WO2015053055A1 - 機能性膜 - Google Patents
機能性膜 Download PDFInfo
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- WO2015053055A1 WO2015053055A1 PCT/JP2014/074577 JP2014074577W WO2015053055A1 WO 2015053055 A1 WO2015053055 A1 WO 2015053055A1 JP 2014074577 W JP2014074577 W JP 2014074577W WO 2015053055 A1 WO2015053055 A1 WO 2015053055A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
- H01B3/12—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances ceramics
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B21/00—Nitrogen; Compounds thereof
- C01B21/082—Compounds containing nitrogen and non-metals and optionally metals
- C01B21/0828—Carbonitrides or oxycarbonitrides of metals, boron or silicon
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/308—Oxynitrides
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
- C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
- C23C16/36—Carbonitrides
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/458—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for supporting substrates in the reaction chamber
- C23C16/4582—Rigid and flat substrates, e.g. plates or discs
- C23C16/4583—Rigid and flat substrates, e.g. plates or discs the substrate being supported substantially horizontally
- C23C16/4586—Elements in the interior of the support, e.g. electrodes, heating or cooling devices
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
- C23C16/505—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using radio frequency discharges
- C23C16/509—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using radio frequency discharges using internal electrodes
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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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/54—Apparatus specially adapted for continuous coating
- C23C16/545—Apparatus specially adapted for continuous coating for coating elongated substrates
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32431—Constructional details of the reactor
- H01J37/32733—Means for moving the material to be treated
- H01J37/32752—Means for moving the material to be treated for moving the material across the discharge
- H01J37/32761—Continuous moving
- H01J37/3277—Continuous moving of continuous material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32009—Arrangements for generation of plasma specially adapted for examination or treatment of objects, e.g. plasma sources
- H01J37/32412—Plasma immersion ion implantation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/34—Gas-filled discharge tubes operating with cathodic sputtering
Definitions
- the present invention relates to a functional film.
- the functional film of the present invention is a film having a function, and the function means a function performed through a physical and / or chemical phenomenon.
- the functional film of the present invention includes films having various functions such as a gas barrier layer, an electrical insulating layer, a hard coat layer (scratch resistant layer), a foreign matter adhesion preventing layer, and a refractive index control layer.
- a silica-based ceramic film as an example of a functional film is useful in various fields such as a semiconductor device, a liquid crystal display device, an organic EL display device, and a printed circuit board.
- Non-Patent Document 1 J. S. Lewis and M. S. Weaver, “Thin-Film Permeation-Barrier Technology for Flexi- lent Electronic Light-Emetic Devices”. 1, 2004, pp. 45-57
- vacuum film forming method in which high energy is applied under vacuum, or energy such as heat or light is applied to the precursor of wet-formed silica-based ceramic film
- a large number of silica-based ceramic films manufactured by this method are disclosed.
- the silica-based ceramic film as described above has insufficient durability under high temperature and high humidity, and is used for extremely long periods of time under severe high temperature and high humidity, or repeatedly bent. When used, there was not sufficient bending resistance, and its improvement was required.
- the present invention has been made in view of the above circumstances, and an object thereof is to provide a functional film excellent in durability and bending resistance under high temperature and high humidity.
- M represents at least one selected from the group consisting of Group 13 elements of the long-period periodic table
- w, x, y, and z represent M, oxygen, nitrogen, and carbon, respectively.
- FIG. 1 10 represents a plasma CVD (PECVD) apparatus
- 11 represents a thin film forming substrate
- 12 represents a chamber
- 13 represents an upper electrode
- 14 represents a lower electrode
- 15 represents a power supply apparatus.
- 16a and 16b represent source gas storage units
- 16c represents an associated gas storage unit
- 17 represents piping
- 18 represents a gas inlet
- 19 represents a plasma discharge region
- 20a, 20b, 20c and 22 Represents a valve
- 21 represents a vacuum pump.
- 2 represents a base material
- 31 represents a manufacturing apparatus
- 32 represents a delivery roller
- 33, 34, 35 and 36 represent transport rollers
- 39 and 40 represent film forming rollers
- 41 represents A gas supply port is represented
- 42 represents a plasma generating power source
- 43 and 44 represent a magnetic field generator
- 45 represents a winding roller.
- X to Y indicating a range means “X or more and Y or less”, “weight” and “mass”, “weight%” and “mass%”, “part by weight” and “weight part”. “Part by mass” is treated as a synonym. Unless otherwise specified, operations and physical properties are measured under conditions of room temperature (20 to 25 ° C.) / Relative humidity 40 to 50%.
- M represents at least one selected from the group consisting of Group 13 elements of the long-period periodic table
- w, x, y, and z represent M, oxygen, nitrogen, and carbon, respectively.
- the functional film of the present invention has a chemical composition (SiM w O x N y C z ) represented by the above chemical formula (1), and element ratios of M, oxygen, nitrogen, and carbon to silicon (The ratio of the absorption intensity derived from Si—H with respect to the absorption intensity derived from Si—O observed in the IR spectrum (I [ Si—H] / I [Si—O] ) is 0.03 or less.
- the functional film of the present invention having such a configuration can perform its function even after being stored under severe high temperature and high humidity conditions (that is, it has durability under high temperature and high humidity conditions), and further repeatedly. Even when used to be bent, it has sufficient bending resistance.
- the entire functional film of the present invention may not satisfy the chemical composition of the present invention (that is, the chemical composition represented by the above-described chemical formula (1) satisfying the above-described mathematical formulas (1) to (4)). If the total thickness of the functional film is 20% or more with respect to 100%, the effect of the present invention can be exhibited, and the region having the chemical composition is preferably 50% or more, more preferably 80% or more. If there exists, the effect of this invention can be expressed. Further, from the viewpoint of avoiding the influence of adsorbed water and organic contamination on the surface of the functional film, it is preferable to have the region from 3% or less than the outermost surface of the functional film, and to reduce the region from 20% or less. It is preferable to have.
- gas barrier layer also referred to as “gas barrier film”
- gas barrier film which is an example of a function related to the functional film of the present invention, will be described, but the present invention is not limited thereto.
- the functional film having the SiM w O x N y C z composition is presumed that the respective elements form a network by covalent bonds with each other.
- hydrogen elements derived from the raw materials used or moisture in the air may also be present in the network.
- the metal M is not particularly limited as long as it is at least one metal selected from the group consisting of Group 13 elements of the long-period periodic table (that is, boron, aluminum, gallium, indium, thallium, and unthorium).
- the element ratio w of M to silicon is preferably 0.01 ⁇ w ⁇ 1.00, and more preferably 0.03 ⁇ w ⁇ 0.30.
- w is less than 0.01, the coordination bond is small and the strength of the film may be insufficient.
- w is 1.00 or more, the presence of a large amount of metal components in the functional film may deteriorate the initial gas barrier properties.
- Oxygen component in SiM w O x N y C z composition has the effect of forming a stable bond and Si element.
- the element ratio x of oxygen to silicon is preferably 1.00 ⁇ x ⁇ 2.40, and more preferably 1.50 ⁇ x ⁇ 2.20. In the range of 1.00 ⁇ x ⁇ 2.40, oxygen atoms and silicon atoms are alternately bonded to form Si—O—Si bonds, thereby forming a stable composition such as SiO 2. Out.
- x is 1.00 or less, since the ratio of highly stable Si—O—Si bonds in the functional film is small, the stabilization is insufficient, especially under severe high temperature and high humidity conditions. There is a risk that the gas barrier properties deteriorate when stored.
- the proportion of Si—O—Si bonds that are stable structures decreases, and the proportion of Si—N—Si bonds in the functional film increases.
- the nitrogen atom has a higher Lewis basicity than the oxygen atom, forms a coordinate bond with the metal element M, and tends to have a denser film than oxygen.
- the element ratio y of nitrogen to silicon is preferably 0.00 ⁇ y ⁇ 0.40, and more preferably 0.01 ⁇ y ⁇ 0.20.
- the carbon component in the SiM w O x N y C z composition has an effect of improving the bending resistance of the functional film.
- the element ratio z of carbon to silicon is preferably 0.01 ⁇ z ⁇ 1.00, and 0.04 ⁇ z ⁇ 0.50 from the viewpoint of achieving both durability at high temperature and high humidity and bending resistance. It is more preferable that
- the values of w, x, y, and z described above are determined by measuring the element ratio (atomic ratio) in the film thickness direction of each component using, for example, the following apparatus and method. be able to.
- XPS analysis conditions Apparatus QUANTERASXM (manufactured by ULVAC-PHI Co., Ltd.)
- X-ray source Monochromatic Al-K ⁇ Measurement area: Si2p, C1s, N1s, O1s, M * (M * is an optimum measurement region depending on the metal.
- boron B1s; aluminum: Al2p; gallium: Ga3d or Ga2p; indium: In3d ; In the case of thallium: Tl4f.
- Sputtering ion Ar (2 keV)
- Depth profile repeat measurement after 1 minute sputtering. One measurement corresponds to a thickness of about 5 nm in terms of a SiO 2 thin film standard sample. Note that the first measurement data is excluded when there is an influence of adsorbed water or organic matter contamination on the surface of the functional film.
- the background was determined by the Shirley method, and quantified using the relative sensitivity coefficient method from the obtained peak area.
- MultiPak manufactured by ULVAC-PHI
- the ratio of the intensity of absorption derived from Si—H near 2200 cm ⁇ 1 to the intensity of absorption derived from Si—O near 1050 cm ⁇ 1 observed by IR spectrum of the functional film (I [Si—H ] / I [Si—O] ) must be 0.03 or less, and more preferably 0.01 to 0.03.
- the value of (I [Si—H] / I [Si—O] ) exceeds 0.03, in a state where there are many Si—H bonds in the functional film, it is particularly severe such as 95 ° C. and 85% RH.
- each of M, oxygen, nitrogen, and carbon in the chemical formula SiM w O x N y C z needs to have a value of (I [Si—H] / I [Si—O] ) of 0.03 or less in addition to satisfying all of the above formulas (1) to (4). is there.
- the IR spectrum (infrared absorption) is measured by a transmission method or a reflection method.
- the transmission method infrared absorption based on Si—O bonds derived from a glass substrate affects the infrared absorption of the functional film. Therefore, a functional film is formed on a KBr plate or a CaF plate instead of the glass substrate. A substrate that is formed or that contains a functional membrane can be placed and measured.
- an attenuated total reflection method (ATR method, attended total reflection) is preferably used because the selection range of the substrate is wide.
- the IR spectrum obtained by the ATR method needs to be corrected by the reciprocal of the wavelength (1 / ⁇ ) because the depth of transmission through the sample differs depending on the wavelength. Thereby, it can correct
- the correction is incorporated in the software of the infrared absorption measurement apparatus and can be easily performed.
- “near” means that the numerical value of ⁇ 30 cm ⁇ 1 of the above-mentioned numerical value is also included in the range in the IR spectrum.
- the values of “I [Si—H] ” and “I [Si—O] ” are values obtained by correcting the spectrum obtained by the transmission method and the ATR method to the spectrum obtained by the transmission method. It shall be.
- the transmission method when the infrared absorption by the base material used cannot be ignored, measures such as attaching the base material to the reference light side are taken to cancel the absorption derived from the base material.
- the reflection method penetrates deeper than the functional film, when infrared absorption by the substrate used is detected, the infrared absorption of only the substrate is separately measured, and the measurement sample (including the substrate) By subtracting the substrate-derived absorption from the infrared absorption of the functional film), the “I [Si—H] ” value and the “I [Si—O] ” value derived from the functional film can be measured. .
- the relationship between the components can be expressed by the formula [(2x + 3y + 4z) / (4 + 3w)].
- (4 + 3w) represents a bond of silicon and metal element M
- (2x + 3y + 4z) represents a bond of oxygen, nitrogen, and carbon.
- the value of [(2x + 3y + 4z) / (4 + 3w)] is more than 0.8 and less than 1.5 (that is, 0.8 ⁇ [(2x + 3y + 4z)). /(4+3w)] ⁇ 1.5), and the closer to 1, the more preferable.
- the value of [(2x + 3y + 4z) / (4 + 3w)] is 1, and in this case, the bond of all elements forms the most stable bond (for example, high electronegativity) In this state, the element and the low element are alternately bonded to each other), resulting in a very strong and dense functional film.
- the thickness of the functional film of the present invention is not particularly limited as long as the effects of the present invention are not impaired, and can be appropriately set depending on the intended use.
- the thickness is preferably 1 to 500 nm, more preferably 5 to 300 nm, and even more preferably 10 to 200 nm.
- the functional film of the present invention can be formed on the surface of a substrate appropriately selected depending on the intended use.
- “on the surface of the substrate” means “on at least one surface of the substrate” and directly on at least one surface of the substrate. This means that the functional film may be formed through other layers, without being limited to the mode of forming the functional film.
- the formation method is not particularly limited, and a vapor deposition method such as a physical vapor deposition method (PVD method), an atomic layer deposition method (ALD method), or a chemical vapor deposition method (CVD method), or an inorganic compound.
- PVD method physical vapor deposition method
- ALD method atomic layer deposition method
- CVD method chemical vapor deposition method
- a method of forming a coating film formed by applying a coating solution containing, preferably a coating solution containing a polysilazane compound, by modification treatment (hereinafter also simply referred to as “coating method”) is preferably used.
- the physical vapor deposition method is a method of depositing a target material, for example, a thin film such as a carbon film, on the surface of the material in a gas phase by a physical method.
- a target material for example, a thin film such as a carbon film
- Examples thereof include a DC sputtering method, an RF sputtering method, an ion beam sputtering method, and a magnetron sputtering method, a vacuum deposition method, and an ion plating method.
- a target is placed in a vacuum chamber, and a rare gas (usually argon) ionized by applying a high voltage is collided with a target such as silicon oxide (SiO x ) to eject atoms on the target surface.
- a target such as silicon oxide (SiO x )
- SiO x silicon oxide
- a reactive sputtering method may be used in which an inorganic layer is formed by causing nitrogen and oxygen gas to flow into the chamber to react nitrogen and oxygen with an element ejected from the target by argon gas.
- the atomic layer deposition method is a method that uses chemical adsorption and chemical reaction of a plurality of low energy gases on the support surface.
- Sputtering and CVD methods use high-energy particles to cause pinholes and damage to the thin film produced.
- This method uses multiple low-energy gases, so pinholes and damage.
- Japanese Patent Laid-Open No. 2003-347042 Japanese Translation of PCT International Publication No. 2004-535514, International Publication No. 2004/105149.
- Chemical vapor deposition supplies a raw material gas containing the components of the target thin film onto the surface of the substrate, and forms the film by a chemical reaction on the surface of the substrate or in the gas phase. It is a method of depositing. In addition, for the purpose of activating the chemical reaction, there is a method of generating plasma or the like.
- Known CVD such as thermal CVD method, catalytic chemical vapor deposition method, photo CVD method, vacuum plasma CVD method, atmospheric pressure plasma CVD method, etc. Examples include methods. Although not particularly limited, it is preferable to apply a plasma CVD method such as a vacuum plasma CVD method or an atmospheric pressure plasma CVD method from the viewpoint of a film forming speed and a processing area.
- the plasma CVD apparatus (not the roll-to-roll system, which fixes the base material) shown in FIG. A functional film is formed (formed).
- the configuration of the plasma CVD apparatus 10 is as shown in FIG.
- an appropriately selected base material is mounted on the thin film forming substrate 11 of the lower electrode 14, and a film forming gas (for example, an organic silicon compound gas (source gas) such as HMDSO gas and oxygen gas)
- a film forming gas for example, an organic silicon compound gas (source gas) such as HMDSO gas and oxygen gas
- the reaction gas and the carrier gas such as helium gas are appropriately adopted as described later, and the opening / closing degree of the valves 22a, 22b, 22c and 22 and the power application degree by the power supply device 15 are controlled, so that there is no chamber 12 Pressure (vacuum degree), gas composition (for example, the flow rate or flow ratio of organosilicon compound and oxygen gas), plasma discharge amount (for example, magnitude of input power per unit flow rate of organosilicon compound gas) within a predetermined range
- a desired desired functional film can be formed as a deposited film on the appropriately selected substrate.
- the film forming gas for forming the functional film of the present invention is not particularly limited as long as each element component of the composition SiM w O x N y C z is contained.
- silicon as a source gas is contained.
- metal M Group 13 elements of the long-period periodic table
- a gas containing a compound, a reaction gas for forming an oxide as a reaction gas, and a reaction gas for forming a nitride may be used in combination, and silicon, metal M, and carbon coexist.
- a compound gas may be used as a source gas.
- Examples of the gas of the compound containing silicon used in the present invention include hexamethyldisiloxane (HMDSO), hexamethyldisilanesiloxane (HMDS), 1,1,3,3-tetramethyldisiloxane, vinyltrimethylsilane, Methyltrimethylsilane, hexamethyldisilane, silane, methylsilane, dimethylsilane, trimethylsilane, tetramethylsilane, diethylsilane, propylsilane, phenylsilane, vinyltriethoxysilane, vinyltrimethoxysilane, tetramethoxysilane (TMOS), and tetra And ethoxysilane (TEOS).
- HMDSO hexamethyldisiloxane
- HMDS hexamethyldisilanesiloxane
- 1,1,3,3-tetramethyldisiloxane vinyltrimethylsilane,
- hexamethyldisiloxane and 1,1,3,3-tetramethyldisiloxane are preferable from the viewpoints of properties such as compound handling properties and gas barrier properties of the functional film obtained.
- these film-forming gas can be used individually by 1 type or in combination of 2 or more types.
- Examples of the carbon-containing compound gas used in the present invention include methane, ethane, ethylene, and acetylene. Moreover, these film-forming gas can be used individually by 1 type or in combination of 2 or more types.
- Examples of the gas of the compound containing metal M used in the present invention include trimethylaluminum, triethylaluminum, trichloroaluminum, borane, diborane, trimethoxyborane, triethoxyborane, trichloroborane, trimethylgallium, trimethoxygallium, and trichloro.
- Examples include gallium, trimethylindium, trimethoxyindium, trichloroindium, trimethylthallium, trimethoxythallium, and trichlorothallium.
- these film-forming gas can be used individually by 1 type or in combination of 2 or more types.
- reaction gas for forming the oxide used in the present invention examples include oxygen and ozone.
- reaction gas for forming nitride examples include nitrogen and ammonia. These reaction gases can be used singly or in combination of two or more. For example, when forming an oxynitride, the reaction gas for forming an oxide and a nitride are formed. Can be used in combination with the reaction gas for
- a carrier gas may be used as necessary in order to supply the source gas into the vacuum chamber.
- a discharge gas may be used as necessary in order to generate plasma discharge.
- carrier gas and discharge gas known ones can be used as appropriate, for example, rare gases such as helium, argon, neon, xenon, or hydrogen gas can be used.
- the w, x, y, and z in the composition SiM w O x N y C z are adjusted as described above by adjusting the supply amount ratio or flow rate ratio of the above-described deposition gas.
- the equation (1) to (4) was filled, and the intensity of absorption derived relative intensities of absorption derived from Si-O in the vicinity of 1050 cm -1 was observed in the IR spectrum Si-H in the vicinity of 2200 cm -1
- the ratio (I [Si-H] / I [Si-O] ) can be controlled to satisfy 0.03 or less.
- the ratio of the source gas and the reaction gas is the amount of the reaction gas that is theoretically required to completely react the source gas and the reaction gas. It is preferable not to make the ratio of the reaction gas excessively higher than the ratio of. This is because by controlling the ratio of the reaction gas so as not to be excessive, excellent barrier properties and bending resistance can be effectively expressed in the formed functional film. Further, when the film forming gas contains the organosilicon compound and oxygen, the amount is less than or equal to the theoretical oxygen amount required for complete oxidation of the entire amount of the organosilicon compound in the film forming gas. It is preferable.
- the functional film of the present invention can be formed using the CVD apparatus shown in FIG. 1, and in addition to the roll-to-roll vacuum film forming apparatus of the opposite roll type (CVD shown in FIG. 2).
- CVD the roll-to-roll vacuum film forming apparatus of the opposite roll type
- a case where the functional film of the present invention is manufactured by the CVD apparatus 31 shown in FIG. 2 will be described as an example.
- FIG. 2 is a schematic configuration diagram showing an example of a film forming apparatus.
- the film forming apparatus 31 includes a delivery roller 32, transport rollers 33 to 36, first and second film forming rollers 39 and 40, a take-up roller 45, a gas supply port 41, a plasma.
- a power supply for generation (not shown), magnetic field generators 43 and 44, a vacuum chamber (not shown), a vacuum pump (not shown), and a controller (not shown) are included.
- the delivery roller 32, the transport rollers 33 to 36, the first and second film forming rollers 39 and 40, and the take-up roller 45 are accommodated in a vacuum chamber.
- the delivery roller 32 feeds the base material 2 installed in a state of being wound in advance toward the transport roll 11.
- the delivery roller 32 is a cylindrical roll extending in a direction perpendicular to the paper surface, and is wound around the delivery roller 32 by rotating counterclockwise by a drive motor (not shown) (see the arrow in FIG. 1).
- the base material 1 is sent out toward the transport roll 11.
- the transport rollers 33 to 36 are cylindrical rolls configured to be rotatable around a rotation axis substantially parallel to the feed roller 32.
- the transport roller 33 is a roller for transporting the base material from the feed roller 32 to the film forming roller 39 while applying an appropriate tension to the base material.
- the transport rollers 34 and 35 are rollers for transporting the base material from the film formation roller 39 to the film formation roller 40 while applying appropriate tension to the base material formed by the film formation roller 39.
- the transport roller 36 is a roll for transporting the base material from the film formation roller 40 to the take-up roller 45 while applying an appropriate tension to the base material formed by the film formation roller 40.
- the first film-forming roller 39 and the second film-forming roller 40 are a pair of film-forming rolls that have a rotation axis substantially parallel to the delivery roller 32 and are opposed to each other by a predetermined distance.
- the first film formation roller 39 and the second film formation roller 40 are discharge electrodes formed of a conductive material and are insulated from each other.
- the material and structure of the 1st film-forming roller 39 and the 2nd film-forming roller 40 can be suitably selected so that a desired function can be achieved as an electrode.
- Magnetic field generators 43 and 44 are installed inside the first and second film forming rollers 39 and 40, respectively.
- a high frequency voltage for plasma generation is applied to the first film formation roller 39 and the second film formation roller 40 by a plasma generation power source. As a result, an electric field is formed in the film forming space between the first film forming roller 39 and the second film forming roller 40, and discharge plasma of the film forming gas supplied from the gas supply port 41 is generated.
- the take-up roller 45 has a rotation axis substantially parallel to the feed roller 32, takes up the base material, and stores it in a roll shape.
- the take-up roller 45 takes up the substrate by rotating counterclockwise by a drive motor (not shown) (see the arrow in FIG. 2).
- the base material fed from the feed roller 32 is wound around the transport rollers 33 to 36, the first film forming roller 39, and the second film forming roller 40 between the feed roller 32 and the take-up roller 45. It is conveyed by rotation of each of these rolls while maintaining an appropriate tension.
- the conveyance direction of a base material is shown by the arrow.
- the conveyance speed of the base material can be appropriately adjusted according to the type of source gas, the pressure in the vacuum chamber, and the like.
- the conveying speed is preferably 0.1 to 100 m / min, and more preferably 0.5 to 20 m / min.
- the conveyance speed is adjusted by controlling the rotation speeds of the drive motors of the delivery roller 32 and the take-up roller 45 by the control unit 41.
- the gas barrier is set by setting the substrate transport direction to a direction (hereinafter referred to as the forward direction) opposite to the direction indicated by the arrow in FIG. 2 (hereinafter referred to as the forward direction).
- the film forming step of the conductive film can also be performed.
- the control unit rotates the rotation direction of the drive motor of the delivery roller 32 and the take-up roller 45 in the opposite direction to the above in the state where the substrate is taken up by the take-up roller 45.
- the base material fed from the take-up roller 45 is transferred between the feed roller 32 and the take-up roller 45, the transport rollers 33 to 36, the first film forming roller 39, and the second film forming roller. While being wound around the roll 40, it is conveyed in the opposite direction by the rotation of each of these rolls while maintaining an appropriate tension.
- the gas supply port 41 supplies a film forming gas such as a plasma CVD source gas into the vacuum chamber.
- the gas supply port 41 has a tubular shape that extends in the same direction as the rotation axes of the first film formation roller 39 and the second film formation roller 40 above the film formation space, and is provided at a plurality of locations. A film forming gas is supplied from the opening to the film forming space.
- the film forming gas such as the source gas is the same as the description of the film forming gas when the CVD apparatus shown in FIG. 1 is used, and thus the description thereof is omitted here.
- the ratio of the deposition gas supply rate / reaction gas supply rate is not particularly limited, but is preferably 0.04 to 0.2, preferably 0.06 to 0 from the viewpoint of gas barrier properties. .15 is more preferable.
- a carrier gas may be further used to supply the source gas into the vacuum chamber 30.
- a discharge gas may be further used to generate plasma.
- a carrier gas and the discharge gas for example, a rare gas such as argon, hydrogen, or nitrogen is used.
- the magnetic field generators 43 and 44 are members that form a magnetic field in the film formation space S between the first film formation roller 39 and the second film formation roller 40.
- the first film formation roller 39 and the second film formation roller It does not follow the rotation of 40 and is stored at a predetermined position.
- the vacuum chamber maintains the decompressed state by sealing the feed roller 32, the transport rollers 33 to 36, the first and second film forming rollers 39 and 40, and the take-up roller 45.
- the pressure in the vacuum chamber (degree of vacuum) can be adjusted as appropriate according to the type of source gas.
- the pressure in the film formation space is preferably 0.1 to 50 Pa. In order to suppress the gas phase reaction, when the plasma CVD is a low pressure plasma CVD method, the pressure is usually 0.1 to 100 Pa.
- the vacuum pump is communicably connected to the control unit, and appropriately adjusts the pressure in the vacuum chamber 30 in accordance with a command from the control unit.
- the control unit controls each component of the film forming apparatus 31.
- the control unit is connected to the drive motors of the feed roller 32 and the take-up roller 45, and adjusts the conveyance speed of the base material by controlling the number of rotations of these drive motors. Moreover, the conveyance direction of a base material is changed by controlling the rotation direction of a drive motor.
- the controller is connected to a film-forming gas supply mechanism (not shown) so as to be communicable, and controls the supply amount of each component gas of the film-forming gas.
- the control unit is communicably connected to the plasma generating power source and controls the output voltage and output frequency of the plasma generating power source.
- control unit is communicably connected to the vacuum pump, and controls the vacuum pump 40 so as to maintain the inside of the vacuum chamber in a predetermined reduced pressure atmosphere.
- the control unit includes a CPU (Central Processing Unit), a HDD (Hard Disk Drive), a RAM (Random Access Memory), and a ROM (Read Only Memory).
- the HDD stores a software program describing a procedure for controlling each component of the film forming apparatus 31 and realizing a method for producing a gas barrier film.
- the software program is loaded into the RAM and sequentially executed by the CPU.
- the ROM stores various data and parameters used when the CPU executes the software program.
- the present invention having the chemical composition represented by the chemical formula (1) described above can be used.
- a functional film can be formed.
- the carbon distribution curve shown is substantially continuous and has at least one extreme value.
- the functional film of the present invention can be formed by a coating method on the surface of a substrate appropriately selected according to the intended use.
- the coating liquid to be used is not particularly limited as long as each component element of composition SiM w O x N y C z is contained.
- a compound containing silicon, metal M, oxygen, nitrogen, and carbon is used.
- the silicon compound containing nitrogen used in combination with the compound of the organometallic M can prepare a coating solution containing the silicon compound containing nitrogen. If it is, it will not specifically limit, For example, a polysilazane compound, a silazane compound, an aminosilane compound, a silylacetamide compound, a silylimidazole compound, the silicon compound containing other nitrogen, etc. are used.
- the polysilazane compound is a polymer having a silicon-nitrogen bond.
- polysilazane compound is also abbreviated as “polysilazane”.
- the polysilazane compound preferably has a structure represented by the following general formula (I).
- R 1 , R 2 and R 3 are each independently a hydrogen atom, a substituted or unsubstituted alkyl group, aryl group, vinyl group or (trialkoxysilyl) alkyl group. .
- R 1 , R 2 and R 3 may be the same or different.
- examples of the alkyl group include linear, branched or cyclic alkyl groups having 1 to 8 carbon atoms.
- the aryl group include aryl groups having 6 to 30 carbon atoms.
- non-condensed hydrocarbon groups such as phenyl group, biphenyl group, terphenyl group; pentarenyl group, indenyl group, naphthyl group, azulenyl group, heptaenyl group, biphenylenyl group, fluorenyl group, acenaphthylenyl group, preadenenyl group , Condensed polycyclic hydrocarbon groups such as acenaphthenyl group, phenalenyl group, phenanthryl group, anthryl group, fluoranthenyl group, acephenanthrenyl group, aceantrirenyl group, triphenylenyl group, pyrenyl group, chrysenyl group, naphthacenyl group, etc.
- non-condensed hydrocarbon groups such as phenyl group, biphenyl group, terphenyl group; pentarenyl group, indenyl group, nap
- the (trialkoxysilyl) alkyl group includes an alkyl group having 1 to 8 carbon atoms having a silyl group substituted with an alkoxy group having 1 to 8 carbon atoms. More specific examples include 3- (triethoxysilyl) propyl group and 3- (trimethoxysilyl) propyl group.
- the substituent optionally present in R 1 to R 3 is not particularly limited, and examples thereof include an alkyl group, a halogen atom, a hydroxyl group (—OH), a mercapto group (—SH), a cyano group (—CN), There are a sulfo group (—SO 3 H), a carboxyl group (—COOH), a nitro group (—NO 2 ) and the like. Note that the optionally present substituent is not the same as R 1 to R 3 to be substituted. For example, when R 1 to R 3 are alkyl groups, they are not further substituted with an alkyl group.
- R 1 , R 2 and R 3 are preferably a hydrogen atom, a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, an isobutyl group, a tert-butyl group, a phenyl group, a vinyl group, 3 -(Triethoxysilyl) propyl group or 3- (trimethoxysilylpropyl) group.
- n is an integer representing the number of structural units of the formula: — [Si (R 1 ) (R 2 ) —N (R 3 )] —, and the general formula (I) It is preferable that the polysilazane compound having the structure represented by the formula is determined so as to have a number average molecular weight of 150 to 150,000 g / mol.
- one of the preferred embodiments of the compound having the structure represented by the general formula (I) is perhydropolysilazane in which all of R 1 , R 2 and R 3 are hydrogen atoms.
- polysilazane compound for example, a structure represented by general formula (II) or general formula (III) described in paragraphs “0051” to “0056” of JP2013-022799A is appropriately employed.
- Perhydropolysilazane is presumed to have a linear structure and a ring structure centered on 6- and 8-membered rings.
- the number average molecular weight (Mn) is about 600 to 2000 (polystyrene conversion), and there are liquid or solid substances, and the state varies depending on the molecular weight.
- the polysilazane compound is commercially available in the form of a solution dissolved in an organic solvent.
- examples of commercially available polysilazane solutions include NN120-10, NN120-20, NAX120-20, NAX-120, NN110, manufactured by AZ Electronic Materials Co., Ltd. NN310, NN320, NL110A, NL120A, NL120-20, NL150A, NP110, NP140, SP140 etc. are mentioned.
- Glycidol-added polysilazane obtained by reaction, alcohol-added polysilazane (JP-A-6-240208) obtained by reacting an alcohol, and metal carboxylic acid obtained by reacting a metal carboxylate Obtained by adding a salt-added polysilazane (JP-A-6-299118), an acetylacetonate complex-added polysilazane obtained by reacting a metal-containing acetylacetonate complex (JP-A-6-306329), and metal fine particles.
- Addition of fine metal particles Rishirazan JP 7-196986, such as, include polysilazane compounds ceramic at low temperatures.
- silazane compound examples include dimethyldisilazane, trimethyldisilazane, tetramethyldisilazane, pentamethyldisilazane, hexamethyldisilazane, and 1,3-divinyl-1,1,3,3- Examples thereof include, but are not limited to, tetramethyldisilazane.
- aminosilane compound examples include 3-aminopropyltrimethoxysilane, 3-aminopropyldimethylethoxysilane, 3-arylaminopropyltrimethoxysilane, propylethylenediaminesilane, N- [3- (trimethoxysilyl) ) Propyl] ethylenediamine, 3-butylaminopropyltrimethylsilane, 3-dimethylaminopropyldiethoxymethylsilane, 2- (2-aminoethylthioethyl) triethoxysilane, and bis (butylamino) dimethylsilane.
- silylacetamide compound examples include N-methyl-N-trimethylsilylacetamide, N, O-bis (tert-butyldimethylsilyl) acetamide, N, O-bis (diethylhydrogensilyl) trifluoroacetamide , N, O-bis (trimethylsilyl) acetamide, and N-trimethylsilylacetamide, but are not limited thereto.
- silylimidazole compound examples include 1- (tert-butyldimethylsilyl) imidazole, 1- (dimethylethylsilyl) imidazole, 1- (dimethylisopropylsilyl) imidazole, and N-trimethylsilylimidazole. However, it is not limited to these.
- silicon compound containing nitrogen for example, bis (trimethylsilyl) carbodiimide, trimethylsilylazide, N, O-bis (trimethylsilyl) hydroxylamine, N, N′-bis (trimethylsilyl) urea, 3 -Bromo-1- (triisopropylsilyl) indole, 3-bromo-1- (triisopropylsilyl) pyrrole, N-methyl-N, O-bis (trimethylsilyl) hydroxylamine, 3-isocyanatopropyltriethoxysilane, and silicon Although tetraisothiocyanate etc. are used, it is not limited to these.
- polysilazane compounds such as perhydropolysilazane and organopolysilazane are preferable in terms of film formation, fewer defects such as cracks, and a small amount of residual organic matter, and high gas barrier performance, Perhydropolysilazane is particularly preferable because gas barrier performance is exhibited even when bent and under high temperature and high humidity conditions.
- the metal M compound is not particularly limited as long as it is a compound containing at least one metal selected from the group consisting of Group 13 elements of the long-period periodic table. Preferably used. Although the preferable compound as a compound of the metal M is illustrated below, this invention is not limited.
- an aluminum compound is particularly preferably used as the metal M compound from the viewpoint of durability at high temperature and high humidity.
- the aluminum compound used in the present invention is not particularly limited, and examples thereof include organic aluminum compounds such as aluminum alkoxide or aluminum chelate compound.
- aluminum alkoxide refers to a compound having at least one alkoxy group bonded to aluminum.
- organoaluminum compounds used in the present invention include aluminum trimethoxide, aluminum triethoxide, aluminum tri n-propoxide, aluminum triisopropoxide, aluminum tri n-butoxide, aluminum tri sec-butoxide, aluminum trimethoxide.
- aluminum acetylacetonate aluminum acetylacetonate, acetoalkoxy aluminum diisopropylate, aluminum ethyl acetoacetate diisopropylate, aluminum ethyl acetoacetate di n-butylate, aluminum diethyl acetoacetate mono n-butyrate, aluminum diisopropylate mono sec- Butyrate, aluminum trisacetylacetonate, aluminum trisethylacetoacetate Bis (ethylacetoacetate) (2,4-pentanedionato) aluminum, aluminum alkyl acetoacetate diisopropylate, aluminum oxide isopropoxide trimers, and aluminum oxide octylate trimer include, but are not limited to.
- a commercial product or a synthetic product may be used as the aluminum compound according to the present invention.
- specific examples of commercially available products include, for example, AMD (aluminum diisopropylate monosec-butyrate), ASBD (aluminum secondary butyrate), ALCH (aluminum ethyl acetoacetate diisopropylate), ALCH-TR (aluminum tris).
- Ethyl acetoacetate Ethyl acetoacetate
- aluminum chelate M aluminum alkyl acetoacetate / diisopropylate
- aluminum chelate D aluminum chelate
- aluminum chelate A W
- AL-M acetoalkoxyaluminum diisopropylate, manufactured by Ajinomoto Fine Chemical Co., Ltd.
- AL-M acetoalkoxyaluminum diisopropylate, manufactured by Ajinomoto Fine Chemical Co., Ltd.
- boron compounds used in the present invention include trimethoxyborane, triethoxyborane, tri-n-propyl borate, triisopropyl borate, tri-n-butyl borate, tri-tert-butyl borate, trichloroborane and the like. For example, but not limited to.
- gallium compound examples include, but are not limited to, trimethoxygallium, triethoxygallium, trimethylgallium, and trichlorogallium.
- indium compound examples include, but are not limited to, trimethoxy indium, triethoxy indium, trimethyl indium, trichloro indium and the like.
- thallium compound examples include, but are not limited to, trimethoxythallium, triethoxythallium, trimethylthallium, trichlorothallium and the like.
- the element ratio w of the metal M to silicon in the functional film of the present invention can be controlled by adjusting the amount of the compound of the metal M to be added with respect to the amount of silicon element contained in the polysilazane. it can.
- the value of w does not substantially change even when coating drying, excimer irradiation treatment, or the like for forming a functional film described later is performed.
- the addition amount of the metal M compound can be determined so that the value of w in the SiM w O x N y C z composition satisfies the range defined in the present invention.
- the element ratio x of oxygen to silicon in the functional film of the present invention tends to increase as the amount of the metal M compound (particularly the alkoxide of metal M) increases.
- the element ratio y of nitrogen to silicon tends to decrease as the amount of the metal M compound added increases. Therefore, although not completely independent, the values of x and y in the SiM w O x N y C z composition can be controlled to satisfy the range defined in the present invention by the amount of the metal M compound added.
- the (I [Si—H] / I [Si—O] ) value in the IR spectrum of the functional film of the present invention can also be adjusted by the amount of metal M added.
- the element ratio z of carbon to silicon in the functional film of the present invention can be selected by selecting a compound of an organometallic M having a different ratio of the contained metal M and carbon, or by increasing or decreasing the excimer irradiation energy. It can be controlled independently of w.
- the coating solution for forming the functional film of the present invention contains a silicon compound not containing nitrogen as long as the effects of the present invention are not impaired, in addition to the above-described silicon compound containing nitrogen and the metal M compound. But you can. Specific examples include silsesquioxane, tetramethylsilane, trimethylmethoxysilane, dimethyldimethoxysilane, and methyltrimethoxysilane. These silicon compounds not containing nitrogen can be used singly or in combination of two or more.
- the coating solution for forming a functional film of the present invention can be prepared by dissolving the aforementioned compound containing silicon, metal M, oxygen, nitrogen, and carbon in an appropriate solvent. Preferably, it can be prepared by dissolving the aforementioned nitrogen-containing silicon compound and organometallic M compound in a suitable solvent.
- a silicon compound containing nitrogen and an organic metal M compound are mixed and then dissolved in a suitable solvent to prepare the coating solution.
- the silicon compound containing nitrogen is dissolved in a suitable solvent, and the coating solution (1) containing the silicon compound containing nitrogen and the compound of the organometallic M are dissolved in a suitable solvent, and the organometallic M is dissolved.
- the coating solution may be prepared by mixing the coating solution (2) containing the compound. From the viewpoint of liquid stability, a coating liquid is prepared by mixing a coating liquid (1) containing a silicon compound containing nitrogen and a coating liquid (2) containing a compound of organometallic M using the same solvent. More preferably.
- the coating liquid (1) may contain a silicon compound containing one kind of nitrogen, may contain a silicon compound containing two or more kinds of nitrogen, and contains the nitrogen described above. It may further contain a silicon compound that does not.
- the coating liquid (2) may contain one type of organometallic M compound or two or more types of organometallic M compounds.
- the solvent for preparing the functional film-forming coating solution is not particularly limited as long as it can dissolve the nitrogen-containing silicon compound and the metal M compound.
- nitrogen-containing silicon When a polysilazane compound is used as the compound, an organic solvent that does not contain water and reactive groups (for example, a hydroxyl group or an amine group) that easily react with the polysilazane compound and is inert to the polysilazane compound is preferable.
- An aprotic organic solvent is more preferable.
- an aprotic solvent for example, carbon such as aliphatic hydrocarbon, alicyclic hydrocarbon, aromatic hydrocarbon such as pentane, hexane, cyclohexane, toluene, xylene, solvesso, terpene, etc.
- Hydrogen solvents Halogen hydrocarbon solvents such as methylene chloride and trichloroethane; Esters such as ethyl acetate and butyl acetate; Ketones such as acetone and methyl ethyl ketone; Dibutyl ether, dioxane, tetrahydrofuran, mono- and polyalkylene glycol dialkyl ethers (diglymes) ) And the like.
- the said solvent may be used independently or may be used in mixture of 2 or more types.
- the solid content concentration of the nitrogen-containing silicon compound in the coating solution (1) is not particularly limited, and varies depending on the thickness of the layer and the pot life of the coating solution, but with respect to the coating solution (1).
- the content is preferably 0.1 to 30% by mass, more preferably 0.5 to 20% by mass, and still more preferably 1 to 15% by mass.
- the solid content concentration of the metal M compound in the coating liquid (2) is not particularly limited, and varies depending on the thickness of the layer and the pot life of the coating liquid.
- the content is preferably 0.1 to 50% by mass, more preferably 0.5 to 20% by mass, and still more preferably 1 to 10% by mass.
- the mixing molar ratio (coating liquid (1): coating liquid (2)) is a compound contained in the coating liquid.
- the coating liquid (1 to 100 mol% with respect to the Si atoms in the coating liquid (1)) may be determined. It is preferable to add 2).
- the coating liquid (1) and the coating liquid (2) when mixing the coating liquid (1) and the coating liquid (2), it is preferable to mix in an inert gas atmosphere.
- an inert gas atmosphere when the metal M alkoxide is used in the coating solution (2), the oxidation reaction of the metal M alkoxide by moisture or oxygen in the atmosphere is suppressed.
- the coating solution (1) and the coating solution (2) it is preferable to carry out stirring while heating at 30 to 90 ° C. from the viewpoint of reactivity control.
- the functional film-forming coating solution of the present invention preferably contains a catalyst in order to promote reforming.
- the catalyst is not particularly limited, and for example, those described in paragraph “0048” of JP2013-022799A can be appropriately employed.
- a coating solution prepared by a sol-gel method can be used for forming the functional film of the present invention as described in JP-A-2005-231039. .
- the coating liquid used when forming a functional film by the sol-gel method contains a silicon compound and a metal M compound. Further, the coating liquid can contain a sol-gel method catalyst, an acid, water, an organic solvent, or a resin. In the sol-gel method, a functional film can be obtained by polycondensation using such a coating solution.
- Method of applying functional film forming coating solution As a method for applying the functional film-forming coating solution of the present invention, a conventionally known appropriate wet coating method may be employed. Specific examples include spin coating method, roll coating method, flow coating method, ink jet method, spray coating method, printing method, dip coating method, die coating method, casting film forming method, bar coating method, gravure printing method and the like. It is done.
- the coating thickness can be appropriately set according to the purpose.
- the coating thickness per functional film layer is preferably 1 to 500 nm after drying, more preferably 5 to 300 nm, and even more preferably 10 to 200 nm. If the film thickness is 1 nm or more, sufficient barrier properties can be obtained, and if it is 500 nm or less, stable coating properties can be obtained at the time of layer formation, and high light transmittance can be realized.
- the coating film After applying the coating solution, it is preferable to dry the coating film.
- the organic solvent contained in the coating film can be removed. At this time, all of the organic solvent contained in the coating film may be dried or may be partially left. Even when a part of the organic solvent is left, a suitable functional film-forming coating solution can be obtained. The remaining solvent can be removed later.
- the drying temperature of the coating film varies depending on the substrate to be applied, but is preferably 50 to 200 ° C.
- the drying temperature is preferably set to 150 ° C. or lower in consideration of deformation of the base material due to heat.
- the temperature can be set by using a hot plate, oven, furnace or the like.
- the drying time is preferably set to a short time. For example, when the drying temperature is 150 ° C., the drying time is preferably set within 30 minutes.
- the drying atmosphere may be any condition such as an air atmosphere, a nitrogen atmosphere, an argon atmosphere, a vacuum atmosphere, or a reduced pressure atmosphere with a controlled oxygen concentration.
- the coating film obtained by applying the functional film-forming coating solution of the present invention may include a step of removing moisture before or during the modification treatment.
- a form of dehumidification while maintaining a low humidity environment is preferable. Since humidity in a low-humidity environment varies depending on temperature, a preferable form is shown for the relationship between temperature and humidity by defining the dew point temperature.
- the preferable dew point temperature is 4 ° C. or less (temperature 25 ° C./humidity 25%), the more preferable dew point temperature is ⁇ 5 ° C. or less (temperature 25 ° C./humidity 10%), and the time for maintaining is the film thickness of the functional film It is preferable to set appropriately.
- the dew point temperature is ⁇ 5 ° C. or less and the maintaining time is 1 minute or more.
- the lower limit of the dew point temperature is not particularly limited, but is usually ⁇ 50 ° C. or higher, and preferably ⁇ 40 ° C. or higher. Removal of moisture before or during the reforming treatment is a preferable form from the viewpoint of promoting the dehydration reaction of the functional film converted to silanol.
- the functional film of the present invention can be formed by a modification treatment.
- the modification treatment in the present invention refers to a reaction in which the silicon compound and the additive element compound are converted to a predetermined chemical composition, and the gas barrier film when the functional film of the present invention is used as a gas barrier layer as a whole is a gas barrier. It refers to the process of forming a thin orientation film that can contribute to the development of sex.
- the modification treatment for forming the functional film of the present invention refers to a reaction in which a silicon compound and a metal M compound are converted into the chemical composition represented by the chemical formula (1) described above.
- Such reforming treatment is performed by a known method, and specifically includes heat treatment, plasma treatment, active energy ray irradiation treatment, and the like. Among these, from the viewpoint that it can be modified at a low temperature and has a high degree of freedom in selecting a base material species, a treatment by irradiation with active energy rays is preferable.
- Heat treatment As a heat treatment method, for example, a method of heating a coating film by heat conduction by bringing a substrate into contact with a heating element such as a heat block, a method of heating an environment in which the coating film is placed by an external heater such as a resistance wire, Although the method using the light of infrared region, such as IR heater, is mentioned, It is not limited to these. What is necessary is just to select suitably the method which can maintain the smoothness of a coating film, when performing heat processing.
- the temperature for heating the coating film is preferably in the range of 40 to 250 ° C, more preferably in the range of 60 to 150 ° C.
- the heating time is preferably in the range of 10 seconds to 100 hours, and more preferably in the range of 30 seconds to 5 minutes.
- a known method can be used for the plasma treatment that can be used as the modification treatment, but from the viewpoint of excellent gas barrier properties, a method of implanting plasma ions is preferable.
- a method of injecting ions present in plasma generated using an external electric field into the coating film surface portion of the functional film, or (B) without using an external electric field A method of injecting ions present in plasma generated only by an electric field by a negative high voltage pulse applied to the coating film into the coating film surface portion of the functional film is preferable.
- the pressure during ion implantation is preferably 0.01 to 1 Pa.
- the pressure at the time of plasma ion implantation is in such a range, ions can be implanted easily and efficiently uniformly, and the target functional film can be efficiently formed.
- the processing operation is simple, and the processing time can be greatly shortened. Moreover, it can process uniformly throughout the said coating film, and the ion in plasma can be continuously inject
- RF radio frequency
- the pulse width when applying a negative high voltage pulse is preferably 1 to 15 ⁇ sec.
- the pulse width is in such a range, ions can be implanted more easily and efficiently and uniformly.
- the applied voltage when generating plasma is preferably -1 to -50 kV, more preferably -1 to -30 kV, and particularly preferably -5 to -20 kV.
- ions to be implanted ions of rare gases such as argon, helium, neon, krypton, and xenon; ions of fluorocarbon, hydrogen, nitrogen, oxygen, carbon dioxide, chlorine, fluorine, sulfur, etc .; methane, ethane, propane, butane Ions of alkane gases such as ethylene, propylene, butene and pentene; ions of alkadiene gases such as pentadiene and butadiene; alkyne gases such as acetylene and methylacetylene Ions of aromatic hydrocarbon gases such as benzene, toluene, xylene, indene, naphthalene and phenanthrene; ions of cycloalkane gases such as cyclopropane and cyclohexane; cycloalkene gases such as cyclopentene and cyclohexene Like On, and the like.
- rare gases such as argon, heli
- the amount of ions to be implanted may be appropriately determined according to the purpose of use of the film to be formed (necessary gas barrier properties, transparency, etc.).
- active energy ray irradiation treatment for example, infrared rays, visible rays, ultraviolet rays, X rays, electron rays, ⁇ rays, ⁇ rays, ⁇ rays and the like can be used, but electron rays or ultraviolet rays are preferable, and ultraviolet rays are more preferable.
- Ozone and active oxygen atoms generated by ultraviolet rays have high oxidation ability, and can form a silicon-containing film with high density and insulation at low temperatures.
- any commonly used ultraviolet ray generator can be used.
- the ultraviolet ray referred to in the present invention generally refers to an electromagnetic wave having a wavelength of 10 to 400 nm, but in the case of an ultraviolet irradiation treatment other than the vacuum ultraviolet ray (10 to 200 nm) treatment described later, it is preferably 210 to 375 nm. Use ultraviolet light.
- the irradiation intensity and the irradiation time are set within a range in which the substrate carrying the irradiated silicon-containing film is not damaged.
- the substrate temperature during ultraviolet irradiation treatment is 150 ° C. or more
- the properties of the substrate are impaired, such as deformation of the substrate or deterioration of its strength.
- a modification treatment at a higher temperature is possible.
- the atmosphere of the ultraviolet irradiation treatment is not particularly limited.
- ultraviolet ray generating means examples include metal halide lamps, high pressure mercury lamps, low pressure mercury lamps, xenon arc lamps, carbon arc lamps, and excimer lamps (single wavelengths of 172 nm, 222 nm, and 308 nm, for example, USHIO INC. Manufactured by M.D. Com Co., Ltd.), UV light laser, and the like, but are not particularly limited.
- metal halide lamps high pressure mercury lamps, low pressure mercury lamps, xenon arc lamps, carbon arc lamps, and excimer lamps (single wavelengths of 172 nm, 222 nm, and 308 nm, for example, USHIO INC. Manufactured by M.D. Com Co., Ltd.), UV light laser, and the like, but are not particularly limited.
- UV irradiation can be applied to both batch processing and continuous processing, and can be appropriately selected depending on the shape of the substrate used.
- a laminated body having a silicon-containing film on the surface can be processed in an ultraviolet baking furnace equipped with the ultraviolet generation source as described above.
- the ultraviolet baking furnace itself is generally known.
- an ultraviolet baking furnace manufactured by I-Graphics Co., Ltd. can be used.
- the ceramic is obtained by continuously irradiating ultraviolet rays in the drying zone having the ultraviolet ray generation source as described above while being conveyed.
- the time required for ultraviolet irradiation is generally 0.1 seconds to 10 minutes, preferably 0.5 seconds to 3 minutes, although it depends on the composition and concentration of the substrate and silicon-containing film to be used.
- the most preferable modification treatment method is treatment by vacuum ultraviolet irradiation (excimer irradiation treatment).
- the treatment by the vacuum ultraviolet irradiation uses light energy of 100 to 200 nm, preferably light energy of a wavelength of 100 to 180 nm, which is larger than the interatomic bonding force in the polysilazane compound, and bonds atoms with only photons called photon processes.
- This is a method of forming a silicon oxide film at a relatively low temperature (about 200 ° C. or lower) by causing an oxidation reaction with active oxygen or ozone to proceed while cutting directly by action.
- the radiation source in the present invention may be any radiation source that emits light having a wavelength of 100 to 180 nm, but is preferably an excimer radiator having a maximum emission at about 172 nm (eg, Xe excimer lamp), and has an emission line at about 185 nm.
- Excimer radiator having a maximum emission at about 172 nm (eg, Xe excimer lamp)
- the Xe excimer lamp emits ultraviolet light having a short wavelength of 172 nm at a single wavelength, and thus has excellent luminous efficiency. Since this light has a large oxygen absorption coefficient, it can generate radical oxygen atom species and ozone at a high concentration with a very small amount of oxygen.
- the energy of light having a short wavelength of 172 nm has a high ability to dissociate organic bonds. Due to the high energy of the active oxygen, ozone and ultraviolet radiation, the polysilazane layer can be modified in a short time.
- ⁇ Excimer lamps have high light generation efficiency and can be lit with low power.
- light having a long wavelength that causes a temperature increase due to light is not emitted, and energy is irradiated in the ultraviolet region, that is, in a short wavelength, so that the increase in the surface temperature of the target object is suppressed.
- it is suitable for flexible film materials such as PET that are easily affected by heat.
- Oxygen is required for the reaction at the time of ultraviolet irradiation, but since vacuum ultraviolet rays are absorbed by oxygen, the efficiency in the ultraviolet irradiation process tends to decrease. It is preferable to perform in a state where the water vapor concentration is low. Moreover, the value of the element ratio x of oxygen to silicon in the SiM w O x N y C z composition of the functional film of the present invention has a balance with the amount of addition of the compound of the metal M described above. While the oxygen concentration tends to decrease when the oxygen concentration is extremely decreased, for example, 50 ppm by volume or less, the element ratios y and z of nitrogen and carbon to silicon tend to increase.
- the oxygen concentration during irradiation with vacuum ultraviolet rays is preferably adjusted as appropriate within the range of 10 to 10,000 volume ppm (0.001 to 1%), and preferably 20 to 5000 volume ppm (0.002 to 0.002%). 0.5%) is more preferable.
- the water vapor concentration during the conversion process is not particularly limited, and is preferably in the range of 1000 to 4000 ppm by volume.
- the gas satisfying the irradiation atmosphere used at the time of irradiation with vacuum ultraviolet rays is preferably a dry inert gas, and particularly preferably dry nitrogen gas from the viewpoint of cost.
- the oxygen concentration can be adjusted by measuring the flow rate of oxygen gas and inert gas introduced into the irradiation chamber and changing the flow rate ratio.
- the value of SiM w O x N y C z elemental ratio z to silicon of carbon in the composition of the functional film of the present invention there is also balance with the kind of the compound of the metal M described above, the vacuum in the coated surface There is a tendency to decrease by increasing the amount of irradiation energy of ultraviolet rays. Therefore, in the present invention, it is preferable to appropriately adjust the irradiation energy amount of vacuum ultraviolet rays on the coating surface within the range of 1 to 10 J / cm 2 . If it is less than 1 J / cm 2, there is a concern that the modification will be insufficient, and if it exceeds 10 J / cm 2 , there is a concern that cracking due to excessive modification or thermal deformation of the substrate may occur. It is particularly preferable to adjust in the range of 1 to 2.5 J / cm 2 .
- the vacuum ultraviolet ray used for the modification may be generated by plasma formed of a gas containing at least one of CO, CO 2 and CH 4 .
- the gas containing at least one of CO, CO 2 and CH 4 hereinafter also referred to as carbon-containing gas
- the carbon-containing gas may be used alone, but carbon containing rare gas or H 2 as the main gas. It is preferable to add a small amount of the contained gas. Examples of plasma generation methods include capacitively coupled plasma.
- the functional film formed by increasing the amount of excimer light, the temperature during modification, or the energy during modification is increased.
- the value of (I [Si—H] / I [Si—O] ) in the IR spectrum can be reduced, and by modifying in an environment rich in oxygen, moisture, etc., (I [Si— H] / I [Si-O] ) can be reduced.
- the functional film of the present invention is excellent in durability and bending resistance under high temperature and high humidity, and has various uses.
- the functional film of the present invention can be used as a film having various functions such as a gas barrier layer, an electrical insulating layer, a hard coat layer (scratch resistant layer), a foreign matter adhesion preventing layer, and a refractive index control layer.
- the gas barrier film according to the present invention has a base material and at least one gas barrier layer on the base material.
- the gas barrier film may further contain other members, for example, between the base material and the gas barrier layer, on the gas barrier layer, or on the other surface of the base material on which the gas barrier layer is not formed. Other members may be included.
- the member used for the conventional gas barrier film can be used similarly or suitably modified. Specific examples include an intermediate layer, a protective layer, a smooth layer, an anchor coat layer, a bleed-out preventing layer, a desiccant layer having moisture adsorption, and an antistatic layer.
- the gas barrier layer may exist as a single layer or may have a laminated structure of two or more layers.
- the gas barrier layer only needs to be formed on at least one surface of the substrate.
- the gas barrier film of the present invention includes both a form in which the gas barrier layer is formed on one surface of the substrate and a form in which the gas barrier layer is formed on both surfaces of the substrate.
- a plastic film or a sheet is usually used as a substrate, and a film or sheet made of a colorless and transparent resin is preferably used.
- the plastic film used is not particularly limited in material and thickness as long as it can hold a gas barrier layer or the like, and can be appropriately selected according to the purpose of use.
- the substrate examples include polyacrylic acid ester, polymethacrylic acid ester, polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate (PEN), polycarbonate (PC), polyarylate, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), cycloolefin polymer (COP), cycloolefin copolymer (COC), triacetate cellulose (TAC), styrene (PS), nylon (Ny), aromatic polyamide, polyether ether ketone, polysulfone, Heat-resistant transparent films based on silsesquioxane having an organic-inorganic hybrid structure (for example, product name S), such as films of resins such as polyethersulfone, polyimide, and polyetherimide la-DEC; manufactured by Chisso Co., Ltd., and product name Sylplus (registered trademark); manufactured by Nippon Steel & Sumitomo Chemical Co.,
- polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate (PEN), polycarbonate (PC), polyimide, and the like are preferably used because of their optical transparency and small birefringence.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- PC polycarbonate
- TAC, COC, COP, PC, etc. produced by the casting method are preferably used.
- silsesquiskies having an organic-inorganic hybrid structure are used.
- a heat-resistant transparent film having oxane as a basic skeleton is preferably used.
- the process temperature may exceed 200 ° C. in the array manufacturing process.
- a certain amount of tension is always applied to the base material. Therefore, when the base material temperature rises when the base material is placed at a high temperature, the base material temperature changes to the glass transition point.
- the elasticity modulus of a base material will fall rapidly, a base material may extend
- a heat-resistant transparent film having polyimide, polyetherimide, or silsesquioxane having an organic / inorganic hybrid structure as a basic skeleton.
- the heat-resistant resin represented by these is non-crystalline, the water absorption rate is larger than that of crystalline PET or PEN, and the dimensional change of the base material due to humidity becomes larger, which makes it a gas barrier layer. There is a concern of damaging it.
- these heat-resistant materials are used as a base material, by forming a gas barrier layer on both sides, dimensional changes due to moisture absorption and desorption of the base film itself under severe conditions of high temperature and high humidity are suppressed. And damage to the gas barrier layer can be suppressed.
- a heat-resistant material as a base material and to form a gas barrier layer on both surfaces.
- the base material containing glass fiber, cellulose, etc. is also preferably used.
- the substrate used in the present invention may be an unstretched film or a stretched film.
- various known treatments for improving adhesion such as corona discharge treatment, flame treatment, oxidation treatment, or plasma treatment, and lamination of a primer layer described later Etc. may be performed, and it is preferable to perform a combination of the above treatments as necessary.
- the thickness of the base material used for the gas barrier film according to the present invention is not particularly limited because it is appropriately selected depending on the application, but is typically 1 to 800 ⁇ m, preferably 10 to 200 ⁇ m.
- These base films may have a functional layer such as a transparent conductive layer, a primer layer, or a hard coat layer.
- a functional layer such as a transparent conductive layer, a primer layer, or a hard coat layer.
- the functional layer in addition to those described above, those described in paragraph numbers “0036” to “0038” of JP-A-2006-289627 can be preferably employed.
- the base material preferably has a high surface smoothness.
- the surface smoothness those having an average surface roughness (Ra) of 2 nm or less are preferable. Although there is no particular lower limit, it is practically 0.01 nm or more. If necessary, both surfaces of the substrate, at least the side on which the gas barrier layer is provided, may be polished to improve smoothness.
- the gas barrier film according to the present invention only needs to have at least one functional layer of the present invention as a gas barrier layer, and more preferably further includes another gas barrier layer from the viewpoint of further improving the gas barrier property.
- the other gas barrier layer is a gas barrier layer having gas barrier properties and having a composition different from that of the functional film described above.
- the “composition different from the functional film” is, for example, a chemical composition in which another gas barrier layer is represented by the chemical formula (1), and the values of w, x, y, and z are expressed by the formula (1).
- the other gas barrier layer can be formed by applying energy to a coating film obtained by applying and drying a coating solution containing a silicon compound such as a polysilazane compound.
- a coating solution containing a silicon compound such as a polysilazane compound.
- the functional film and other gas barrier layers may be laminated on the base material in this order, and the other gas barrier layer and functional film may be laminated on the base material in this order.
- gas barrier layers formed by such a coating method may be formed by adding an additive element other than silicon.
- additive elements include, for example, beryllium (Be), boron (B), magnesium (Mg), aluminum (Al), calcium (Ca), scandium (Sc), titanium (Ti), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), zinc (Zn), gallium (Ga), germanium (Ge), strontium (Sr), yttrium (Y), zirconium (Zr), niobium (Nb), molybdenum (Mo), technetium (Tc), ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), cadmium (Cd), indium (In), tin (Sn), barium (Ba), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium Nd), promethium (Pm), samarium (S
- boron (B), magnesium (Mg), aluminum (Al), calcium (Ca), titanium (Ti), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), Copper (Cu), zinc (Zn), gallium (Ga), zirconium (Zr), silver (Ag), and indium (In) are preferable, and boron (B), magnesium (Mg), aluminum (Al), and calcium (Ca ), Iron (Fe), gallium (Ga), and indium (In) are more preferable, and boron (B), aluminum (Al), gallium (Ga), and indium (In) are more preferable.
- Group 13 elements such as boron (B), aluminum (Al), gallium (Ga), and indium (In) have a trivalent valence, and the valence is insufficient compared to the tetravalent valence of silicon. Therefore, the flexibility of the film is increased. Due to this improvement in flexibility, defects are repaired, and the other gas barrier layers become dense films, improving the gas barrier properties. Further, since the flexibility is increased, oxygen is supplied to the inside of the other gas barrier layer, and the gas barrier layer that has been oxidized to the inside of the film becomes a gas barrier layer that has high oxidation resistance when the film is formed.
- the additive element may be present alone or in the form of a mixture of two or more.
- the other gas barrier layer formed by the coating method can be formed by coating a coating solution containing a silicon compound such as a polysilazane compound.
- the silicon compound used for forming another gas barrier layer according to the present invention is not particularly limited and may be a silicon compound containing nitrogen or a silicon compound not containing nitrogen, but a polysilazane compound. It is preferable that More specifically, silicon compounds containing nitrogen and silicon compounds not containing nitrogen, and preferred embodiments thereof can be used as appropriate when forming the functional film described above. For this reason, explanation is omitted here.
- the method for preparing a coating solution containing a silicon compound, the solvent to be used, the catalyst, the method for coating, and the method for applying (modifying) energy are the functions described above.
- the same operation as that for forming the conductive film can be performed.
- the energy application is preferably performed by irradiating with vacuum ultraviolet rays.
- the oxygen concentration at the time of vacuum ultraviolet irradiation is preferably 10 to 10,000 volume ppm, more preferably 20 to 5000 volume ppm.
- the amount of irradiation energy of vacuum ultraviolet rays on the coating film surface formed by applying a coating solution for forming another gas barrier layer is 1 to 10 J. / Cm 2 is preferable, and 1.5 to 8 J / cm 2 is more preferable.
- the above-described functional film is formed with respect to the coating thickness, coating drying temperature, energy application (modification process), etc. It can carry out similarly to the suitable aspect at the time of doing, and the description part corresponding to the functional film mentioned above is referred suitably.
- the solid content concentration of the silicon compound in the coating solution is not particularly limited, and varies depending on the thickness of the layer and the pot life of the coating solution.
- the content is preferably 0.1 to 30% by mass, more preferably 0.5 to 20% by mass, and still more preferably 1 to 15% by mass.
- the thickness of the other gas barrier layer formed by the coating method is not particularly limited as long as the effects of the present invention are not impaired, but it is preferably 1 to 500 nm, and preferably 5 to 300 nm. More preferably, it is 10 to 200 nm.
- gas barrier layers according to the present invention are formed by vapor deposition methods such as physical vapor deposition, atomic layer deposition, and chemical vapor deposition, as with the functional film, except for the coating method described above. be able to.
- the present invention when another gas barrier layer and a functional film are laminated in this order on the substrate, defects in the other gas barrier layer formed by the vapor deposition method can be efficiently repaired.
- a synergistic effect that remarkably improves the gas barrier property of the gas barrier film is obtained, which is more preferable. This is because when excimer modification treatment is performed on the functional film, the excimer light transmitted through the functional film directly modifies the interface of the other gas barrier layer / functional film (the structure of the structure by bond breakage and recombination). It can be estimated that the effect is due to
- the film is formed using the above-described CVD apparatus shown in FIG. 1 or the CVD apparatus shown in FIG. 2 (opposed roll type roll-to-roll vacuum film forming apparatus). More preferably, the film is formed by using a roll-to-roll vacuum film forming apparatus of a counter roll type.
- a more specific film formation method can be performed by appropriately selecting a film formation gas or the like exemplified when forming the above-described functional film. The description is omitted here.
- the thickness of the other gas barrier layer formed by the plasma CVD method preferably used is not particularly limited as long as the effects of the present invention are not impaired, but is preferably 20 to 1000 nm, More preferably, it is -500 nm.
- layers having various functions can be further provided.
- a layer include, but are not limited to, an intermediate layer, a smooth layer, or a bleed-out layer.
- an intermediate layer may be further formed between the gas barrier film substrate and the gas barrier layer.
- the intermediate layer preferably has a function of improving the adhesion between the substrate surface and the gas barrier layer.
- a commercially available support with an easy-adhesion layer can also be preferably used.
- the intermediate layer may be a smooth layer.
- the smooth layer used in the present invention is provided to flatten the rough surface of the support on which the protrusions and the like are present, or to fill the unevenness and pinholes generated in the gas barrier layer by the protrusions existing on the base material. It is done.
- Such a smooth layer is basically produced by curing a photosensitive material or a thermosetting material.
- the gas barrier film according to the present invention may have a bleed-out preventing layer on the support surface opposite to the surface on which the gas barrier layer is provided.
- a bleed-out prevention layer can be provided.
- the bleed-out prevention layer is used for the purpose of suppressing the phenomenon that unreacted oligomers migrate from the film base material to the surface when the film having the smooth layer is heated and contaminate the contact surface. It is provided on the opposite surface of the supporting body.
- the bleed-out prevention layer may basically have the same configuration as the smooth layer as long as it has this function.
- the gas barrier film of the present invention can be preferably used for a device whose performance is deteriorated by chemical components (oxygen, water, nitrogen oxide, sulfur oxide, ozone, etc.) in the air.
- the device include electronic devices such as an organic EL element, a liquid crystal display element (LCD), a thin film transistor, a touch panel, electronic paper, and a solar cell (PV). From the viewpoint that the effect of the present invention can be obtained more efficiently, it is preferably used for an organic EL device or a solar cell, and particularly preferably used for an organic EL device.
- the gas barrier film of the present invention can also be used for device film sealing. That is, it is a method of providing the gas barrier film of the present invention on the surface of the device itself as a support.
- the device may be covered with a protective layer before providing the gas barrier film.
- the gas barrier film of the present invention can also be used as a device substrate or a film for sealing by a solid sealing method.
- the solid sealing method is a method in which after a protective layer is formed on a device, an adhesive layer and a gas barrier film are stacked and cured.
- the adhesive is not particularly limited, and examples thereof include a thermosetting epoxy resin and a photocurable acrylate resin.
- Organic EL device As examples of the organic EL device using the gas barrier film of the present invention, the description in JP-A-2007-30387 can be appropriately referred to.
- the reflective liquid crystal display device has a configuration including a lower substrate, a reflective electrode, a lower alignment film, a liquid crystal layer, an upper alignment film, a transparent electrode, an upper substrate, a ⁇ / 4 plate, and a polarizing film in order from the bottom.
- the gas barrier film in the present invention can be used as the transparent electrode substrate and the upper substrate.
- the gas barrier film of the present invention can also be used as a sealing film for solar cell elements.
- the gas barrier film of the present invention is preferably sealed so that the barrier layer is closer to the solar cell element.
- gas barrier film of the present invention examples include, for example, a thin film transistor described in JP-A-10-512104, a touch panel described in JP-A-5-127822, JP-A-2002-48913, and the like. Examples thereof include electronic paper described in Japanese Utility Model Publication No. 2000-98326.
- the gas barrier film of the present invention can also be used as an optical member.
- the optical member include a circularly polarizing plate.
- a circularly polarizing plate can be produced by laminating a ⁇ / 4 plate and a polarizing plate using the gas barrier film in the present invention as a substrate. In this case, the lamination is performed so that the angle formed by the slow axis of the ⁇ / 4 plate and the absorption axis of the polarizing plate is 45 °.
- a polarizing plate one that is stretched in a direction of 45 ° with respect to the longitudinal direction (MD) is preferably used.
- MD longitudinal direction
- those described in JP-A-2002-865554 can be suitably used. .
- the functional film of the present invention can be used as an electrical insulating film.
- the relative dielectric constant measured by the method is preferably in the range of 1.0 to 5.0.
- the functional film of the present invention has a dielectric constant in the range of 2.5 to 3.5, and thus has excellent insulation performance and can be preferably used as an electrical insulation film.
- Insulating films as disclosed in Japanese Patent Application Laid-Open No. 2012-174756 are usually formed at a high temperature of 850 ° C.
- the functional film of the present invention has a low temperature (modified) of 100 ° C. or less as described above. And can be preferably used as an electrical insulating film since it is excellent in durability and bending resistance under high temperature and high humidity.
- the thickness when the functional film of the present invention is used as an electrical insulating film is not particularly limited, but is preferably 10 to 1000 nm.
- the functional film of the present invention can be used as a hard coat layer (scratch resistant layer).
- a film as a hard coat layer tends to be brittle and easily broken when the hardness is increased, but the functional film of the present invention is dense and elastic, so that it may be brittle and easily broken while having scratch resistance. Has no features.
- the hard coat layer that substitutes for glass exhibits a hardness of “5H” or more in a pencil hardness test specified by JIS K5600-5-4 (ISO / DIN 15184).
- a cured film having the above-mentioned hardness it can be used as a hard coat layer.
- the functional film of the present invention has a pencil hardness in the range of 6H to 9H, and can be preferably used as a hard coat layer.
- the functional film of the present invention has high adhesion to the substrate surface and has desired antistatic performance, optical characteristics, and hardness. It can preferably be used as a hard coat layer that also serves as a material.
- the thickness when the functional film of the present invention is used as a hard coat layer is not particularly limited, but is preferably 100 to 1000 nm.
- the functional film of the present invention is excellent in durability and bending resistance under high temperature and high humidity, and can be used as a film having various functions.
- the effect of the present invention can be exhibited.
- the effect of the present invention appears more remarkably.
- Example 1 Using the CVD apparatus 10 (parallel plate capacitive coupling type PECVD apparatus) shown in FIG. 1, the thin film forming substrate 11 and the polyethylene naphthalate film base (thickness: 50 ⁇ m) are installed, and hexamethyl is formed on the film base.
- a gas barrier layer (functional film) having the composition shown in Table 1 was formed by supplying disiloxane gas, silane gas, oxygen gas, ammonia gas, and trimethylaluminum gas and adjusting the supply amount of each gas.
- the total flow rate of hexamethyldisiloxane and silane gas is 50 sccm
- the flow rate of helium gas is 50 sccm
- the internal pressure of the chamber 12 is 10 Pa
- the temperature of the thin film forming substrate 11 is 60 ° C.
- the RF power supply power is 500 W.
- a gas barrier including a gas barrier layer having the composition shown in Table 1 was formed by adjusting the film formation time so that the film thickness was 150 nm under the film forming conditions where the RF power supply frequency was 13.56 MHz. Film sample No. 101 to 117 were produced.
- XPS analysis conditions ⁇ Device: QUANTERASXM (manufactured by ULVAC-PHI) ⁇ X-ray source: Monochromatic Al-K ⁇ Measurement area: Si2p, C1s, N1s, O1s, M * (M * is an optimum measurement region depending on the metal.
- boron B1s; aluminum: Al2p; gallium: Ga3d or Ga2p; indium: In3d ; In the case of thallium: Tl4f.)
- Sputtering ion Ar (2 keV)
- Depth profile After sputtering for 1 minute, the composition was determined from the average value of 30 nm to 120 nm from the outermost surface of the gas barrier layer.
- the background was determined by the Shirley method, and quantified using the relative sensitivity coefficient method from the obtained peak area.
- a layer other than the target gas barrier layer (for example, a base material or another layer described later) is used as a base, and IR spectrum measurement is separately performed only on the corresponding base. By subtracting both measurement results, the influence of the substrate was cancelled.
- chemical composition in the formula represented by SiM w O x N y C z , M is selected from the group consisting of Group 13 elements of the long form periodic table Wherein w, x, y, and z are element ratios of M, oxygen, nitrogen, and carbon to silicon, respectively, and satisfy the following formulas (1) to (4): And the ratio of the absorption intensity derived from Si—H near 2200 cm ⁇ 1 to the absorption intensity derived from Si—O near 1050 cm ⁇ 1 observed by IR spectrum (I [Si—H] / I [ The gas barrier layer having a Si—O] ) of 0.03 or less is the functional film of the present invention, and the others are comparative examples. Furthermore, when there are two or more gas barrier layers, at least one layer may be the functional film of the present invention, and the others are comparative examples. The same applies to the following.
- the gas barrier film containing the functional film of the present invention has high gas barrier properties, and there is no deterioration in gas barrier properties before and after storage under high temperature and high humidity conditions, and before and after bending. It was found that the gas barrier property was exhibited even after storage under the severe high temperature and high humidity condition of 95 ° C. and 85% RH, that is, it had durability and bending resistance.
- Example 2 Gas barrier film sample No. 1 containing a gas barrier layer having the composition shown in Table 2 by the following method. 201-213 were produced.
- NAX-120 manufactured by AZ Electronic Materials Co., Ltd. which is a perhydropolysilazane solution under a nitrogen atmosphere, has an Al content of 10 mol% with respect to Si atoms.
- Aluminum triisopoloxide was added so that the mixture was stirred at 80 ° C. for 2 hours to obtain a coating solution.
- a heat resistant polyimide film “UPILEX (registered trademark) -S” (thickness: 50 ⁇ m) manufactured by Ube Industries, Ltd. is formed in a nitrogen atmosphere so that the dry film thickness is 150 nm. It is coated on top and dried at 80 ° C.
- NAX-120 manufactured by AZ Electronic Materials Co., Ltd. which is a perhydropolysilazane solution in a nitrogen atmosphere, has an Al content of 10 mol% with respect to Si atoms.
- aluminum triisopoloxide was added and stirred at 60 ° C. for 3 hours to obtain a coating solution.
- a heat-resistant polyimide film “UPILEX (registered trademark) -S” manufactured by Ube Industries, Ltd. is produced in an atmosphere of 23 ° C. and 50% RH so that the dry film thickness is 150 nm.
- the coating was performed on (thickness: 50 ⁇ m) and dried at room temperature for 10 minutes. Thereafter, under a nitrogen atmosphere with an oxygen concentration adjusted to 0.01 to 0.1%, irradiation with 172 nm vacuum ultraviolet light to a light quantity of 2 J / cm 2 on a hot plate at 80 ° C. Film sample No. 204 was obtained.
- Plasma ion implantation treatment ⁇ RF power supply: JEOL Ltd., model number “RF” 56000 ⁇ High voltage pulse power supply: “PV-3-HSHV-0835” manufactured by Kurita Manufacturing Co., Ltd. Plasma ion implantation conditions ⁇ Plasma product gas: Ar ⁇ Gas flow rate: 100sccm ⁇ Duty ratio: 0.5% ⁇ Applied voltage: -6kV ⁇ RF power supply: frequency 13.56MHz, applied power 1000W -Chamber internal pressure: 0.2 Pa ⁇ Pulse width: 5 ⁇ sec Processing time (ion implantation time): 200 seconds (Production of sample No. 206) Sample No.
- gas barrier film sample No. 206 was obtained.
- sample No. 210 instead of aluminum ethyl acetoacetate diisopropylate, sample No. 1 was added except that trimethoxyborane was added so as to have a B content of 10 mol% with respect to Si atoms. In the same manner as in the production method 204, gas barrier film sample No. 210 was obtained.
- a coating solution composed of 50 mol% tetramethoxysilane, 10 mol% trisecondary butoxyaluminum, 35 mol% 3-glycidoxypropyltrimethoxysilane, and 5 mol% 3-aminopropyltriethoxysilane is used as a film after the modification treatment.
- As a modification treatment it was coated on a heat-resistant polyimide film “UPILEX (registered trademark) -S” (thickness: 50 ⁇ m) manufactured by Ube Industries Co., Ltd. so as to have a thickness of 150 nm, and dried at 80 ° C. for 1 minute. Heat treatment was performed at 130 ° C. for 30 minutes, and gas barrier film sample No. 211 was obtained.
- the gas barrier film including the functional film of the present invention has high gas barrier properties, and there is no deterioration in gas barrier properties before and after storage under high temperature and high humidity conditions and before and after bending. It was found that the gas barrier properties were exhibited even after being stored under severe high temperature and high humidity conditions of 95 ° C. and 85% RH, that is, they had durability and bending resistance.
- Example 3 A zeonore film ZF-14 (thickness: 50 ⁇ m) made by Nippon Zeon Co., Ltd., which is a cycloolefin polymer, is backed with a 75 ⁇ m PET-type heat-resistant protective film, and the plasma CVD composition shown in FIG. 2 is formed on the film ZF-14.
- Plasma is generated by supplying electric power between opposing rolls using a membrane device, and forming gas (hexamethyldisiloxane (HMDSO) as a source gas and oxygen gas (discharge) as a reaction gas) in such a discharge region.
- the first gas barrier layer having a thickness of 80 nm was formed by forming a thin film by a plasma CVD method under the following conditions.
- NAX-120 manufactured by AZ Electronic Materials Co., Ltd. which is a perhydropolysilazane solution in a nitrogen atmosphere, has an Al content of 10 mol% with respect to Si atoms.
- aluminum triisopoloxide was added and stirred at 60 ° C. for 3 hours to obtain a coating solution.
- coating solution is allowed to cool, coating is performed on the first gas barrier layer obtained above so that the dry film thickness becomes 150 nm in an atmosphere of 23 ° C. and 50% RH in the atmosphere. And then dried at 100 ° C. for 3 minutes and further at 200 ° C. for 3 hours to form a second gas barrier layer. 302 was obtained.
- the cleaning surface modification treatment of the gas barrier film on which the first electrode layer is formed is performed using a low-pressure mercury lamp with a wavelength of 184.9 nm and an irradiation intensity of 15 mW. / Cm 2 and a distance of 10 mm.
- the charge removal treatment was performed using a static eliminator with weak X-rays.
- ⁇ Drying and heat treatment conditions> After applying the hole transport layer forming coating solution, the solvent was removed by applying hot air at a height of 100 mm toward the film formation surface, a discharge air speed of 1 m / s, a width of 5% of the wide air speed, and a temperature of 100 ° C. Subsequently, a back surface heat transfer system heat treatment was performed at a temperature of 150 ° C. using a heat treatment apparatus to form a hole transport layer.
- the following white light emitting layer forming coating solution was applied with an applicator under the following conditions, and then dried and heated under the following conditions to form a light emitting layer.
- the white light emitting layer forming coating solution was applied so that the thickness of the light emitting layer after drying was 40 nm.
- ⁇ White luminescent layer forming coating solution> As a host material, 1.0 g of a compound represented by the following chemical formula HA, 100 mg of a compound represented by the following chemical formula DA as a dopant material, and 0.1 mg of a compound represented by the following chemical formula DB as a dopant material. 2 mg of a compound represented by the following chemical formula DC as a dopant material was dissolved in 0.2 mg and 100 g of toluene to prepare a white light emitting layer forming coating solution.
- the coating process was performed in an atmosphere having a nitrogen gas concentration of 99% or more, a coating temperature of 25 ° C., and a coating speed of 1 m / min.
- the following coating liquid for forming an electron transport layer was applied with an applicator under the following conditions, and then dried and heated under the following conditions to form an electron transport layer.
- the coating liquid for forming an electron transport layer was applied so that the thickness of the electron transport layer after drying was 30 nm.
- the coating process was performed in an atmosphere having a nitrogen gas concentration of 99% or more, the coating temperature of the electron transport layer forming coating solution was 25 ° C., and the coating speed was 1 m / min.
- the electron transport layer was prepared by dissolving a compound represented by the following chemical formula EA in 2,2,3,3-tetrafluoro-1-propanol to form a 0.5 mass% solution, which was used as an electron transport layer forming coating solution. .
- An electron injection layer was formed on the electron transport layer formed above.
- the substrate was put into a decompression chamber and decompressed to 5 ⁇ 10 ⁇ 4 Pa.
- cesium fluoride prepared in a tantalum vapor deposition boat was heated in a vacuum chamber to form an electron injection layer having a thickness of 3 nm.
- Second electrode layer On the electron injection layer formed above, a mask pattern was formed by vapor deposition using aluminum as the second electrode layer forming material under a vacuum of 5 ⁇ 10 ⁇ 4 Pa and having an extraction electrode. A second electrode layer having a thickness of 100 nm was stacked.
- an electronic element body 1 having a first electrode layer, a hole transport layer, a light emitting layer, an electron transport layer, an electron injection layer, a second electrode layer, and a protective layer was produced.
- the gas barrier film including the functional film of the present invention has a high gas barrier property, and the organic EL device using the same is before and after storage under high temperature and high humidity conditions, and before and after bending. Further, it was found that the incidence of dark spots is low, that is, it has durability and bending resistance.
- Example 4 A first gas barrier layer was formed on a PET film substrate (thickness: 50 ⁇ m) by the same method as in Example 3 described above. The following second gas barrier layer was laminated on the first gas barrier layer thus formed, and gas barrier film sample No. 401 to 405 were produced.
- a perhydropolysilazane solution NAX-120 manufactured by AZ Electronic Materials Co., Ltd. has a dry film thickness of 150 nm in an atmosphere of 23 ° C. and 50% RH. And then dried at room temperature for 10 minutes. Thereafter, under a nitrogen atmosphere with an oxygen concentration adjusted to 0.01 to 0.1%, a vacuum ultraviolet ray of 172 nm is irradiated on the hot plate at 80 ° C. so as to obtain a light quantity of 6 J / cm 2 .
- the gas barrier layer was formed.
- NAX-120 manufactured by AZ Electronic Materials Co., Ltd. which is a perhydropolysilazane solution, has aluminum ethyl acetoacetate diisopropyl compound so that the Al content is 10 mol% with respect to Si atoms.
- the rate was added and the mixture was stirred at 60 ° C. for 2 hours to obtain a coating solution.
- coating solution is allowed to cool, coating is performed on the first gas barrier layer obtained above so that the dry film thickness becomes 150 nm in an atmosphere of 23 ° C. and 50% RH in the atmosphere. Let dry for minutes.
- ITO indium tin oxide
- a resistance of 12 ⁇ / square was patterned to a width of 10 mm using a normal photolithography method and wet etching to form a first electrode layer.
- the patterned first electrode layer was cleaned in the order of ultrasonic cleaning with a surfactant and ultrapure water, followed by ultrasonic cleaning with ultrapure water, dried by nitrogen blowing, and finally subjected to ultraviolet ozone cleaning.
- PEDOT-PSS CLEVIOS (registered trademark) PVP AI 4083, manufactured by Helios Co., Ltd., conductivity: 1 ⁇ 10 ⁇ 3 S / cm
- An isopropanol solution containing% was prepared, and the substrate was applied and dried using a blade coater adjusted to 65 ° C. so that the dry film thickness was about 30 nm. After that, heat treatment was performed with warm air of 120 ° C. for 20 seconds to form a hole transport layer on the first electrode layer. From then on, it was brought into the glove box and worked under a nitrogen atmosphere.
- the element formed up to the hole transport layer was heated at 120 ° C. for 3 minutes in a nitrogen atmosphere.
- This solution was applied and dried using a blade coater whose temperature was adjusted to 65 ° C. so that the dry film thickness was about 5 nm. Thereafter, heat treatment was performed for 2 minutes with warm air at 100 ° C. to form an electron transport layer on the photoelectric conversion layer.
- the element on which the electron transport layer was formed was placed in a vacuum deposition apparatus. Then, the element was set so that the shadow mask with a width of 10 mm was orthogonal to the transparent electrode, the pressure inside the vacuum deposition apparatus was reduced to 10 ⁇ 3 Pa or less, and then 100 nm of silver was deposited at a deposition rate of 2 nm / second, A second electrode layer (cathode) was formed on the electron transport layer.
- a sealing member As a sealing member, a polyethylene terephthalate (PET) film (12 ⁇ m thickness) is used on a 30 ⁇ m thick aluminum foil (manufactured by Toyo Aluminum Co., Ltd.), and an adhesive for dry lamination (a two-component reaction type urethane adhesive) is used. Using a dry laminate (adhesive layer thickness of 1.5 ⁇ m), sealing was performed using a sheet-like sealant TB1655 manufactured by ThreeBond Co., Ltd. Solar cell sample Nos. 401 to 407 corresponding to 401 to 407 were produced.
- PET polyethylene terephthalate
- Each solar cell sample was wound on a 50 mm ⁇ cylinder for 1 second, and then a cycle of spreading it to a flat surface in 1 second was repeated 100,000 times. Each solar cell sample was accelerated and deteriorated for 10 hours in an environment of 95 ° C. and 85% RH. After carrying out the treatment, the power generation efficiency was measured.
- the gas barrier film including the functional film of the present invention has a high gas barrier property, and solar cells using the same are stored before and after storage under high temperature and high humidity conditions, and before and after bending. It has been found that the power generation efficiency is high, that is, it has durability and bending resistance.
- aluminum ethyl acetoacetate in a NAX-120 made by AZ Electronic Materials Co., Ltd. which is a perhydropolysilazane solution, has an Al content of 10 mol% with respect to Si atoms.
- Diisopropylate was added and stirred at 60 ° C. for 2 hours to obtain a coating solution.
- the coating solution was allowed to cool and then applied in an atmosphere of 23 ° C. and 50% RH so that the dry film thickness was 150 nm and dried at room temperature for 10 minutes.
- an insulating film that can only be obtained at a high temperature of about 850 ° C. can be formed at a low temperature of 100 ° C. or lower in the present invention.
- Example 6 ⁇ Production of functional film as hard coat layer>
- aluminum ethyl acetoacetate was added to a PET substrate on NAX-120, a perhydropolysilazane solution, manufactured by AZ Electronic Materials Co., so that the Al content was 10 mol% with respect to Si atoms.
- Diisopropylate was added and stirred at 60 ° C. for 2 hours to obtain a coating solution.
- the coating solution was allowed to cool and then applied in an atmosphere of 23 ° C. and 50% RH so that the dry film thickness was 150 nm and dried at room temperature for 10 minutes.
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Abstract
Description
で表される化学組成を含み、かつ、IRスペクトルで観察した1050cm-1付近のSi-Oに由来する吸収の強度に対して2200cm-1付近のSi-Hに由来する吸収の強度の比(I[Si-H]/I[Si-O])が、0.03以下である、機能性膜を提供することによって、上記課題が解決できることを見出し、本発明を完成するに至った。
本発明の第一の形態によれば、下記化学式(1):
で表される化学組成を含み、かつ、IRスペクトルで観察した1050cm-1付近のSi-Oに由来する吸収の強度に対して2200cm-1付近のSi-Hに由来する吸収の強度の比(I[Si-H]/I[Si-O])が、0.03以下である、機能性膜が提供される。
装置:QUANTERASXM(アルバック・ファイ株式会社製)
X線源:単色化Al-Kα
測定領域:Si2p、C1s、N1s、O1s、M*
(M*とは、金属によって最適な測定領域である。例えば、ホウ素の場合:B1sであり;アルミニウムの場合:Al2pであり;ガリウムの場合:Ga3dまたはGa2pであり;インジウムの場合:In3dであり;タリウムの場合:Tl4fである。)
スパッタイオン:Ar(2keV)
デプスプロファイル:1分間のスパッタ後に測定を繰り返す。1回の測定は、SiO2薄膜標準サンプル換算で、約5nmの厚さ分に相当する。なお、機能性膜の表面の吸着水や有機物汚染の影響がある場合に、1回目の測定データは除く。
また、機能性膜をIRスペクトルで観察した1050cm-1付近のSi-Oに由来する吸収の強度に対して2200cm-1付近のSi-Hに由来する吸収の強度の比(I[Si-H]/I[Si-O])が、0.03以下である必要があり、0.01~0.03であることがより好ましい。(I[Si-H]/I[Si-O])の値が0.03を超えると、機能性膜中のSi-H結合が多い状態では、特に95℃85%RHのような過酷な高温高湿の環境において、湿熱によりSi-H結合が加水分解し、Si-OHが生成される確率も多くなるため、結果的にガスバリア性の劣化をもたらしてしまうおそれがある。特に長時間に亘って、上記した過酷な高温高湿の環境におかれた場合でも、そのガスバリア性の劣化を抑制できる。
次に、本発明の機能性膜を形成する好ましい方法について説明する。本発明の機能性膜は、使用用途によって適当に選択される基材の表面上に形成することができる。なお、本発明の機能性膜を形成する際に、「基材の表面上に」というのは、「基材の少なくとも一方の表面上に」を意味し、直接基材の少なくとも一方の表面上に機能性膜を形成する態様のみに限定せず、他の層を介して機能性膜を形成してもよいことを意味する。
<気相成膜法>
物理気相成長法(Physical Vapor Deposition、PVD法)は、気相中で物質の表面に物理的手法により、目的とする物質、例えば、炭素膜などの薄膜を堆積する方法であり、例えば、スパッタ法(DCスパッタ法、RFスパッタ法、イオンビームスパッタ法、およびマグネトロンスパッタ法など)、真空蒸着法、イオンプレーティング法などが挙げられる。
本発明の機能性膜は、使用用途によって適宜に選択された基材の表面上に塗布法によって形成することができる。用いられる塗布液としては、組成SiMwOxNyCzの各性元素成分が含有されていれば特に限定されず、例えば、ケイ素、金属M、酸素、窒素、および炭素を含有する化合物を含む塗布液、好ましくは窒素を含有するケイ素化合物および金属Mの化合物を含む塗布液、より好ましくは、ポリシラザン化合物および有機金属Mの化合物を含む塗布液、を塗布し、乾燥して得られた塗膜にエネルギーを印加する(改質する)方法などが挙げられる。
本発明の機能性膜を形成する塗布液を調製する際に、有機金属Mの化合物と併用する窒素を含有するケイ素化合物は、当該窒素を含有するケイ素化合物を含む塗布液を調製することが可能であれば、特に限定されず、例えば、ポリシラザン化合物、シラザン化合物、アミノシラン化合物、シリルアセトアミド化合物、シリルイミダゾール化合物、およびその他の窒素を含有するケイ素化合物などが用いられる。
本発明において、ポリシラザン化合物とは、ケイ素-窒素結合を有するポリマーである。具体的に、その構造内にSi-N、Si-H、N-Hなどの結合を有し、SiO2、Si3N4、および両方の中間固溶体SiOxNyなどのセラミック前駆体無機ポリマーである。なお、本明細書において「ポリシラザン化合物」を「ポリシラザン」とも略称する。
本発明に好ましく用いられるシラザン化合物の例として、ジメチルジシラザン、トリメチルジシラザン、テトラメチルジシラザン、ペンタメチルジシラザン、ヘキサメチルジシラザン、および1,3-ジビニル-1,1,3,3-テトラメチルジシラザンなどが挙げられるが、これらに限定されない。
本発明に好ましく用いられるアミノシラン化合物の例として、3-アミノプロピルトリメトキシシラン、3-アミノプロピルジメチルエトキシシラン、3-アリールアミノプロピルトリメトキシシラン、プロピルエチレンジアミンシラン、N-[3-(トリメトキシシリル)プロピル]エチレンジアミン、3-ブチルアミノプロピルトリメチルシラン、3-ジメチルアミノプロピルジエトキシメチルシラン、2-(2-アミノエチルチオエチル)トリエトキシシラン、およびビス(ブチルアミノ)ジメチルシランなどが挙げられるが、これらに限定されない。
本発明に好ましく用いられるシリルアセトアミド化合物の例として、N-メチル-N-トリメチルシリルアセトアミド、N,O-ビス(tert-ブチルジメチルシリル)アセトアミド、N,O-ビス(ジエチルヒドロゲンシリル)トリフルオロアセトアミド、N,O-ビス(トリメチルシリル)アセトアミド、およびN-トリメチルシリルアセトアミドなどが挙げられるが、これらに限定されない。
本発明に好ましく用いられるシリルイミダゾール化合物の例として、1-(tert-ブチルジメチルシリル)イミダゾール、1-(ジメチルエチルシリル)イミダゾール、1-(ジメチルイソプロピルシリル)イミダゾール、およびN-トリメチルシリルイミダゾールなどが挙げられるが、これらに限定されない。
本発明において、上述の窒素を含有するケイ素化合物の他に、例えば、ビス(トリメチルシリル)カルボジイミド、トリメチルシリルアジド、N,O-ビス(トリメチルシリル)ヒドロキシルアミン、N,N’-ビス(トリメチルシリル)尿素、3-ブロモ-1-(トリイソプロピルシリル)インドール、3-ブロモ-1-(トリイソプロピルシリル)ピロール、N-メチル-N,O-ビス(トリメチルシリル)ヒドロキシルアミン、3-イソシアネートプロピルトリエトキシシラン、およびシリコンテトライソチオシアナートなどが用いられるがこれらに限定されない。
本発明において、金属Mの化合物としては、長周期型周期表の第13族元素からなる群より選択される少なくとも1種の金属を含む化合物であれば特に限定されが、有機金属Mの化合物が好ましく用いられる。以下金属Mの化合物としての好ましい化合物を例示するが、本発明を限定するものではない。
本発明において、高温高湿での耐久性の観点から、金属Mの化合物としてアルミニウム化合物が特に好ましく用いられる。
本発明に用いられるホウ素化合物の例としては、トリメトキシボラン、トリエトキシボラン、ホウ酸トリn-プロピル、ホウ酸トリイソプロピル、ホウ酸トリn-ブチル、ホウ酸トリtert-ブチル、トリクロロボランなどが挙げられるが、これらに限定されない。
本発明に用いられるガリウム化合物の例としては、トリメトキシガリウム、トリエトキシガリウム、トリメチルガリウム、トリクロロガリウムなどが挙げられるが、これらに限定されない。
本発明に用いられるインジウム化合物の例としては、トリメトキシインジウム、トリエトキシインジウム、トリメチルインジウム、トリクロロインジウムなどが挙げられるが、これらに限定されない。
本発明に用いられるタリウム化合物の例としては、トリメトキシタリウム、トリエトキシタリウム、トリメチルタリウム、トリクロロタリウムなどが挙げられるが、これらに限定されない。
本発明の機能性膜形成用塗布液は、前述したケイ素、金属M、酸素、窒素、および炭素を含有する化合物を適当な溶剤に溶解させることによって、調製することができる。好ましくは、前述した窒素を含有するケイ素化合物および有機金属Mの化合物を適当な溶剤に溶解させることによって、調製することができる。また、本発明の機能性膜形成用塗布液を調製する際に、窒素を含有するケイ素化合物および有機金属Mの化合物を混合させてから、適当な溶剤に溶解させて当該塗布液を調製してもよく、窒素を含有するケイ素化合物を適当な溶剤に溶解させて、窒素を含有するケイ素化合物を含む塗布液(1)と、有機金属Mの化合物を適当な溶剤に溶解させて、有機金属Mの化合物を含む塗布液(2)とを混合することによって塗布液を調製してもよい。液の安定性の観点から、同じ溶剤を用いて、窒素を含有するケイ素化合物を含む塗布液(1)と有機金属Mの化合物を含む塗布液(2)とを混合することによって塗布液を調製することがより好ましい。また、前記塗布液(1)には、一種類の窒素を含有するケイ素化合物を含んでいてもよく、二種類以上の窒素を含有するケイ素化合物を含んでいてもよく、また上述した窒素を含有しないケイ素化合物をさらに含んでいてもよい。同様に、前記塗布液(2)には、一種類の有機金属Mの化合物を含んでいてもよく、二種類以上の有機金属Mの化合物を含んでいてもよい。
本発明の機能性膜形成用塗布液を塗布する方法としては、従来公知の適切な湿式塗布方法が採用され得る。具体例としては、スピンコート法、ロールコート法、フローコート法、インクジェット法、スプレーコート法、プリント法、ディップコート法、ダイコート法、流延成膜法、バーコート法、グラビア印刷法等が挙げられる。
上述した塗布液を塗布後、改質処理によって本発明の機能性膜を形成することができる。本発明における改質処理とは、ケイ素化合物および添加元素化合物が所定の化学組成へ転化する反応を指し、また本発明の機能性膜がガスバリア層として使用される場合のガスバリア性フィルムが全体としてガスバリア性を発現するに貢献できるレベルの向き薄膜を形成する処理を指す。例えば、本発明の機能性膜を形成するための改質処理とは、ケイ素化合物および金属Mの化合物が上述した化学式(1)で表される化学組成へ転化する反応を指す。
加熱処理の方法としては、例えば、ヒートブロック等の発熱体に基板を接触させ熱伝導により塗膜を加熱する方法、抵抗線等による外部ヒーターにより塗膜が載置される環境を加熱する方法、IRヒーターといった赤外領域の光を用いた方法等が挙げられるが、これらに限定されない。加熱処理を行う場合、塗膜の平滑性を維持できる方法を適宜選択すればよい。
本発明において、改質処理として用いることのできるプラズマ処理は、公知の方法を用いることができるが、ガスバリア性が優れる観点から、プラズマイオンを注入する方法が好ましい。
活性エネルギー線としては、例えば、赤外線、可視光線、紫外線、X線、電子線、α線、β線、γ線等が使用可能であるが、電子線または紫外線が好ましく、紫外線がより好ましい。紫外線(紫外光と同義)によって生成されるオゾンや活性酸素原子は高い酸化能力を有しており、低温で高い緻密性と絶縁性とをシリコン含有膜を形成することが可能である。
本発明において、最も好ましい改質処理方法は、真空紫外線照射による処理(エキシマ照射処理)である。真空紫外線照射による処理は、ポリシラザン化合物内の原子間結合力より大きい100~200nmの光エネルギーを用い、好ましくは100~180nmの波長の光エネルギーを用い、原子の結合を光量子プロセスと呼ばれる光子のみの作用により、直接切断しながら活性酸素やオゾンによる酸化反応を進行させることで、比較的低温(約200℃以下)で、酸化ケイ素膜の形成を行う方法である。
本発明の機能性膜は、高温高湿下での耐久性および屈曲耐性に優れ、様々な用途を有する。例えば、本発明の機能性膜は、ガスバリア層、電気絶縁層、ハードコート層(耐傷層)、異物付着防止層、屈折率制御層などの各種の機能を有する膜として使用することができる。
以下の説明では、機能性膜の一例であるガスバリア層として使用される場合の、機能性膜を有するガスバリア性フィルムについて説明するが、本発明を限定するものではない。
本発明に係るガスバリア性フィルムは、基材と、前記基材上に少なくとも1層のガスバリア層とを有する。また、ガスバリア性フィルムには、他の部材をさらに含んでもよく、例えば、基材とガスバリア層との間に、ガスバリア層の上に、またはガスバリア層が形成されていない基材の他方の面に、他の部材を有していてもよい。本発明において、他の部材としては、特に限定されず、従来のガスバリア性フィルムに使用される部材が同様にしてあるいは適宜修飾して使用できる。具体的には、中間層、保護層、平滑層、アンカーコート層、ブリードアウト防止層、水分吸着性を有するデシカント性層、帯電防止層などが挙げられる。
本発明に係るガスバリア性フィルムは、通常、基材として、プラスチックフィルムまたはシートが用いられ、無色透明な樹脂からなるフィルムまたはシートが好ましく用いられる。用いられるプラスチックフィルムは、ガスバリア層などを保持できるフィルムであれば材質、厚さなどに特に限定はなく、使用目的などに応じて適宜選択することができる。
本発明に係るガスバリア性フィルムは、少なくとも1層の本発明の機能性層をガスバリア層として有していればよく、さらなるガスバリア性向上の観点から、他のガスバリア層をさらに有することがより好ましい。
本発明において、塗布法により形成される他のガスバリア層は、ポリシラザン化合物などのケイ素化合物を含有する塗布液を塗布して形成されうる。
本発明に係る他のガスバリア層は、上述した塗布法以外は、機能性膜と同様に、物理気相成長法、原子層堆積法、化学気相成長法などの気相成膜法によって形成することができる。
本発明において、ガスバリア性フィルムの基材とガスバリア層との間には、さらに中間層を形成してもよい。中間層は、基材表面とガスバリア層との接着性を向上させる機能を有することが好ましい。市販の易接着層付き支持体も好ましく用いることができる。
本発明に係るガスバリア性フィルムにおいては、上記中間層は、平滑層であってもよい。本発明に用いられる平滑層は、突起等が存在する支持体の粗面を平坦化し、あるいは、基材に存在する突起によりガスバリア層に生じた凹凸やピンホールを埋めて平坦化するために設けられる。このような平滑層は、基本的には感光性材料または熱硬化性材料を硬化させて作製される。
本発明に係るガスバリア性フィルムは、ガスバリア層を設ける面とは反対側の支持体面にブリードアウト防止層を有してもよい。ブリードアウト防止層を設けることができる。ブリードアウト防止層は、平滑層を有するフィルムを加熱した際に、フィルム基材中から未反応のオリゴマー等が表面へ移行して、接触する面を汚染する現象を抑制する目的で、平滑層を有する支持体の反対面に設けられる。ブリードアウト防止層は、この機能を有していれば、基本的に平滑層と同じ構成をとっても構わない。
本発明の他の形態において、本発明のガスバリア性フィルムを有する電子デバイスが提供される。
本発明のガスバリア性フィルムを用いた有機EL素子の例としては、特開2007-30387号公報の記載を適宜に参照されうる。
反射型液晶表示装置は、下から順に、下基板、反射電極、下配向膜、液晶層、上配向膜、透明電極、上基板、λ/4板、そして偏光膜からなる構成を有する。本発明におけるガスバリア性フィルムは、前記透明電極基板および上基板として使用することができる。
本発明のガスバリア性フィルムは、太陽電池素子の封止フィルムとしても用いることができる。ここで、本発明のガスバリア性フィルムは、バリア層が太陽電池素子に近い側となるように封止することが好ましい。
本発明のガスバリア性フィルムのその他の適用例としては、例えば特表平10-512104号公報に記載の薄膜トランジスタ、特開平5-127822号公報、特開2002-48913号公報などに記載のタッチパネル、特開2000-98326号公報に記載の電子ペーパーなどが挙げられる。
また、本発明のガスバリア性フィルムは、光学部材として用いられることもできる。光学部材の例としては円偏光板などが挙げられる。
本発明におけるガスバリア性フィルムを基板としλ/4板と偏光板とを積層し、円偏光板を作製することができる。この場合、λ/4板の遅相軸と偏光板の吸収軸とのなす角が45°になるように積層する。このような偏光板は、長手方向(MD)に対し45°の方向に延伸されているものを用いることが好ましく、例えば、特開2002-865554号公報に記載のものを好適に用いることができる。
本発明の機能性膜は、電気絶縁膜として使用することができる。
本発明の機能性膜は、ハードコート層(耐傷層)として使用することができる。通常、ハードコート層としての膜は、硬度を高くすると、脆く割れやすい傾向があるが、本発明の機能性膜は、緻密で且つ弾性を有するため、耐傷性を有しながら脆く割れやすいことがない特徴を有する。
図1に示すCVD装置10(平行平板容量結合型PECVD装置)を用いて、薄膜形成用基板11上記ポリエチレンナフタレートフィルム基材(厚さ:50μm)を設置し、当該フィルム基材上にヘキサメチルジシロキサンガス、シランガス、酸素ガス、アンモニアガス、トリメチルアルミニウムガスを供給し、各々のガスの供給量と調整することによって表1に示す組成を有するガスバリア層(機能性膜)を成膜した。なお、各々のガスの供給量を調整する際には、I[Si-H]/I[Si-O]の値を大きくする形態においては、シランを多く供給し、I[Si-H]/I[Si-O]の値を小さくする形態においては、酸素ガスを多く供給することで行った。
下記の装置および測定条件により、作製したガスバリア性フィルムサンプルNo.101~117のガスバリア層について、膜厚方向の組成プロファイルを分析し、それぞれのw、x、y、zの値を求めた。それぞれの結果を表1に示す。
・装置:QUANTERASXM(アルバック・ファイ株式会社製)
・X線源:単色化Al-Kα
・測定領域:Si2p、C1s、N1s、O1s、M*
(M*とは、金属によって最適な測定領域である。例えば、ホウ素の場合:B1sであり;アルミニウムの場合:Al2pであり;ガリウムの場合:Ga3dまたはGa2pであり;インジウムの場合:In3dであり;タリウムの場合:Tl4fである。)
・スパッタイオン:Ar(2keV)
・デプスプロファイル:1分間スパッタ後、測定をガスバリア層の最表面から30nm~120nmの平均値より該塗布生成物の組成を求めた。
<ガスバリア層のIRスペクトルの測定>
作製したガスバリア性フィルムサンプルNo.101~117について、それぞれのIRスペクトルを測定した。
作製したガスバリア性フィルムサンプルNo.101~117について、株式会社日本エイピーアイ製フィルム透過性評価装置API-BA90を用いて、40℃90%RHにおける水分透過率(WVTR)を測定した。それぞれの結果を表1に示す。
作製したガスバリア性フィルムサンプルNo.101~117に対して、以下の2種類の劣化処理試験を行い、上記水分透過率測定の操作と同様に水分透過率を測定し、それぞれの結果を表1に示した。
各サンプルを、95℃85%RHの環境中にて500時間を放置し、高温高湿処理を行った。
各サンプルを、10cm角に切りだし、ガスバリア層の側が内側になるように、10mmΦ円柱に1秒かけて巻き取った後、1秒で平面に広げるサイクルを100,000回繰り返し、屈曲処理を行った。
以下の方法によって、表2に示す組成を有するガスバリア層を含むガスバリア性フィルムサンプルNo.201~213を作製した。
特開昭63-191832号公報に記載の方法に準じ、窒素雰囲気下でパーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120に、Si原子に対して10mol%のAl含量になるようにアルミニウムトリイソポロキシドを加え、80℃で2時間攪拌し塗布液を得た。当該塗布液を放冷し後、窒素雰囲気化下で、乾燥膜厚が150nmになるように、宇部興産株式会社製の耐熱性ポリイミドフィルム「ユーピレックス(登録商標)-S」(厚さ:50μm)上に塗布を行い、窒素気流下で80℃にて5分間乾燥させ、その後、2℃/minの昇温スピードで350℃まで加熱し、350℃で1時間加熱し、その後5℃/minで降温し、ガスバリア性フィルムサンプルNo.201を得た。
特開平11-105185号公報に記載の方法に準じ、窒素雰囲気下でパーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120に、Si原子に対して10mol%のAl含量になるようにアルミニウムトリイソポロキシドを加え、60℃で3時間攪拌し塗布液を得た。当該塗布液を放冷し後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、宇部興産株式会社製の耐熱性ポリイミドフィルム「ユーピレックス(登録商標)-S」(厚さ:50μm)上に塗布を行い、室温で10分間乾燥させ、その後、100℃で3分間、さらに200℃3分間乾燥させ、さらに350℃で1時間加熱し、その後5℃/minで降温し、ガスバリア性フィルムサンプルNo.202を得た。
パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120を、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、宇部興産株式会社製の耐熱性ポリイミドフィルム「ユーピレックス(登録商標)-S」(厚さ:50μm)上に塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2J/cm2の光量になるように照射して、ガスバリア性フィルムサンプルNo.203を得た。
窒素雰囲気下、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120中に、Si原子に対して10mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加え、60℃2時間攪拌し塗布液を得た。当該塗布液を放冷し後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、宇部興産株式会社製の耐熱性ポリイミドフィルム「ユーピレックス(登録商標)-S」(厚さ:50μm)上に塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2J/cm2の光量になるように照射して、ガスバリア性フィルムサンプルNo.204を得た。
上記のサンプルNo.204と同様の方法で塗布液を調製し塗布を行った後、真空紫外線処理の代わりに、プラズマイオン注入処理を行い、ガスバリア性フィルムサンプルNo.205を得た。
・RF電源:日本電子社製、型番号「RF」56000
・高電圧パルス電源:栗田製作所社製、「PV-3-HSHV-0835」
プラズマイオン注入条件
・プラズマ生成ガス:Ar
・ガス流量:100sccm
・Duty比:0.5%
・印加電圧:-6kV
・RF電源:周波数13.56MHz、印加電力1000W
・チャンバー内圧:0.2Pa
・パルス幅:5μsec
・処理時間(イオン注入時間):200秒
(サンプルNo.206の作製)
Si原子に対して2mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加えたこと以外は、サンプルNo.204の作製方法と同様にして、ガスバリア性フィルムサンプルNo.206を得た。
Si原子に対して1mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加えたこと以外は、サンプルNo.204の作製方法と同様にして、ガスバリア性フィルムサンプルNo.207を得た。
Si原子に対して90mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加えたこと以外は、サンプルNo.204の作製方法と同様にして、ガスバリア性フィルムサンプルNo.208を得た。
Si原子に対して110mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加えたこと以外は、サンプルNo.204の作製方法と同様にして、ガスバリア性フィルムサンプルNo.209を得た。
アルミニウムエチルアセトアセテート・ジイソプロピレートの代わりに、Si原子に対して10mol%のB含量になるようにトリメトキシボランを加えたこと以外は、サンプルNo.204の作製方法と同様にして、ガスバリア性フィルムサンプルNo.210を得た。
50mol%のテトラメトキシシラン、10mol%のトリセカンダリーブトキシアルミニウム、35mol%の3-グリシドキシプロピルトリメトキシシラン、5mol%の3-アミノプロピルトリエトキシシランからなる塗布液を、改質処理後の膜厚が150nmになるように、宇部興産株式会社製の耐熱性ポリイミドフィルム「ユーピレックス(登録商標)-S」(厚さ:50μm)上に塗布し、80℃で1分間乾燥し、改質処理として130℃で30分間の加熱処理を行い、ガスバリア性フィルムサンプルNo.211を得た。
トリセカンダリーブトキシアルミニウムの代わりに、トリエトキシインジウムを用いたこと以外は、サンプルNo.211の作製方法と同様にして、ガスバリア性フィルムサンプルNo.212を得た。
トリセカンダリーブトキシアルミニウムの代わりに、トリエトキシタリウムを用いたこと以外は、サンプルNo.211の作製方法と同様にして、ガスバリア性フィルムサンプルNo.213を得た。
上記で得られたガスバリア性フィルムサンプルNo.201~213に対して、ガスバリア層の元素組成比の測定、ガスバリア層のIRスペクトルの測定、水分透過率(WVTR)の測定、および劣化処理の評価を、上記実施例1の測定条件と同様にして行い、それぞれの結果を表2に示す。
シクロオレフィンポリマーである、日本ゼオン(株)製ゼオノアフィルムZF-14(厚さ:50μm)に75μmのPET性耐熱性保護フィルムを裏打ちし、フィルムZF-14上に、図2に示すプラズマCVD成膜装置を用い対向ロール間に電力を供給し放電してプラズマを発生させ、このような放電領域に成膜ガス(原料ガスとしてのヘキサメチルジシロキサン(HMDSO)と反応ガスとしての酸素ガス(放電ガスとしても機能する)の混合ガス)を供給して、下記条件にてプラズマCVD法による薄膜形成を行い、膜厚が80nmである第1のガスバリア層を形成した。
・成膜ガスの混合比(ヘキサメチルジシロキサン/酸素):100/1000[単位:sccm(Standard Cubic Centimeter per Minute)、0℃、1気圧基準]
・真空チャンバー内の真空度:1.5Pa
・プラズマ発生用電源からの印加電力:2kW
・プラズマ発生用電源の周波数:60kHz
・フィルムの搬送速度:5m/min
このように形成した第1のガスバリア層上に、以下の第2のガスバリア層を積層し、ガスバリア性フィルムサンプルNo.301~305を作製した。なお、第1のバリア層のWVTRは、5×10-2g/m2/dayであった。
特開昭63-191832号公報に記載の方法に準じ、窒素雰囲気下でパーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120に、Si原子に対して10mol%のAl含量になるようにアルミニウムトリイソポロキシドを加え、80℃で2時間攪拌し塗布液を得た。当該塗布液を放冷し後、窒素雰囲気化下で、乾燥膜厚が150nmになるように、上記で得られた第1のガスバリア層上に塗布を行い、窒素気流下で80℃にて5分間乾燥させ、その後、120℃で3時間加熱し、第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.301を得た。
特開平11-105185号公報に記載の方法に準じ、窒素雰囲気下でパーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120に、Si原子に対して10mol%のAl含量になるようにアルミニウムトリイソポロキシドを加え、60℃で3時間攪拌し塗布液を得た。当該塗布液を放冷し後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、上記で得られた第1のガスバリア層上に塗布を行い、室温で10分間乾燥させ、その後、100℃で3分間、さらに200℃で3時間乾燥させ、第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.302を得た。
パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120を、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、上記で得られた第1のガスバリア層上に塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2.1J/cm2の光量になるように照射して、第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.303を得た。
窒素雰囲気下、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120中に、Si原子に対して10mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加え、60℃2時間攪拌し塗布液を得た。当該塗布液を放冷した後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように、上記で得られた第1のガスバリア層上に塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2J/cm2の光量になるように照射して、第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.304を得た。
上記のサンプルNo.304と同様の方法で塗布液を調製し塗布を行った後、真空紫外線処理の代わりに、プラズマイオン注入処理を行い、ガスバリア性フィルムサンプルNo.305を得た。なお、プラズマイオン注入処理は、上記サンプルNo.205の場合と同様な条件で行った。
上記で得られたガスバリア性フィルムサンプルNo.301~305に対して、上述した実施例1で行った元素組成比の測定と同様な方法にて、第1のガスバリア層および第2のガスバリア層の元素組成比を測定した。第1のガスバリア層の組成比の結果は、SiO1.5C0.5であった。第2のガスバリア層の元素組成比のそれぞれの結果を表3に示す。
上記で得られたガスバリア性フィルムサンプルNo.301~305に対して、上述した実施例1で行ったIRスペクトルの測定と同様な方法にて、ATR法によって、第1のガスバリア層および第2のガスバリア層を積層後に測定を行い、ATRの浸透距離からほぼ第2のガスバリア層の成分が観測された。それぞれの結果を表3に示す。
上記で得られたガスバリア性フィルムサンプルNo.301~305に対して、第1のバリア層および第2のバリア層のバリア性を総合した水分透過率(WVTR)の測定を、上記実施例1の測定条件と同様にして行い、それぞれの結果を表3に示す。なお、第1のガスバリア層のみの水分透過率(WVTR)は、同様にして測定し、5×10-2(g/m2/day)であった。
(第1電極層の形成)
上記で作製したそれぞれのガスバリア性フィルム301~305上に、ITO(酸化インジウムスズ)をスパッタ法により厚さ150nmに成膜し、120℃で10分間加熱し、透明導電膜を形成した。これを、フォトリソグラフィー法によりパターニングを行い、第1電極層を形成した。
上記で形成した第1電極層の上に、以下に示す正孔輸送層形成用塗布液を、25℃、相対湿度50%RHの環境下で、アプリケーターで塗布した後、下記の条件で乾燥および加熱処理を行い、正孔輸送層を形成した。なお、正孔輸送層形成用塗布液を、乾燥後の正孔輸送層の厚みが50nmになるように塗布した。
ポリエチレンジオキシチオフェン・ポリスチレンスルホネート(PEDOT/PSS、Bayer社製 Bytron(登録商標) P AI 4083)を純水で65質量%まで希釈してから、メタノールで5質量%まで希釈した溶液を正孔輸送層形成用塗布液として準備した。
正孔輸送層形成用塗布液を塗布した後、成膜面に向け高さ100mm、吐出風速1m/s、幅手の風速分布5%、温度100℃で温風を当て溶媒を除去した後、引き続き、加熱処理装置を用い温度150℃で裏面伝熱方式の熱処理を行い、正孔輸送層を形成した。
上記で形成した正孔輸送層上に、以下に示す白色発光層形成用塗布液を、下記の条件によりアプリケーターで塗布した後、下記の条件で乾燥および加熱処理を行い、発光層を形成した。白色発光層形成用塗布液は乾燥後の発光層の厚みが40nmになるように塗布した。
ホスト材として下記化学式H-Aで表される化合物1.0gと、ドーパント材として下記化学式D-Aで表される化合物を100mg、ドーパント材として下記化学式D-Bで表される化合物を0.2mg、ドーパント材として下記化学式D-Cで表される化合物を0.2mg、100gのトルエンに溶解し白色発光層形成用塗布液として準備した。
塗布工程を窒素ガス濃度99%以上の雰囲気で、塗布温度を25℃とし、塗布速度1m/minで行った。
白色発光層形成用塗布液を塗布した後、成膜面に向け高さ100mm、吐出風速1m/s、幅手の風速分布5%、温度60℃で温風を当て溶媒を除去した後、引き続き、温度130℃で加熱処理を行い、発光層を形成した。
上記で形成した発光層の上に、以下に示す電子輸送層形成用塗布液を、下記の条件によりアプリケーターで塗布した後、下記の条件で乾燥および加熱処理し、電子輸送層を形成した。電子輸送層形成用塗布液は、乾燥後の電子輸送層の厚みが30nmになるように塗布した。
塗布工程は窒素ガス濃度99%以上の雰囲気で、電子輸送層形成用塗布液の塗布温度を25℃とし、塗布速度1m/minで行った。
電子輸送層は下記化学式E-Aで表される化合物を2,2,3,3-テトラフルオロ-1-プロパノール中に溶解し0.5質量%溶液とし、電子輸送層形成用塗布液とした。
電子輸送層形成用塗布液を塗布した後、成膜面に向け高さ100mm、吐出風速1m/s、幅手の風速分布5%、温度60℃で温風を当て溶媒を除去した後、引き続き、加熱処理部で、温度200℃で加熱処理を行い、電子輸送層を形成した。
上記で形成した電子輸送層上に、電子注入層を形成した。まず、基板を減圧チャンバに投入し、5×10-4Paまで減圧した。あらかじめ、真空チャンバにタンタル製蒸着ボートに用意しておいたフッ化セシウムを加熱し、厚さ3nmの電子注入層を形成した。
上記で形成した電子注入層の上に、5×10-4Paの真空下で、第2電極層形成材料としてアルミニウムを使用し、取り出し電極を有するように蒸着法にて、マスクパターン成膜し、厚さ100nmの第2電極層を積層した。
続いて、第1電極および第2電極の取り出し部になる部分を除き、CVD法でSiO2を厚さ200nmに積層し、第2電極層上に保護層を形成した。
上記で作製したガスバリア性フィルムサンプルNo.301~305を、それぞれ封止部材として使用し、スリーボンド株式会社製シート状封止剤TB1655を用いて、上記得られた電子素子本体に対して封止を行い、ガスバリア性フィルムサンプルNo.301~305に対応する有機EL素子サンプルNo.301~305を作製した。
上記で得られた有機EL素子サンプルNo.301~305について、下記の方法に従い、耐久性評価を行った。それぞれの結果を表3に示す。
上記で作製した各有機EL素子を、95℃85%RHの環境下で10時間加速劣化処理を施し、各有機EL素子に対し、それぞれ1mA/cm2の電流を印加し、発光像を写真撮影した際のダークスポットを面積比率(DSの発生率)として算出した。それぞれの結果を表3に示す。
上記で作製した各有機EL素子に対して、以下の2種類の劣化処理試験を行い、上記DS発生率の求め方法と同様に、劣化処理後のダークスポット(DS)の発生率を評価した。それぞれの結果を表3に示す。
各有機EL素子サンプルを、95℃85%RHの環境下で、500時間放置後、上記と同様な方法で発光させ、ダークスポットの面積比率(DSの発生率)を求めた。
各有機EL素子サンプルを、50mmΦ円柱に1秒かけて巻き取った後、1秒で平面に広げるサイクルを100,000回繰り返し、有機EL素子の加速劣化処理を実施した後、上記と同様の方法でダークスポットの面積比率(DSの発生率)を求めた。
PETフィルム基材(厚さ:50μm)上に、上述した実施例3と同様の方法によって第1のガスバリア層を形成した。このように形成した第1のガスバリア層上に、以下の第2のガスバリア層を積層し、ガスバリア性フィルムサンプルNo.401~405を作製した。
上記で得られた第1のガスバリア層上に、上述したガスバリア性フィルムサンプルNo.301の作製方法と同様にして第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.401を得た。
上記で得られた第1のガスバリア層上に、上述したガスバリア性フィルムサンプルNo.302の作製方法と同様にして第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.402を得た。
上記で得られた第1のガスバリア層上に、上述したガスバリア性フィルムサンプルNo.303の作製方法と同様にして第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.403を得た。
上記で得られた第1のガスバリア層上に、上述したガスバリア性フィルムサンプルNo.304の作製方法と同様にして第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.404を得た。
上記で得られた第1のガスバリア層上に、上述したガスバリア性フィルムサンプルNo.305の作製方法と同様にして第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.405を得た。
PETフィルム基材(厚さ:50μm)上に、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120を、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を6J/cm2の光量になるように照射し、第1のガスバリア層を形成した。
上記のサンプルNo.406と同様の第1のガスバリア層の上に、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120を、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2J/cm2の光量になるように照射し、第2のガスバリア層を形成し、ガスバリア性フィルムサンプルNo.407を得た。
上記で得られたガスバリア性フィルムサンプルNo.401~407に対して、第2のガスバリア層の元素組成比の測定、第2のガスバリア層のIRスペクトルの測定、第1のバリア層および第2のバリア層のバリア性を総合した水分透過率(WVTR)の測定を、上記実施例1の測定条件と同様にして行い、それぞれの結果を表4に示す。
上記で得られた各ガスバリア性フィルムサンプルのガスバリア層と反対側の基材面に、第1電極層(陽極)としてインジウムスズ酸化物(ITO)透明導電膜を厚さ150nmで堆積したもの(シート抵抗12Ω/square)を、通常のフォトリソグラフィー法と湿式エッチングとを用いて10mm幅にパターニングし、第1電極層を形成した。パターン形成した第1電極層を、界面活性剤と超純水とによる超音波洗浄、超純水による超音波洗浄の順で洗浄後、窒素ブローで乾燥させ、最後に紫外線オゾン洗浄を行った。
上記で得られた太陽電池サンプルNo.401~407について、下記の方法に従い、耐久性の評価を行った。
作製した各態様電池を、ソーラーシミュレーター(AM1.5Gフィルタ)を用いて100mW/cm2の強度の光を照射し、有効面積を1cm2にしたマスクを受光部に重ね、IV特性を評価することで、短絡電流密度Jsc(mA/cm2)、開放電圧Voc(V)、および曲線因子FFを測定し、初期光電変換効率(%)を下記式により算出した。それぞれの結果を表4に示す。
各太陽電池サンプルを95℃85%RHの環境下で、500時間放置後の発電効率を測定した。
各太陽電池サンプルを50mmΦ円柱に1秒かけて巻き取った後、1秒で平面に広げるサイクルを100,000回繰り返し、各太陽電池サンプルを95℃85%RHの環境下で10時間の加速劣化処理を実施した後、発電効率を測定した。
<半導体絶縁膜としての機能性膜の作製>
窒素雰囲気下で、シリコン基板上に、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120中に、Si原子に対して10mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加え、60℃2時間攪拌し塗布液を得た。当該塗布液を放冷し後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を1J/cm2の光量になるように照射して、絶縁膜を形成した。常法に従い、比誘電率を測定したところ、3.1であった。また、元素組成比およびIRスペクトルを上記実施例1と測定条件と同様にして測定した結果、本発明の範囲内の組成を有し、かつ本発明のIRスペクトルにおける(I[Si-H]/I[Si-O])値も本発明の範囲内であった。このように、本発明の機能性膜が半導体の絶縁膜として使用できることが分かった。
<ハードコート層としての機能性膜の作製>
窒素雰囲気下で、PET基板上に、パーヒドロポリシラザン溶液であるAZエレクトロニックマテリアルズ(株)製のNAX-120中に、Si原子に対して10mol%のAl含量になるようにアルミニウムエチルアセトアセテート・ジイソプロピレートを加え、60℃2時間攪拌し塗布液を得た。当該塗布液を放冷し後、大気中23℃50%RHの環境下で、乾燥膜厚が150nmになるように塗布を行い、室温で10分間乾燥させた。その後、酸素濃度を0.01~0.1%に調整した窒素雰囲気下で、80℃のホットプレート上にて、172nmの真空紫外線を2.5J/cm2の光量になるように照射して、ハードコート層を形成した。JIS K5600-5-4(ISO/DIN 15184)に従い鉛筆硬度を測定したところ、9Hであった。また、元素組成比およびIRスペクトルを上記実施例1と測定条件と同様にして測定した結果、本発明の範囲内の組成を有し、かつ本発明のIRスペクトルにおける(I[Si-H]/I[Si-O])値も本発明の範囲内であった。このように、本発明の機能性膜がハードコート層として使用できることが分かった。
Claims (8)
- 前記Mが、ホウ素、アルミニウム、ガリウムおよびインジウムからなる群より選択される少なくとも1種を示す、請求項1~3のいずれか1項に記載の機能性膜。
- 前記Mが、アルミニウムである、請求項1~4のいずれか1項に記載の機能性膜。
- ガスバリア層である、請求項1~5のいずれか1項に記載の機能性膜。
- 基材、および前記基材上に少なくとも1層の請求項6に記載のガスバリア層を有する、ガスバリア性フィルム。
- 請求項7に記載のガスバリア性フィルムを有する、電子デバイス。
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CN105764845A (zh) | 2016-07-13 |
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