect with a small incident angle dependency over a wide wavelength range, can be applied to many materials, and can form an uneven pattern directly on a substrate. As a result, a low-cost and high-performance antireflection film (or antireflection surface) can be provided.
- Patent Documents 2 to 4 As a method for producing a moth-eye structure, a method using an anodized porous alumina layer obtained by anodizing aluminum is attracting attention (Patent Documents 2 to 4).
- anodized porous alumina layer obtained by anodizing aluminum will be briefly described.
- a method for producing a porous structure using anodization has attracted attention as a simple method capable of forming regularly ordered nano-sized cylindrical pores (fine concave portions).
- an acidic or alkaline electrolyte such as sulfuric acid, oxalic acid, or phosphoric acid
- a voltage is applied using the aluminum substrate as an anode
- oxidation and dissolution proceed simultaneously on the surface of the aluminum substrate.
- An oxide film having pores can be formed. These cylindrical pores are oriented perpendicular to the oxide film and exhibit self-organized regularity under certain conditions (voltage, type of electrolyte, temperature, etc.). Is expected.
- the porous alumina layer formed under specific conditions takes an array in which almost regular hexagonal cells are two-dimensionally filled with the highest density when viewed from the direction perpendicular to the film surface.
- Each cell has a pore in the center, and the arrangement of the pores has periodicity.
- the cell is formed as a result of local dissolution and growth of the film, and dissolution and growth of the film proceed simultaneously at the bottom of the pores called a barrier layer.
- the cell size that is, the distance between adjacent pores (center-to-center distance) corresponds to approximately twice the thickness of the barrier layer and is approximately proportional to the voltage during anodization.
- the diameter of the pores depends on the type, concentration, temperature, etc.
- the pores of such porous alumina have an arrangement with high regularity (having periodicity) under a specific condition, an arrangement with irregularity to some extent or an irregularity (having no periodicity) depending on the conditions. ).
- Patent Document 2 discloses a method of forming an antireflection film (antireflection surface) using a stamper having an anodized porous alumina film on the surface.
- Patent Document 3 discloses a technique for forming a tapered concave portion in which the pore diameter continuously changes by repeating anodization of aluminum and pore diameter enlargement processing.
- Patent Document 4 a technique for forming an antireflection film using an alumina layer in which fine concave portions have stepped side surfaces.
- a mold for forming a moth-eye structure on the surface (hereinafter referred to as “moth-eye mold”) can be easily manufactured.
- the surface of an anodized aluminum film is used as it is as a mold, the effect of reducing the manufacturing cost is great.
- the surface structure of the moth-eye mold that can form the moth-eye structure is referred to as an “inverted moth-eye structure”.
- Patent Documents 5 to 8 a method for producing an anodized porous alumina film (self-supporting film) having a through-hole has been studied.
- Patent Document 5 discloses that a porous alumina layer having only a porous layer is formed on the aluminum layer side by anodizing the aluminum layer in close contact with the aluminum base material. And the method of isolate
- membrane is disclosed.
- Patent Documents 6 to 8 disclose a method of obtaining a porous alumina film by dissolving and removing an aluminum base material remaining on a base of a porous alumina layer after anodization.
- Patent Documents 1, 2, and 4 to 8 are incorporated herein by reference.
- JP-T-2001-517319 Special Table 2003-531962 JP 2005-156695 A International Publication No. 2006/059686 JP 2008-45170 A Japanese Patent Application Laid-Open No. 2009-120892 JP 2009-299188 A JP 2010-64924 A
- Patent Documents 6 to 8 it is difficult to dissolve the remaining aluminum base material over the entire surface with a treatment liquid that permeates from the interface, and it is particularly difficult to form a porous alumina film having a large area. .
- the present invention has been made to solve the above problems, and its main object is to provide a self-supporting anode having a porous alumina layer obtained by anodizing an aluminum layer formed on a substrate.
- An object of the present invention is to provide a method for producing an oxide film more easily than in the past.
- the method for producing an anodized film of the present invention comprises a laminated structure comprising a base material, a sacrificial layer containing aluminum formed on the base material, and an aluminum layer formed on the surface of the sacrificial layer.
- the base material may be an inorganic substrate (for example, a glass substrate) or a plastic substrate, but a remarkable effect is obtained particularly when a glass substrate containing an alkali metal is used.
- the laminated structure further includes an inorganic underlayer formed on the surface of the base material, and the sacrificial layer is formed on the inorganic underlayer.
- the method further includes a step (c) of bringing the porous alumina layer into contact with an etching solution after the step (b).
- the step (c) includes a step (c1) of enlarging the plurality of fine recesses of the porous alumina layer by bringing the porous alumina layer into contact with an etching solution.
- the method further includes a step (b1) of growing the plurality of fine recesses by further anodizing.
- the step (c1) and the step (b1) may be alternately performed a plurality of times.
- the porous alumina layer has a plurality of recesses having a two-dimensional size of 10 nm or more and less than 500 nm when viewed from the normal direction of the surface.
- the plurality of recesses may be regularly arranged or irregularly arranged.
- the porous alumina layer has a plurality of through-holes having a two-dimensional size of 10 nm or more and less than 500 nm when viewed from the normal direction of the surface.
- the plurality of through holes may be regularly arranged or irregularly arranged.
- the inorganic underlayer is a silicon oxide layer or a titanium oxide layer.
- the sacrificial layer includes aluminum and oxygen or nitrogen, and the aluminum content rate is higher on the aluminum layer side than on the base material side.
- the base material is a glass base material (glass substrate) containing an alkali metal
- the sacrificial layer is an AlO x layer.
- the oxygen atom concentration of AlO x layer is preferably not more than 30 atomic% 10 atomic% or more, preferably a thickness of the AlO x layer is 40nm or more 500nm or less, in some embodiments, More preferably, the thickness of the AlO x layer is not less than 50 nm and not more than 150 nm.
- a method for producing a self-supporting anodic oxide film having a porous alumina layer obtained by anodizing an aluminum layer formed on a substrate more easily than before is provided.
- (A) And (b) is a figure which shows the SEM image of the surface of the aluminum layer of the laminated structure 10 of Experimental example 2, (a) shows the SEM image immediately after film-forming of an aluminum layer, (b) Indicates an SEM image after immersion in a phosphoric acid aqueous solution. (A) And (b) is a figure which shows the SEM image of the surface of the aluminum layer of 30 A of laminated structures of the comparative example 3, (a) shows the SEM image immediately after film-forming of an aluminum layer, (b) Indicates an SEM image after immersion in a phosphoric acid aqueous solution.
- (A) And (b) is a figure which shows the SEM image of the surface of the aluminum layer of the laminated structure 30B of the comparative example 4, (a) shows the SEM image immediately after film-forming of an aluminum layer, (b) Indicates an SEM image after immersion in a phosphoric acid aqueous solution.
- (A) is a figure which shows the cross-sectional SEM image of the laminated structure 10 of an experiment example
- (b) is cross-sectional SEM of 10 A of laminated structures after performing the anodic oxidation process and the etching process to the laminated structure 10 It is a figure which shows an image
- (c) is a figure which shows the enlarged SEM image of the part enclosed with the circle of the broken line in (b).
- (A)-(e) is typical sectional drawing for demonstrating the manufacturing method of the well-known porous alumina layer.
- the Al layer (partially anodized) was formed in the anodizing process or etching process.
- the adhesion between the glass substrate and the glass substrate decreased. This problem was significant when a glass substrate containing alkali metal (soda lime glass) was used.
- a plastic film is used as a base material, there is a problem that the adhesiveness between the Al layer and the plastic film is lowered.
- the adhesion between the base material and the Al layer is not only difficult to peel off when the Al layer is directly formed on the surface of the base material, but also between the surface of the base material and the Al layer. It also represents the difficulty of peeling off the Al layer when other layers are interposed.
- a laminated structure having an Al layer 18 on the surface is prepared.
- the Al layer 18 is formed by a sputtering method using, for example, an aluminum target having a purity of 99.99% by mass or more.
- the thickness of the Al layer 18 is, for example, 1000 nm (1 ⁇ m).
- the thickness of the Al layer 18 is appropriately set according to the thickness of the target anodized alumina layer. For example, the thickness of the Al layer 18 is not less than 100 nm and not more than 3000 nm.
- a porous alumina layer 20 having pores 22 is formed by partially anodizing the Al layer 18 (surface portion) under predetermined conditions. Controlling the size of the pores 22, the generation density of the pores 22, the depth of the pores 22, etc., depending on the conditions of anodization (for example, the formation voltage, the type and concentration of the electrolytic solution, and the anodizing time) I can do it. Further, the regularity of the arrangement of the pores 22 can be controlled by controlling the magnitude of the formation voltage. For example, by applying a voltage of 80 V for 40 seconds at 20 ° C. using a 0.1 M oxalic acid aqueous solution, the porous alumina layer 20 having a distance between adjacent pores of 190 nm and a thickness of about 100 nm is obtained. can get.
- the initially produced porous alumina layer 20 may contain many defects due to the influence of impurities and the like.
- the thickness of the porous alumina layer 20 formed and removed first is preferably 200 nm or more from the viewpoint of reproducibility, and preferably 2000 nm or less from the viewpoint of productivity.
- the initially formed porous alumina layer 20 may be partially removed (for example, from the surface to a certain depth).
- the removal of the porous alumina layer 20 can be performed by a known method, for example, by immersing the porous alumina layer 20 in a phosphoric acid aqueous solution or a chromium phosphoric acid mixed solution for a predetermined time.
- the pore diameter of the pores 22 is expanded by etching the porous alumina layer 20 having the pores 22 in contact with an alumina etchant by a predetermined amount.
- the amount of etching (that is, the size and depth of the pores 22) can be controlled by adjusting the type / concentration of the etching solution and the etching time.
- the etching solution for example, an aqueous solution of 10% by mass of phosphoric acid, an organic acid such as formic acid, acetic acid or citric acid, or a mixed solution of chromium phosphoric acid can be used.
- the Al layer 18 is partially anodized again to grow the pores 22 in the depth direction and to thicken the porous alumina layer 20.
- the side surfaces of the pores 22 are stepped.
- the porous alumina layer 20 is further etched by bringing it into contact with an alumina etchant, whereby the pore diameter of the pores 22 is further expanded.
- an alumina etchant it is preferable to use the above-described etchant, and in practice, the same etch bath may be used.
- anodic oxidation step (FIG. 9B) and the etching step (FIG. 9C) are alternately repeated (for example, four anodizing steps and three etching steps) to obtain desired irregularities.
- a porous alumina layer 20 having pores (fine concave portions) 22 having a shape is obtained.
- the two-dimensional size of the pores (recesses) 22 when viewed from the normal direction of the surface is, for example, 10 nm or more and less than 500 nm, and the distance between adjacent pores (recesses) 22 is 30 nm or more and less than 600 nm. It is.
- the cleaning step and the drying step are performed between the anodizing step and the etching step or between the etching step and the anodizing step. You can go. Moreover, you may change conditions, such as a formation voltage, between each anodizing process.
- FIG. 1 shows a schematic cross-sectional view of a laminated structure 10 used in the method for producing an anodic oxide film according to an embodiment of the present invention
- FIGS. 2 (a) to (d) show the anode according to the embodiment of the present invention.
- the typical sectional view for explaining the manufacturing method of an oxide film is shown.
- FIGS. 3A to 3D are schematic cross-sectional views for explaining a method for manufacturing an anodized film according to another embodiment of the present invention.
- 4A and 4B are schematic cross-sectional views of laminated structures 30A and 30B of comparative examples, respectively.
- a laminated structure 10 used in the method for manufacturing an anodized film according to an embodiment of the present invention includes a glass substrate 12, an inorganic underlayer 14 formed on the surface of the glass substrate 12, and an inorganic base layer.
- a sacrificial layer 16 containing aluminum formed on the ground layer 14 and an Al layer 18 formed on the surface of the sacrificial layer 16 are included.
- a conductive layer (preferably a valve metal layer) is provided on the base in order to uniformly anodize the Al layer 18, it is between the inorganic base layer 14 and the sacrificial layer 16 or between the sacrificial layer 16 and the Al layer 18. It is preferable to provide a conductive layer between them.
- the inorganic underlayer 14 is directly formed on the surface of the glass substrate 12 and functions to prevent the alkali metal element contained in the glass substrate 12 from eluting. From the viewpoint of adhesiveness with the glass substrate 12, it is preferably formed of an inorganic oxide or an inorganic nitride.
- an inorganic oxide for example, a silicon oxide layer or a titanium oxide layer is preferable.
- an inorganic nitride for example, a silicon nitride layer is preferable.
- the thermal expansion coefficient can be increased by adding germanium (Ge), phosphorus (P), or boron (B).
- Ge germanium
- P phosphorus
- B boron
- the thermal expansion coefficient becomes about 2.8 ⁇ 10 ⁇ 6 / ° C., which is about three times that when Ge is not added.
- glass with small elution amount of alkalis such as Pyrex (trademark) glass, as a material of a glass substrate, you may abbreviate
- the thickness of the inorganic underlayer 14 is preferably 40 nm or more, and more preferably 100 nm or more. If the thickness of the inorganic underlayer 14 is less than 40 nm, the effect of providing the inorganic underlayer 14 may not be sufficiently exerted, and the elution of alkali metal elements from the glass substrate 12 may not be sufficiently blocked. Table 1 shows the results of evaluating the alkali passivation property.
- each sample shown in Table 1 (both were square soda lime glass plates with a side of 70 mm) was washed with pure water ultrasonic cleaning for 2 minutes.
- each sample is placed on a platinum plate 65 mm ⁇ , and the analysis surface is set to the platinum plate side (bottom surface), followed by heat treatment (after raising the temperature to 200 ° C. in about 2 hours, holding at 200 ° C. for 1 hour, and then releasing spontaneously. Cold (about half a day)). Thereafter, pure water was brought into contact with the analysis surface of each sample, and Na dissolved in the pure water was quantified by a flame method.
- the thickness of the inorganic underlayer 14 is preferably 500 nm or less, and more preferably 200 nm or less. If the thickness of the inorganic underlayer 14 exceeds 500 nm, the formation time of the inorganic underlayer 14 becomes unnecessarily long. In addition, the adhesive force between the glass substrate 12 and the inorganic underlayer 14 may be reduced due to thermal stress (shear stress) caused by the difference in thermal expansion coefficient between the glass substrate 12 and the inorganic underlayer 14. . Further, when a flexible base material such as a plastic film is used, if the thickness of the inorganic base layer 14 exceeds 500 nm, the inorganic base layer 14 is cracked when the base material is bent. There are things to do.
- the sacrificial layer 16 is provided between the inorganic underlayer 14 and the Al layer 18 and acts to improve the adhesion between the inorganic underlayer 14 and the Al layer 18.
- the sacrificial layer 16 is formed of a material having excellent acid resistance, and protects the inorganic underlayer 14 from acid.
- the sacrificial layer 16 preferably contains aluminum and oxygen or nitrogen. Although the oxygen or nitrogen content may be constant, it is particularly preferable that the aluminum content has a higher profile on the Al layer 18 side than on the inorganic underlayer 14 side (base material side). It is because it is excellent in matching of physical property values such as thermal expansion coefficient.
- the thickness of the sacrificial layer 16 is preferably 40 nm or more. The thickness of the sacrificial layer 16 is preferably 500 nm or less, and more preferably 200 nm or less.
- the inorganic underlayer 14 is sufficiently protected from the treatment liquid that penetrates from the Al layer 18 side (the electrolytic solution in the anodizing step and / or the etching solution in the etching step). In some cases, the effects of providing the sacrificial layer 16 may not be sufficiently exhibited. Further, if the thickness of the sacrificial layer 16 exceeds 500 nm, it is not preferable because the formation time of the sacrificial layer 16 becomes unnecessarily long.
- the profile in the thickness direction of the aluminum content in the sacrificial layer 16 may change stepwise or may change continuously.
- the sacrificial layer 16 is formed of aluminum and oxygen, a plurality of Al oxide layers whose oxygen content gradually decreases are formed, and the Al layer 18 is formed on the uppermost layer. The same applies to the case where the sacrificial layer 16 containing aluminum and nitrogen is formed.
- the Al layer 18 is formed by a known method (for example, an electron beam evaporation method or a sputtering method).
- the Al layer 18 having a thickness of about 1 ⁇ m is preferably deposited in a plurality of times rather than in a single deposition. That is, rather than continuously depositing to a desired thickness (for example, 1 ⁇ m), the process of interrupting the deposition to a certain thickness and restarting the deposition after a certain time has elapsed is repeated. It is preferable to obtain the Al layer 18.
- the quality (for example, chemical resistance and adhesion) of the finally obtained Al layer 18 can be improved.
- the continuous deposition of aluminum raises the temperature of the substrate (which has the surface on which the Al layer is deposited), which results in a distribution of thermal stress in the Al layer 18 and reduces film quality It is thought to make it.
- the porous alumina layer 20a is formed by the method described with reference to FIGS. 9A to 9E, using the laminated structure 10 shown in FIG.
- the laminated structure 10A includes a glass substrate 12, an inorganic underlayer 14 formed on the surface of the glass substrate 12, a sacrificial layer 16 containing aluminum formed on the inorganic underlayer 14, and a surface of the sacrificial layer 16 And the porous alumina layer 20a formed on the surface of the Al layer 18a.
- the porous alumina layer 20a has a porous layer 20ap having a recess 22a and a barrier layer 20ab.
- the laminated structure 10 includes the sacrificial layer 16
- the adhesion between the glass substrate 12 and the Al layer 18 is unnecessarily reduced during the anodizing process or the etching process, as will be described with reference to an experimental example.
- the anodic oxidation process and the etching process can be repeated as many times as necessary. For example, by repeating the anodic oxidation process and the etching process alternately many times, the stepped side surface of the concave portion 22a shown in FIG.
- the recess 22a having various cross-sectional shapes can be formed.
- the adhesiveness between the glass substrate 12 and the Al layer 18 may be adjusted in consideration of the balance between the anodic oxidation process and etching process necessary for forming the porous alumina layer 20a and the separation process described later.
- the adhesion between the glass substrate 12 and the Al layer 18 can be controlled, for example, by adjusting the composition (concentration and distribution of oxygen atoms and nitrogen atoms) and thickness of the sacrificial layer 16.
- the porous alumina layer 20a is separated (separated) from the laminated structure 10A. This separation occurs, for example, by peeling (interface failure) at the interface Sa between the inorganic underlayer 14 and the sacrificial layer 16.
- the interface Sb between the sacrificial layer 16 and the Al layer 18a is high in the aluminum concentration in the sacrificial layer 16 on the side of the Al layer 18a. Hard to occur.
- the adhesiveness of the interface Sc between the porous alumina layer 20a formed by partly anodizing the Al layer 18 and the remaining part (the part that has not been anodized) 18a of the Al layer 18 is high, and the interface Sc Peeling (interfacial failure) hardly occurs.
- peeling at the interface Sa is likely to occur, cohesive failure may occur in the inorganic underlayer 14, the sacrificial layer 16, and the Al layer 18a, or interface failure may occur partially at the interface Sb or Sc. .
- a silicone rubber having tackiness is pressed against the entire surface of the porous alumina layer 20a to peel off the silicone rubber, and one end of the porous alumina layer 20a is sucked by vacuum tweezers or the like. Then, starting from that, a method of gradually peeling, or a vacuum adsorption film (for example, FIXFILm (registered trademark) manufactured by Fuji Copian Corporation) is pressed against the entire surface of the porous alumina layer 20a, and the vacuum adsorption film is pulled.
- FIXFILm registered trademark
- the sacrificial layer 16 and the Al layer 18a of the laminated structure 10B are removed.
- This step can be performed using an appropriate treatment liquid.
- the sacrificial layer 16 is an AlOx layer
- the removal of the Al layer 18a can be performed by the method described in Patent Documents 6 to 8 (for example, a method using methanol bromide, iodomethanol, or mercuric chloride solution).
- the removal of the barrier layer 20ab is a mixed solution of chromic acid and phosphoric acid, an aqueous acid solution such as a phosphoric acid solution and a sulfuric acid solution, or an alkaline aqueous solution such as a sodium hydroxide solution. May be removed chemically, may be physically removed by irradiation with an ion beam or an electron beam, or may be removed mechanically by polishing or the like.
- a part of the surface of the Al layer 18 is anodized to form a porous alumina layer 20b.
- a body 20A is obtained.
- the porous alumina layer 20b has a porous layer 20bp having a cylindrical recess 22b and a barrier layer 20bb. Since the laminated structure 10 includes the sacrificial layer 16, the adhesion between the glass substrate 12 and the Al layer 18 does not deteriorate more than necessary during the anodic oxidation process.
- the porous alumina layer 20b is separated (separated) from the laminated structure 20A. This step can be performed in the same manner as described above with reference to FIG.
- the sacrificial layer 16 and the Al layer 18a of the laminated structure 20B are removed.
- This step can be performed in the same manner as described above with reference to FIG. In this way, a self-supporting anodic oxide film 20C composed only of the porous alumina layer 20b is obtained.
- the barrier layer 20bb of the porous alumina layer 20b is removed to obtain a self-supporting anodic oxide film 20D having a through hole 22b.
- This step can be performed in the same manner as described above with reference to FIG.
- a self-supporting anodic oxide film 10C or 20C composed only of a porous alumina layer 20a or 20b having a recess 22a or 22b. it can.
- a concave portion having a stepped side surface or a gently curved side surface, or a cylindrical concave portion can be formed.
- the self-supporting anodic oxide film 10D or 20D having the through holes 22a or 22b can be obtained.
- the recesses or the through holes can be arranged regularly or irregularly by appropriately setting the conditions for anodic oxidation.
- the step of separating the porous alumina layers 20a, 20b from the laminated structures 10A, 20A is mainly performed at the interface Sa at the interface Sa between the sacrificial layer 16 and the inorganic underlayer 14. It occurs by destruction (peeling) and cohesive failure in the sacrificial layer 16.
- the sacrificial layer 16 functions to stably adhere the Al layer 18 to the substrate 12 in the anodic oxidation process and / or etching process, and after the porous alumina layers 20a and 20b are formed, the porous alumina layer 20a. , 20b can be easily separated from the laminated structures 10A and 20A.
- the adhesiveness of the sacrificial layer 16 may be adjusted according to the conditions and number of times of the anodizing step and / or etching step necessary for forming the porous alumina layers 20a and 20b.
- soda-lime glass (also referred to as “blue plate glass”) substrate having a thickness of 2.8 mm was prepared.
- a SiO 2 layer 14 having a thickness of about 100 nm, a sacrificial layer (including aluminum and oxygen) 16 having a thickness of about 100 nm, and an Al layer 18 having a thickness of 1 ⁇ m were formed directly on the surface of the glass substrate 12. . All these layers were formed by sputtering in the same vacuum chamber. The sputtering conditions, the background degree of vacuum: 1 ⁇ 10 -5 Torr (0.0013Pa ), atmospheric gas: Ar, a vacuum degree during sputtering: 1 ⁇ 10 -3 Torr (0.13Pa ), the Al target Purity: 99.999 mass% was used.
- a sacrificial layer having a plurality of Al oxide layers having different oxygen contents was formed as the sacrificial layer 16.
- the oxygen content of the plurality of aluminum oxide layers has a higher profile as the layer is closer to the SiO 2 layer 14, in other words, the aluminum content has a higher profile on the Al layer 18 side than on the SiO 2 layer 14 side.
- a sacrificial layer 16 composed of a single aluminum oxide layer can also be used.
- the oxygen content of the aluminum oxide layer on the SiO 2 layer 14 side is 30 at% or more and 60 at% or less, and the oxygen content of the aluminum oxide layer on the Al layer 18 side is 5 at%. More than 30 at%, and the oxygen content of the two aluminum oxide layers satisfies the above relationship.
- the oxygen content of the aluminum oxide layer on the SiO 2 layer 14 side is 35 at% or more and 60 at% or less, and the oxygen content of the intermediate aluminum oxide layer is 20 at% or more and 35 at%.
- the oxygen content of the aluminum oxide layer on the Al layer 18 side is 5 at% or more and 20 at% or less, and the oxygen content of the three aluminum oxide layers satisfies the above relationship.
- the sacrificial layer 16 may be composed of four or more aluminum oxide layers.
- the sacrificial layer 16 can be formed using, for example, the following three methods (1) to (3).
- the oxygen content in the target is preferably in the range of 1 at% to 40 at%. If the oxygen content in the target is less than 1 at%, there is no effect of containing oxygen in the target, and if it exceeds 40 at%, it is not necessary to use O 2 gas.
- a film is formed by a reactive sputtering method using a pure Ar gas as a sputtering gas and an Al target containing an oxygen element.
- the oxygen content in the target is preferably in the range of 5 at% to 60 at%.
- the oxygen content in the target is less than 5 at%, the aluminum oxide layer to be formed may not be able to contain a sufficient amount of oxygen, and when it exceeds 60 at%, the oxygen contained in the aluminum oxide layer to be formed The element content may be too high.
- the content of the oxygen element contained in the aluminum oxide layer of the inorganic undercoat layer side (substrate side) is more than 60at%, the adhesion of the inorganic undercoat layer and (SiO 2) and aluminum oxide layer may be decreased.
- a film is formed by a reactive sputtering method using a pure aluminum target.
- the flow rate ratio of the mixed gas Ar gas and O 2 gas used for sputtering is set to about 2: 0 to about 2: 1. If the flow ratio of Ar gas to O 2 gas exceeds 2: 1, the content of oxygen element contained in the aluminum oxide layer to be formed may be too high.
- a sacrificial layer 16 having two aluminum oxide layers was formed using the method of (3) above.
- the oxygen content of each aluminum oxide layer was 5 at% and 48 at%, which satisfied the above relationship.
- the oxygen content was determined by X-ray photoelectron spectroscopy (ESCA).
- the thermal expansion coefficient (between room temperature and around 100 ° C.) of each component of the laminated structure 10 is as follows.
- Substrate 12 Soda lime glass: 8.7 ⁇ 10 ⁇ 6 / ° C.
- Inorganic underlayer 14 SiO 2 : 1.0 ⁇ 10 ⁇ 6 / ° C.
- Sacrificial layer 16 Al 2 O 3 : 6.9 ⁇ 10 ⁇ 6 / ° C.
- Al layer 18 Al: 23 ⁇ 10 ⁇ 6 / ° C.
- the thermal expansion coefficient is the thermal expansion coefficient of Al 2 O 3 (6 .9 ⁇ 10 ⁇ 6 / ° C.) and smaller than the thermal expansion coefficient of Al (23 ⁇ 10 ⁇ 6 / ° C.). Therefore, the adhesion to the Al layer 18 is improved by forming the sacrificial layer 16.
- the thermal expansion coefficient of the inorganic underlayer 14 formed of SiO 2 is smaller than the thermal expansion coefficients of the substrate 12 and the sacrificial layer 16 (lowermost layer), Ge is contained in SiO 2 in an amount of 5% by mass to 10% by mass. It is preferable to match the thermal expansion coefficient by doping about%.
- the laminated structure 30A of Comparative Example 1 shown in FIG. 4A is an inorganic layer made of SiO 2 on the glass substrate 12 without forming the sacrificial layer 16 in the method for producing the laminated structure of the experimental example. After forming the base layer 34, the Al layer 18 was formed.
- the laminated structure 30B of Comparative Example 2 shown in FIG. 4B is the same sacrificial layer as described above on the glass substrate 12 without forming the inorganic underlayer 14 in the method for producing the laminated structure of the experimental example. After forming 36, the Al layer 18 was formed.
- the adhesion between the glass substrate 12 and the Al layer 18 in the obtained laminated structure was evaluated by a so-called peel test (cross cut test) as follows.
- Comparative Examples 1 and 2 are not sufficient in adhesion after anodization and etching, whereas when the laminated structure of Experimental Example 1 is used, Adhesiveness with the Al layer 18 is improved, and sufficient adhesiveness is obtained even after anodic oxidation and etching.
- the SiO 2 is chemically damaged by the treatment liquid entering from the Al layer 18 side in the anodic oxidation process and / or etching process. It is thought to be for receiving.
- the processing liquid enters between the glass substrate 12 and the sacrificial layer 36 in the anodic oxidation process and / or etching process, It is considered that the alkali metal element in the glass is eluted by the reaction and corrodes the anodized alumina layer.
- Example 2 Comparative Examples 3 and 4
- the glass substrate 12 is used, whereas in the Experimental Example 2, the plastic film 12 is used.
- the laminated structure of Experimental Example 2 has the structure of the laminated structure 10 shown in FIG. 2, and includes a plastic film 12, an inorganic base layer 14 formed on the surface of the plastic film 12, and an inorganic base layer 14.
- a conductive layer preferably a valve metal layer
- a conductive layer is preferably provided between the sacrificial layer 16 and the Al layer 18.
- the material of the conductive layer is preferably a material having a small difference in standard electrode potential from aluminum such as titanium or magnesium so that electric corrosion does not occur. Titanium is also known to have an effect of improving adhesion.
- a PET (polyethylene terephthalate) film manufactured by Kimoto, thickness of 188 ⁇ m
- a SiO 2 layer having a thickness of 70 nm is formed as the inorganic underlayer 14
- the sacrificial layer 16 is thick.
- an Al layer 18 having a thickness of 1 ⁇ m was formed.
- the laminated structure of Comparative Example 3 has the structure of the laminated structure 30A shown in FIG. 4A.
- the sacrificial layer 16 is not formed, and a plastic film is formed.
- the inorganic underlayer 34 made of SiO 2 was formed on the (PET film) 12, the Al layer 18 was formed.
- the laminated structure of Comparative Example 4 has the structure of the laminated structure 30B shown in FIG. 4B.
- the inorganic underlayer 14 is not formed, and the plastic
- the same sacrificial layer 36 as described above was formed on the film (PET film) 12 and then the Al layer 18 was formed.
- the adhesion between the plastic film 12 and the Al layer 18 was evaluated by the same method as described above immediately after the Al layer 18 was formed and after being immersed in an aqueous phosphoric acid solution (1 M, 30 ° C.) for 30 minutes.
- the evaluation result of the laminated structure 30A of Comparative Example 3 was “X” immediately after the film formation and after immersion in the phosphoric acid aqueous solution, and the adhesiveness was poor.
- the evaluation result immediately after the film formation was “ ⁇ ”, but the evaluation result after immersion in the phosphoric acid aqueous solution was “x”.
- the laminated structure 10 of Experimental Example 2 had an evaluation result of “ ⁇ ” immediately after film formation and after immersion in a phosphoric acid aqueous solution, and good adhesiveness was obtained.
- FIGS. 5 (a) and 5 (b) show SEM images of the surface of the Al layer 18 of the laminated structure 30A of Comparative Example 3 and FIGS. 6 (a) and 6 (b) show the Al of the laminated structure 30B of Comparative Example 4.
- SEM images of the surface of the layer 18 are shown, and FIGS. 7A and 7B show SEM images of the surface of the Al layer 18 of the laminated structure 10 of Experimental Example 2.
- the small black dots seen in FIG. 5 (a) are pits (dents), and it can be seen from FIG. 5 (b) that they are enlarged by immersing them in an aqueous phosphoric acid solution.
- the laminated structure 30B of Comparative Example 4 has fewer pits than the laminated structure 30A of Comparative Example 3, and You can see that it is getting smaller.
- the sacrificial layer 16 composed of a single aluminum oxide layer is used, but as described in Experimental Example 1, the sacrificial layer 16 composed of a plurality of aluminum oxide layers may be used.
- the plastic film 12 is used.
- the sacrificial layer 16 an aluminum oxide layer having an oxygen content of 60 at% on the inorganic base layer 14 side, an aluminum oxide layer having an oxygen content of 1 at% on the Al layer 18 side, and asymptotically between these aluminum oxide layers.
- an aluminum oxide layer having a gradient in oxygen content was formed, a good result equal to or better than that of Experimental Example 2 was obtained.
- an Al layer can be formed on a plastic substrate other than the illustrated plastic film.
- Example 3 In Experimental Example 3, as in Experimental Example 1, as the sacrificial layer 16, an AlOx layer continuously changing so that the aluminum concentration is higher on the Al layer 18a side is formed, and the thickness of the AlOx layer and the AlOx layer are increased. The relationship between oxygen content and adhesiveness was investigated.
- the oxygen content in the AlOx layer was 0 at% on the SiO 2 layer 14 side and 100 at% on the Al layer 18 side, and the oxygen content during this period was increased linearly.
- Such an AlOx layer was formed by controlling the flow rate of oxygen during sputtering.
- the oxygen content was determined by X-ray photoelectron spectroscopy (ESCA).
- ESA X-ray photoelectron spectroscopy
- an Al layer 18 having a thickness of 1 ⁇ m was formed.
- the evaluation of adhesiveness was performed as follows. From the Al layer 18 side of the obtained laminated structure 10, 10 ⁇ 10 square lattices each having a 1 mm ⁇ 1 mm square were formed using a cutter knife. The cuts reached the surface of the glass substrate 12. After the adhesive tape (Scotch Tape BH-24 manufactured by Sumitomo 3M Co.) was adhered to the Al layer 18 in the cut area, the adhesive tape was peeled off, and the cells peeled off together with the adhesive tape (Al layer 18, inorganic underlayer 14 and Evaluation was made using the number of sacrificial layers 16).
- the evaluation was made in 10 stages, and the case where all were peeled was set to 0 and the case where all were left was set to 10 according to the number of cells which were not peeled off.
- the results are shown in Table 3.
- the oxygen content rate in the AlOx layer in Table 3 indicates the average oxygen content rate in the AlOx layer.
- the adhesiveness of the AlOx layer can be controlled by adjusting the thickness of the AlOx layer and the oxygen content in the AlOx layer.
- FIG. 8A shows an SiO 2 layer 14 having a thickness of about 100 nm, an AlOx layer (oxygen content 10 at%) 16 having a thickness of about 150 nm, and an Al layer 18 having a thickness of about 1 ⁇ m are provided on the glass substrate 12.
- FIG. 8B shows the laminated structure 10 after the anodic oxidation step and the etching step (both under the same conditions as in Experimental Example 1) were alternately performed seven times (four anodic oxidation steps and three etching steps).
- 8A shows a cross-sectional SEM image of the laminated structure 10A (see FIG. 2A)
- FIG. 8C shows an enlarged SEM image of a portion surrounded by a broken-line circle in FIG. 8B.
- the laminated structure 10 having the SiO 2 layer 14, the AlO x layer 16, and the Al layer 18 is formed. Further, as apparent from FIGS. 8B and 8C, the AlOx layer 16 is damaged through the anodic oxidation process and the etching process, and the AlOx layer 16 and the underlying SiO 2 layer 14 It can be seen that the contact area of the interface is small.
- the thickness of the AlOx layer is 50 nm or more and 150 nm or less, and the oxygen content is When it is within the range of 10 at% or more and 30 at% or less, the Al layer does not peel off during the anodizing step and the etching step, and after passing through the anodizing step and the etching step, the porous alumina can be easily obtained by the above method. Layer 20a can be separated.
- a titanium oxide layer or a silicon nitride layer can be used as the inorganic underlayer, and a layer containing aluminum and nitrogen can be used as the sacrificial layer.
- a well-known thing can be used suitably for the processing liquid for removing these.
- soda glass is used as the material of the glass substrate, but Pyrex glass, Tempax glass, or quartz glass can be used. Since these glass materials have a small alkali elution amount as shown in Table 4 below, when these glass materials are used for the substrate 12, the above-mentioned inorganic underlayer can be omitted. At this time, the sacrificial layer 16 serves to relieve stress due to a difference in thermal expansion coefficient between the base material and the Al layer, and improves the adhesiveness.
- an anodic oxide film having a through hole can be used as an electrolyte film for a fuel cell by filling the through hole with, for example, an electrolyte.
- a magnetic recording medium can also be comprised by filling a recessed part and a through-hole with a magnetic material.
- an optical element such as an antireflection film can be formed.
- DNA etc. can be regularly arranged using the through-hole and recessed part arranged regularly.
- the anodized film having a through hole can be used as a precise separation filter. Furthermore, it can also be used for a heat dissipation element, a thermoelectric element, etc. utilizing the large surface area.
- the present invention is used to manufacture a self-supporting anodic oxide film used in various applications.
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Abstract
Description
図1に示した構成を有する実験例1の積層構造体10を以下のようにして作製した。
基板12 :ソーダライムガラス :8.7×10-6/℃、
無機下地層14 :SiO2 :1.0×10-6/℃、
犠牲層16 :Al2O3 :6.9×10-6/℃
Al層18 :Al :23×10-6/℃
上記の実験例1の積層構造体では、ガラス基板12を用いたのに対し、本実験例2ではプラスチックフィルム12を用いる。
実験例3では、実験例1と同様に、犠牲層16として、アルミニウム濃度がAl層18a側で高くなるように連続的に変化しているAlOx層を形成し、AlOx層の厚さおよびAlOx層中の酸素含有率と接着性との関係を検討した。ガラス基板12としては、実験例1と同様に、厚さが2.8mmのソーダライムガラスの基板を用意し、ガラス基板12の表面上に直接、厚さが約100nmのSiO2層14を形成した。AlOx層中の酸素含有率は、SiO2層14側で0at%、Al層18側で100at%となり、且つ、この間の酸素含有率が直線的に増加するようにした。このような、AlOx層は、スパッタリング中の酸素の流量を制御することによって形成した。酸素含有率はX線光電子分光法(ESCA)で求めた。犠牲層16の形成と連続して、厚さ1μmのAl層18を形成した。
10C、10D、20C、20D 自己支持型の陽極酸化膜
12 基材(ガラス基板)またはプラスチックフィルム(プラスチック基板)
14、34 無機下地層
16、36 犠牲層
18、18a アルミニウム層(Al層)
20、20a、20b ポーラスアルミナ層
20ap、20bp ポーラス層
20ab、20bb バリア層
22、22a、22b 細孔、凹部または貫通孔
Claims (9)
- 陽極酸化膜の製造方法であって、
基材と、前記基材の上に形成されたアルミニウムを含有する犠牲層と、前記犠牲層の表面に形成されたアルミニウム層とを備える積層構造体を用意する工程(a)と、
前記アルミニウム層を部分的に陽極酸化することによって、複数の微細な凹部を有するポーラスアルミナ層を形成する工程(b)と、
前記工程(b)の後に、前記ポーラスアルミナ層を前記積層構造体から分離する工程(d)と
を包含し、前記陽極酸化膜は前記ポーラスアルミナ層を有する自己支持型の膜である、陽極酸化膜の製造方法。 - 前記積層構造体は、前記基材の表面に形成された無機下地層をさらに備え、前記犠牲層は前記無機下地層の上に形成されている、請求項1に記載の陽極酸化膜の製造方法。
- 前記工程(b)の後に、前記ポーラスアルミナ層を、エッチング液に接触させる工程(c)をさらに包含する、請求項1または2に記載の陽極酸化膜の製造方法。
- 前記工程(c)は、前記ポーラスアルミナ層をエッチング液に接触させることによって、前記ポーラスアルミナ層の前記複数の微細な凹部を拡大させる工程(c1)を包含し、
前記工程(c1)の後に、さらに陽極酸化することによって、前記複数の微細な凹部を成長させる工程(b1)を包含する、請求項3に記載の陽極酸化膜の製造方法。 - 前記工程(d)の後に、前記ポーラスアルミナ層に付着した前記アルミニウム層および/または前記犠牲層を除去する工程(e)をさらに包含する、請求項1から4のいずれかに記載の陽極酸化膜の製造方法。
- 前記工程(e)の後に、前記ポーラスアルミナ層が有するバリア層を除去する工程(f)をさらに包含する、請求項5に記載の陽極酸化膜の製造方法。
- 前記ポーラスアルミナ層は、表面の法線方向から見たときの2次元的な大きさが10nm以上500nm未満の複数の凹部または貫通孔を有する、請求項1から6のいずれかに記載の陽極酸化膜の製造方法。
- 前記無機下地層は、酸化シリコン層または酸化チタン層である、請求項2に記載の陽極酸化膜の製造方法。
- 前記犠牲層は、アルミニウムと、酸素または窒素とを含み、前記アルミニウムの含有率が前記基材側よりも前記アルミニウム層側において高いプロファイルを有する、請求項1から8のいずれかに記載の陽極酸化膜の製造方法。
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JPH0328397A (ja) * | 1989-02-02 | 1991-02-06 | Alcan Internatl Ltd | 二重酸化物膜フィルム及びその製造方法 |
JPH0361905A (ja) * | 1989-02-02 | 1991-03-18 | Alcan Internatl Ltd | 色変装置 |
JP2005307333A (ja) * | 2003-08-11 | 2005-11-04 | Canon Inc | 構造体、その製造方法及び多孔質体 |
JP2010090430A (ja) * | 2008-10-07 | 2010-04-22 | Fuji Electric Device Technology Co Ltd | アルミニウム合金形成基板及びその製造方法 |
WO2010116728A1 (ja) * | 2009-04-09 | 2010-10-14 | シャープ株式会社 | 型およびその製造方法 |
WO2010125795A1 (ja) * | 2009-04-30 | 2010-11-04 | シャープ株式会社 | 型およびその製造方法 |
WO2011135976A1 (ja) * | 2010-04-28 | 2011-11-03 | シャープ株式会社 | 型および型の製造方法 |
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CN103154329A (zh) | 2013-06-12 |
JP5595511B2 (ja) | 2014-09-24 |
US9133558B2 (en) | 2015-09-15 |
CN103154329B (zh) | 2015-09-16 |
US20130206600A1 (en) | 2013-08-15 |
JPWO2012046808A1 (ja) | 2014-02-24 |
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