WO2015125870A1 - 感光性樹脂組成物、硬化物及びその製造方法、樹脂パターン製造方法、硬化膜、液晶表示装置、有機el表示装置、赤外線カットフィルター、並びに、固体撮像装置 - Google Patents
感光性樹脂組成物、硬化物及びその製造方法、樹脂パターン製造方法、硬化膜、液晶表示装置、有機el表示装置、赤外線カットフィルター、並びに、固体撮像装置 Download PDFInfo
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- WO2015125870A1 WO2015125870A1 PCT/JP2015/054631 JP2015054631W WO2015125870A1 WO 2015125870 A1 WO2015125870 A1 WO 2015125870A1 JP 2015054631 W JP2015054631 W JP 2015054631W WO 2015125870 A1 WO2015125870 A1 WO 2015125870A1
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- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 7
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Classifications
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- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/30—Imagewise removal using liquid means
- G03F7/32—Liquid compositions therefor, e.g. developers
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/40—Treatment after imagewise removal, e.g. baking
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/844—Encapsulations
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/86—Arrangements for improving contrast, e.g. preventing reflection of ambient light
- H10K50/865—Arrangements for improving contrast, e.g. preventing reflection of ambient light comprising light absorbing layers, e.g. light-blocking layers
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/30—Devices specially adapted for multicolour light emission
- H10K59/38—Devices specially adapted for multicolour light emission comprising colour filters or colour changing media [CCM]
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/8791—Arrangements for improving contrast, e.g. preventing reflection of ambient light
- H10K59/8792—Arrangements for improving contrast, e.g. preventing reflection of ambient light comprising light absorbing layers, e.g. black layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L27/00—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate
- H01L27/14—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation
- H01L27/144—Devices controlled by radiation
- H01L27/146—Imager structures
- H01L27/14601—Structural or functional details thereof
- H01L27/1462—Coatings
- H01L27/14621—Colour filter arrangements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L27/00—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate
- H01L27/14—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation
- H01L27/144—Devices controlled by radiation
- H01L27/146—Imager structures
- H01L27/14601—Structural or functional details thereof
- H01L27/1462—Coatings
- H01L27/14623—Optical shielding
Definitions
- the present invention relates to a photosensitive resin composition (hereinafter sometimes simply referred to as “the resin composition of the present invention” or “the composition of the present invention”). Moreover, the resin pattern manufacturing method using the said photosensitive resin composition, the hardened
- the present invention relates to various image display devices, infrared cut filters, and solid-state imaging devices used.
- a photosensitive resin composition suitable for forming a black matrix (light-shielding color filter) of a color filter used for a liquid crystal display device, an organic EL display device, a solid-state imaging device, or a light-shielding film of an infrared cut filter, and
- the present invention relates to a method for producing a cured film using the same.
- a color filter used in a liquid crystal display device includes a light shielding film called a black matrix for the purpose of shielding light between colored pixels and improving contrast. Also in the solid-state imaging device, a black matrix is provided for the purpose of preventing noise and improving image quality.
- a black matrix contains a polymerizable composition in which a light-shielding black color material is dispersed, a polymerizable compound, a polymerization initiator, and other components to form a polymerizable composition, which is then patterned. Manufactured by. As a conventional photosensitive resin composition, what was described in patent document 1 or 2 is known.
- the black matrix plays a role such as defining the shape by dividing the colored pixels, shielding the colored pixel boundaries to prevent color bleeding, and the like.
- steps such as forming a colored pixel portion and forming ITO after forming the black matrix, and therefore the black matrix is required to have surface hardness. That is, there is a demand for a black matrix that is thin and excellent in light shielding properties and has high surface hardness.
- “Thin film having excellent light shielding properties” means that the value of “OD / film thickness” obtained by dividing the optical density (OD) value by the film thickness is large.
- Patent Document 2 Increasing the proportion of carbon black in the composition to meet the above-mentioned demand for high OD / film thickness has resulted in a problem of poor surface hardness. Therefore, recently, titanium black has been studied as a black colorant having excellent surface hardness (Patent Document 2). When the present inventors tried, although the composition described in patent document 2 had sufficient surface hardness, it turned out that OD / film thickness is not enough.
- the problem to be solved by the present invention is a photosensitive resin composition that provides a cured product having excellent light shielding properties and high surface hardness while being a thin film, a cured product obtained by curing the photosensitive resin composition, and a cured film And a manufacturing method thereof, a resin pattern manufacturing method, and a liquid crystal display device, an organic EL display device, an infrared cut filter, and a solid-state imaging device having the cured film.
- Component A A polymer component containing a polymer satisfying at least one of the following (1) and (2), (Component B) a photoacid generator, (Component C) a solvent, and (Component S) titanium A photosensitive resin composition characterized by containing black, (1) (a1) a polymer having a structural unit having an acid group protected with an acid-decomposable group and (a2) a structural unit having a crosslinkable group, (2) (a1) the acid group is acid-decomposed A polymer having a structural unit having a group protected by a functional group, and (a2) a polymer having a structural unit having a crosslinkable group, ⁇ 2>
- the crosslinkable group is at least one selected from the group consisting of an epoxy group, an oxetanyl group, —NH—CH 2 —OR 1 , an ethylenically unsaturated group, and a blocked isocyanate group, ⁇ 1 >, Wherein R 1 represents an alkyl group having 1 to 20 carbon
- An exposure step of irradiating the resin composition with actinic rays ⁇ 9>
- a resin pattern manufacturing method comprising at least steps (1) to (4) in this order, (1) The photosensitive resin composition according to any one of ⁇ 1> to ⁇ 7> An application step of applying on the substrate, (2) a solvent removal step of removing the solvent from the applied resin composition, (3) an exposure step of exposing the resin composition from which the solvent has been removed to a pattern with actinic rays, 4) Development step of developing the exposed resin composition and the unexposed resin composition with an aqueous developer, ⁇ 10>
- the cured film according to ⁇ 11> which is a light-shielding color filter, ⁇ 13>
- the photosensitive resin composition from which the hardened
- a polymer component containing a polymer satisfying at least one of (component A) (1) and (2)” or the like is also simply referred to as “component A” or the like
- component A component A
- (a1) acid group is The “structural unit having a group protected with an acid-decomposable group” or the like is also simply referred to as “structural unit (a1)” or the like.
- structural unit (a1) structural unit (a1)” or the like.
- the “alkyl group” includes not only an alkyl group having no substituent (unsubstituted alkyl group) but also an alkyl group having a substituent (substituted alkyl group).
- “mass%” and “wt%” are synonymous, and “part by mass” and “part by weight” are synonymous. In the present invention, a combination of preferred embodiments is more preferred.
- the photosensitive resin composition of the present invention (hereinafter also simply referred to as “resin composition”) comprises (Component A) a polymer component containing a polymer satisfying at least one of the following (1) and (2), (Component B) A photoacid generator, (Component C) a solvent, and (Component S) titanium black.
- Component A a polymer having a structural unit having an acid group protected by an acid-decomposable group and (a2) a structural unit having a crosslinkable group
- (2) (a1) an acid group having an acid-decomposable property A polymer having a structural unit having a group protected by a group, and (a2) a polymer having a structural unit having a crosslinkable group
- the photosensitive resin composition of the present invention can be suitably used as a positive resist composition.
- the photosensitive resin composition of the present invention is preferably a resin composition having a property of being cured by heat.
- the photosensitive resin composition of the present invention is preferably a positive photosensitive resin composition, and is a chemically amplified positive photosensitive resin composition (chemically amplified positive photosensitive resin composition). Is more preferable.
- the photosensitive resin composition of the present invention preferably contains no 1,2-quinonediazide compound as a photoacid generator sensitive to actinic rays. A 1,2-quinonediazide compound generates a carboxy group by a sequential photochemical reaction, but its quantum yield is always 1 or less.
- (Component B) photoacid generator used in the present invention is such that an acid generated in response to actinic light acts as a catalyst for deprotection of the protected acid group in Component A. Therefore, the acid generated by the action of one photon contributes to a number of deprotection reactions, and the quantum yield exceeds 1, for example, a large value such as the power of 10, which is a result of so-called chemical amplification. As a result, high sensitivity can be obtained.
- the photosensitive resin composition of the present invention is preferably a photosensitive resin composition for a black matrix (light-shielding color filter) of a color filter.
- cured material which hardened the photosensitive resin composition of this invention can be used suitably as a light shielding film or a light shielding member in various display apparatuses.
- the photosensitive resin composition of the present invention will be described in detail.
- the photosensitive resin composition of the present invention comprises a polymer satisfying at least one of the following (1) and (2).
- the photosensitive resin composition of the present invention further contains a polymer other than these. May be.
- component A in the present invention means those including other polymers added as needed in addition to the above (1) and / or (2).
- the photosensitive resin composition of the present invention preferably contains as component A a component that satisfies the above (1).
- the photosensitive resin composition of the present invention preferably contains a component satisfying the above (2) as the component A.
- (a1) a polymer having a structural unit having a group in which an acid group is protected by an acid-decomposable group and / or (a2) cross-linking A polymer having a structural unit having a functional group may be contained.
- Component A is preferably an addition polymerization type resin, and is a polymer including a structural unit derived from (meth) acrylic acid and / or an ester thereof, and a structural unit derived from hydroxystyrene and / or an ester thereof. Is more preferable. In addition, you may have structural units other than the above, for example, the structural unit derived from styrene, the structural unit derived from a vinyl compound, etc.
- the “structural unit derived from (meth) acrylic acid and / or its ester” is also referred to as “acrylic structural unit”. Further, “(meth) acrylic acid” means “methacrylic acid and / or acrylic acid”.
- Component A includes (a1) a polymer having at least a structural unit having a group in which an acid group is protected with an acid-decomposable group.
- component A contains a polymer having the structural unit (a1), a highly sensitive photosensitive resin composition can be obtained.
- group in which the acid group is protected with an acid-decomposable group those known as an acid group and an acid-decomposable group can be used, and are not particularly limited.
- Specific examples of the acid group preferably include a carboxyl group and a phenolic hydroxyl group.
- Examples of the acid-decomposable group include groups that are relatively easily decomposed by an acid (for example, an ester structure of a group represented by the formula (a1-10) described later, a tetrahydropyranyl ester group, or a tetrahydrofuranyl ester group).
- An acetal functional group) or a group that is relatively difficult to decompose by an acid for example, a tertiary alkyl ester group such as a tert-butyl ester group or a tertiary alkyl carbonate group such as a tert-butyl carbonate group
- a tertiary alkyl ester group such as a tert-butyl ester group
- a tertiary alkyl carbonate group such as a tert-butyl carbonate group
- a structural unit having a group in which an acid group is protected with an acid-decomposable group is a structural unit having a protected carboxyl group in which a carboxyl group is protected with an acid-decomposable group (“protection protected with an acid-decomposable group”
- the structural unit (a1-1) having a protected carboxyl group protected with an acid-decomposable group is a protected carboxyl in which the carboxyl group of the structural unit having a carboxyl group is protected by an acid-decomposable group described in detail below.
- a structural unit having a group is not particularly limited, and a known structural unit can be used.
- a structural unit (a1-1-1) derived from an unsaturated carboxylic acid having at least one carboxyl group in the molecule, such as an unsaturated monocarboxylic acid, an unsaturated dicarboxylic acid, or an unsaturated tricarboxylic acid
- a structural unit (a1-1-2) having both an ethylenically unsaturated group and a structure derived from an acid anhydride.
- the structural units having both the unsaturated group and the structure derived from the acid anhydride will be described in order.
- ⁇ (a1-1-1) Structural unit derived from unsaturated carboxylic acid having at least one carboxyl group in the molecule >>>
- Examples of the unsaturated carboxylic acid used in the present invention as the structural unit (a1-1-1) derived from an unsaturated carboxylic acid having at least one carboxyl group in the molecule include those listed below. . That is, examples of the unsaturated monocarboxylic acid include acrylic acid, methacrylic acid, crotonic acid, ⁇ -chloroacrylic acid, cinnamic acid, 2- (meth) acryloyloxyethyl succinic acid, and 2- (meth) acryloyl.
- Examples include loxyethyl hexahydrophthalic acid and 2- (meth) acryloyloxyethyl phthalic acid.
- Examples of the unsaturated dicarboxylic acid include maleic acid, fumaric acid, itaconic acid, citraconic acid, and mesaconic acid.
- the acid anhydride may be sufficient as unsaturated polyhydric carboxylic acid used in order to obtain the structural unit which has a carboxyl group. Specific examples include maleic anhydride, itaconic anhydride, citraconic anhydride, and the like.
- the unsaturated polyvalent carboxylic acid may be a mono (2-methacryloyloxyalkyl) ester of a polyvalent carboxylic acid, such as succinic acid mono (2-acryloyloxyethyl), succinic acid mono (2 -Methacryloyloxyethyl), mono (2-acryloyloxyethyl) phthalate, mono (2-methacryloyloxyethyl) phthalate and the like.
- the unsaturated polyvalent carboxylic acid may be a mono (meth) acrylate of a dicarboxy polymer at both ends, and examples thereof include ⁇ -carboxypolycaprolactone monoacrylate and ⁇ -carboxypolycaprolactone monomethacrylate.
- unsaturated carboxylic acid acrylic acid-2-carboxyethyl ester, methacrylic acid-2-carboxyethyl ester, maleic acid monoalkyl ester, fumaric acid monoalkyl ester, 4-carboxystyrene and the like can also be used.
- the structural unit (a1-1-1) derived from an unsaturated carboxylic acid having at least one carboxyl group in the molecule acrylic acid, methacrylic acid, 2- (meth) acryloyloxyethyl succinic acid, 2- (meth) acryloyloxyethyl hexahydrophthalic acid, 2- (meth) acryloyloxyethyl phthalic acid, anhydride of unsaturated polyvalent carboxylic acid, etc. It is preferable to use acrylic acid, methacrylic acid, and 2- (meth) acryloyloxyethyl hexahydrophthalic acid.
- the structural unit (a1-1-1) derived from an unsaturated carboxylic acid or the like having at least one carboxyl group in the molecule may be composed of one kind alone or two or more kinds. May be.
- a structural unit having both an ethylenically unsaturated group and a structure derived from an acid anhydride is obtained by reacting a hydroxyl group present in the structural unit having an ethylenically unsaturated group with an acid anhydride.
- a unit derived from the obtained monomer is preferred.
- the acid anhydride known ones can be used, and specifically, maleic anhydride, succinic anhydride, itaconic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, chlorendic anhydride, etc.
- phthalic anhydride, tetrahydrophthalic anhydride, or succinic anhydride is preferable from the viewpoint of developability.
- the reaction rate of the acid anhydride with respect to the hydroxyl group is preferably 10 to 100 mol%, more preferably 30 to 100 mol% from the viewpoint of developability.
- the above-mentioned acid-decomposable groups can be used.
- these acid-decomposable groups it is a protected carboxyl group in which the carboxyl group is protected in the form of an acetal.
- Basic properties of the photosensitive resin composition in particular, sensitivity and pattern shape, contact hole formation, photosensitive resin It is preferable from the viewpoint of the storage stability of the composition.
- the carboxyl group is more preferably a protected carboxyl group protected in the form of an acetal represented by the following formula (a1-10) from the viewpoint of sensitivity.
- the carboxyl group is a protected carboxyl group protected in the form of an acetal represented by the following formula (a1-10)
- the entire protected carboxyl group is — (C ⁇ O) —O—CR 101 R
- the structure is 102 (OR 103 ).
- R 101 and R 102 each independently represent a hydrogen atom, an alkyl group or an aryl group, provided that, .R 103 except in the case of the R 101 and R 102 are both hydrogen atoms Represents an alkyl group or an aryl group, and R 101 or R 102 and R 103 may be linked to form a cyclic ether.
- R 101 and R 102 each independently represents a hydrogen atom, an alkyl group or an aryl group
- R 103 represents an alkyl group or an aryl group
- the alkyl group is linear or branched Either a chain or a ring may be used.
- both R 101 and R 102 do not represent a hydrogen atom, and at least one of R 101 and R 102 represents an alkyl group.
- R 101 , R 102 and R 103 represent an alkyl group
- the alkyl group may be linear, branched or cyclic.
- the linear or branched alkyl group preferably has 1 to 12 carbon atoms, more preferably 1 to 6 carbon atoms, and still more preferably 1 to 4 carbon atoms.
- methyl group, ethyl group, n-propyl group, i-propyl group, n-butyl group, i-butyl group, sec-butyl group, tert-butyl group, n-pentyl group, neopentyl group, n examples include -hexyl group, texyl group (2,3-dimethyl-2-butyl group), n-heptyl group, n-octyl group, 2-ethylhexyl group, n-nonyl group, n-decyl group and the like.
- the cyclic alkyl group preferably has 3 to 12 carbon atoms, more preferably 4 to 8 carbon atoms, and still more preferably 4 to 6 carbon atoms.
- Examples of the cyclic alkyl group include a cyclopropyl group, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, a cyclooctyl group, a norbornyl group, and an isobornyl group.
- the alkyl group may have a substituent, and examples of the substituent include a halogen atom, an aryl group, and an alkoxy group.
- R 101 , R 102 and R 103 When it has a halogen atom as a substituent, R 101 , R 102 and R 103 become a haloalkyl group, and when it has an aryl group as a substituent, R 101 , R 102 and R 103 become an aralkyl group.
- the halogen atom include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom, and among these, a fluorine atom or a chlorine atom is preferable.
- the aryl group is preferably an aryl group having 6 to 20 carbon atoms, and more preferably an aryl group having 6 to 12 carbon atoms.
- Specific examples include a phenyl group, an ⁇ -methylphenyl group, a naphthyl group, and the like, and examples of the entire alkyl group substituted with an aryl group, that is, an aralkyl group include a benzyl group, an ⁇ -methylbenzyl group, a phenethyl group, A naphthylmethyl group etc. can be illustrated.
- the alkoxy group is preferably an alkoxy group having 1 to 6 carbon atoms, more preferably an alkoxy group having 1 to 4 carbon atoms, and still more preferably a methoxy group or an ethoxy group.
- the alkyl group is a cycloalkyl group
- the cycloalkyl group may have a linear or branched alkyl group having 1 to 10 carbon atoms as a substituent, and the alkyl group is a linear chain. Or a branched alkyl group, it may have a cycloalkyl group having 3 to 12 carbon atoms as a substituent. These substituents may be further substituted with the above substituents.
- R 101 , R 102 and R 103 represent an aryl group
- the aryl group preferably has 6 to 12 carbon atoms, and more preferably 6 to 10 carbon atoms.
- the aryl group may have a substituent, and preferred examples of the substituent include an alkyl group having 1 to 6 carbon atoms. Examples of the aryl group include a phenyl group, a tolyl group, a xylyl group, a cumenyl group, and a 1-naphthyl group.
- R 101 , R 102 and R 103 can be bonded together to form a ring together with the carbon atom to which they are bonded.
- Examples of the ring structure when R 101 and R 102 , R 101 and R 103 or R 102 and R 103 are bonded include, for example, a cyclobutyl group, a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, a tetrahydrofuranyl group, an adamantyl group, and a tetrahydropyrani group. And the like.
- any one of R 101 and R 102 is preferably a hydrogen atom or a methyl group.
- radical polymerizable monomer used for forming the structural unit having a protected carboxyl group represented by the above formula (a1-10) a commercially available one may be used, or one synthesized by a known method Can also be used. For example, it can be synthesized by the synthesis method described in paragraphs 0037 to 0040 of JP2011-212494A.
- a first preferred embodiment of the structural unit (a1-1) having a protected carboxyl group protected by the acid-decomposable group is a structural unit represented by the following formula.
- R 1 and R 2 each independently represent a hydrogen atom, an alkyl group or an aryl group, at least one of R 1 and R 2 is an alkyl group or an aryl group, and R 3 is an alkyl group. Or R 1 or R 2 and R 3 may be linked to form a cyclic ether, R 4 represents a hydrogen atom or a methyl group, and X represents a single bond or an arylene group. .
- R 1 and R 2 are alkyl groups, alkyl groups having 1 to 10 carbon atoms are preferred. When R 1 and R 2 are aryl groups, a phenyl group is preferred. R 1 and R 2 are preferably each independently a hydrogen atom or an alkyl group having 1 to 4 carbon atoms. R 3 represents an alkyl group or an aryl group, preferably an alkyl group having 1 to 10 carbon atoms, more preferably an alkyl group having 1 to 6 carbon atoms. X represents a single bond or an arylene group, and a single bond is preferable.
- a second preferred embodiment of the structural unit (a1-1) having a protected carboxyl group protected by the acid-decomposable group is a structural unit represented by the following formula.
- R 121 represents a hydrogen atom or an alkyl group having 1 to 4 carbon atoms
- L 1 represents a carbonyl group or a phenylenecarbonyl group
- R 122 to R 128 each independently represents a hydrogen atom or 1 to 4 represents an alkyl group.
- R 121 is preferably a hydrogen atom or a methyl group.
- L 1 is preferably a carbonyl group.
- R 122 to R 128 are preferably hydrogen atoms.
- R represents a hydrogen atom or a methyl group.
- the structural unit (a1-2) having a protected phenolic hydroxyl group protected with an acid-decomposable group is a protected phenolic group in which the structural unit having a phenolic hydroxyl group is protected by an acid-decomposable group described in detail below.
- ⁇ (a1-2-1) Structural unit having phenolic hydroxyl group Examples of the structural unit having a phenolic hydroxyl group include a hydroxystyrene-based structural unit and a structural unit in a novolac-based resin. Among these, a structural unit derived from hydroxystyrene or ⁇ -methylhydroxystyrene is sensitive. From the viewpoint of In addition, as a structural unit having a phenolic hydroxyl group, a structural unit represented by the following formula (a1-20) is also preferable from the viewpoint of sensitivity.
- R 220 represents a hydrogen atom or a methyl group
- R 221 represents a single bond or a divalent linking group
- R 222 represents a halogen atom or a linear or branched group having 1 to 5 carbon atoms.
- R 220 represents a hydrogen atom or a methyl group, and is preferably a methyl group.
- R 221 represents a single bond or a divalent linking group. A single bond is preferable because the sensitivity can be improved and the transparency of the cured film can be further improved.
- the divalent linking group for R 221 include an alkylene group, preferably an alkylene group having 1 to 12 carbon atoms, more preferably an alkylene group having 1 to 8 carbon atoms, and still more preferably an alkylene group having 1 to 3 carbon atoms.
- R 221 is an alkylene group
- R 221 is an alkylene group
- R 221 is preferably a single bond, a methylene group, an ethylene group, a 1,2-propylene group, a 1,3-propylene group, or a 2-hydroxy-1,3-propylene group.
- the divalent linking group may have a substituent, and examples of the substituent include a halogen atom, a hydroxyl group, and an alkoxy group.
- A represents an integer of 1 to 5, but a is preferably 1 or 2 and more preferably 1 from the viewpoint of the effects of the present invention and the ease of production.
- the bonding position of the hydroxyl group in the benzene ring is preferably bonded to the 4-position when the carbon atom bonded to R 221 is defined as the reference (first position).
- R 222 each independently represents a halogen atom or a linear or branched alkyl group having 1 to 5 carbon atoms.
- a chlorine atom, a bromine atom, a methyl group, or an ethyl group is preferable from the viewpoint of easy production.
- B represents 0 or an integer of 1 to 4;
- the acid-decomposable group that can be used in the structural unit (a1-2) having a protected phenolic hydroxyl group protected by the acid-decomposable group includes a structure having a protected carboxyl group protected by the acid-decomposable group Similar to the acid-decomposable group that can be used for the unit (a1-1), known ones can be used and are not particularly limited.
- a structural unit having a protected phenolic hydroxyl group protected with acetal is a basic physical property of the photosensitive resin composition, particularly sensitivity and pattern shape, storage stability of the photosensitive resin composition, contact This is preferable from the viewpoint of hole formability.
- the phenolic hydroxyl group is more preferably a protected phenolic hydroxyl group protected in the form of an acetal represented by the above formula (a1-10) from the viewpoint of sensitivity.
- the phenolic hydroxyl group is a protected phenolic hydroxyl group protected in the form of an acetal represented by the above formula (a1-10)
- the entire protected phenolic hydroxyl group is —Ar—O—CR 101 R 102.
- the structure is (OR 103 ).
- Ar represents an arylene group.
- Examples of the radical polymerizable monomer used to form a structural unit having a protected phenolic hydroxyl group in which the phenolic hydroxyl group is protected in the form of an acetal include, for example, paragraph 0042 of JP2011-215590A And the like.
- a 1-alkoxyalkyl protector of 4-hydroxyphenyl methacrylate and a tetrahydropyranyl protector of 4-hydroxyphenyl methacrylate are preferable from the viewpoint of transparency.
- acetal protecting group for the phenolic hydroxyl group examples include a 1-alkoxyalkyl group, such as a 1-ethoxyethyl group, a 1-methoxyethyl group, a 1-n-butoxyethyl group, and a 1-isobutoxyethyl group.
- 1- (2-chloroethoxy) ethyl group, 1- (2-ethylhexyloxy) ethyl group, 1-n-propoxyethyl group, 1-cyclohexyloxyethyl group, 1- (2-cyclohexylethoxy) ethyl group, 1 -A benzyloxyethyl group etc. can be mentioned, These can be used individually by 1 type or in combination of 2 or more types.
- the radical polymerizable monomer used for forming the structural unit (a1-2) having a protected phenolic hydroxyl group protected by the acid-decomposable group a commercially available one may be used, or a known method may be used. What was synthesized with can also be used. For example, it can be synthesized by reacting a compound having a phenolic hydroxyl group with vinyl ether in the presence of an acid catalyst. In the above synthesis, a monomer having a phenolic hydroxyl group may be previously copolymerized with another monomer, and then reacted with vinyl ether in the presence of an acid catalyst.
- R represents a hydrogen atom or a methyl group.
- the structural unit (a1) is 20 to 100 mol% in the polymer having the structural unit (a1). It is preferably 30 to 90 mol%.
- the single structural unit (a1) is sensitive to the polymer having the structural unit (a1) and the structural unit (a2). From this viewpoint, it is preferably 3 to 70 mol%, more preferably 10 to 60 mol%.
- the structural unit (a1) is a structural unit having a protected carboxyl group in which the carboxyl group is protected in the form of an acetal, 20 to 50 mol% is preferable.
- the “structural unit” is synonymous with the “monomer unit”.
- the “monomer unit” may be modified after polymerization by a polymer reaction or the like. The same applies to the following.
- the structural unit (a1-1) having a protected carboxyl group protected with an acid-decomposable group is more developed than the structural unit (a1-2) having a protected phenolic hydroxyl group protected with the acid-decomposable group. Is characterized by being fast. Therefore, when it is desired to develop quickly, the structural unit (a1-1) having a protected carboxyl group protected with an acid-decomposable group is preferred. Conversely, when it is desired to delay the development, it is preferable to use the structural unit (a1-2) having a protected phenolic hydroxyl group protected with an acid-decomposable group.
- Component A contains a polymer having a structural unit (a2) having a crosslinkable group.
- the crosslinkable group is not particularly limited as long as it is a group that causes a curing reaction by heat treatment.
- Preferred embodiments of the structural unit having a crosslinkable group are represented by an epoxy group, an oxetanyl group, and —NH—CH 2 —O—R (R represents a hydrogen atom or an alkyl group having 1 to 20 carbon atoms).
- a structural unit containing at least one selected from the group consisting of a group, an ethylenically unsaturated group, and a blocked isocyanate group includes an epoxy group, an oxetanyl group, —NH—CH 2 —O—R (R is hydrogen It is preferably at least one selected from the group consisting of an atom or an alkyl group having 1 to 20 carbon atoms), a (meth) acryloyl group, and a blocked isocyanate group, an epoxy group, oxetanyl group, and, -NH-CH 2 -O-R of at least one (R is representing.
- the component A includes a structural unit containing at least one of an epoxy group and an oxetanyl group. In more detail, the following are mentioned.
- Component A preferably contains a polymer having a structural unit (structural unit (a2-1)) having an epoxy group and / or an oxetanyl group.
- structural unit (a2-1) having an epoxy group and / or an oxetanyl group.
- a 3-membered cyclic ether group is also called an epoxy group, and a 4-membered cyclic ether group is also called an oxetanyl group.
- the structural unit (a2-1) having an epoxy group and / or oxetanyl group may have at least one epoxy group or oxetanyl group in one structural unit, one or more epoxy groups and one It may have an oxetanyl group, two or more epoxy groups, or two or more oxetanyl groups, and is not particularly limited, but preferably has a total of 1 to 3 epoxy groups and / or oxetanyl groups, It is more preferable to have one or two epoxy groups and / or oxetanyl groups in total, and it is even more preferable to have one epoxy group or oxetanyl group.
- radical polymerizable monomer used for forming the structural unit having an epoxy group include, for example, glycidyl acrylate, glycidyl methacrylate, glycidyl ⁇ -ethyl acrylate, and glycidyl ⁇ -n-propyl acrylate.
- radical polymerizable monomer used for forming the structural unit having an oxetanyl group include, for example, a (meth) acryl having an oxetanyl group described in paragraphs 0011 to 0016 of JP-A No. 2001-330953. Acid esters, and the like, the contents of which are incorporated herein.
- radical polymerizable monomer used for forming the structural unit (a2-1) having the epoxy group and / or oxetanyl group include a monomer having a methacrylic ester structure and an acrylic ester structure. It is preferable that it is a monomer to contain.
- These structural units can be used individually by 1 type or in combination of 2 or more types.
- R represents a hydrogen atom or a methyl group.
- (a2-2) Structural unit having an ethylenically unsaturated group is a structural unit (a2-2) having an ethylenically unsaturated group (hereinafter also referred to as “structural unit (a2-2)”).
- the structural unit (a2-2) having an ethylenically unsaturated group is preferably a structural unit having an ethylenically unsaturated group in the side chain, having an ethylenically unsaturated group at the terminal, and having 3 to 16 carbon atoms.
- a structural unit having a side chain is more preferred.
- the copolymer used in the present invention is a structural unit (a2-3) having a group represented by —NH—CH 2 —O—R (R represents a hydrogen atom or an alkyl group having 1 to 20 carbon atoms). Is also preferable.
- a curing reaction can be caused by a mild heat treatment, and a cured film having excellent characteristics can be obtained.
- R is preferably an alkyl group having 1 to 20 carbon atoms, more preferably an alkyl group having 1 to 9 carbon atoms, and still more preferably an alkyl group having 1 to 4 carbon atoms.
- the alkyl group may be a linear, branched or cyclic alkyl group, but is preferably a linear or branched alkyl group.
- the structural unit (a2) is more preferably a structural unit having a group represented by the following formula (a2-30).
- R 31 represents a hydrogen atom or a methyl group
- R 32 represents an alkyl group having 1 to 20 carbon atoms.
- R 32 is preferably an alkyl group having 1 to 9 carbon atoms, and more preferably an alkyl group having 1 to 4 carbon atoms.
- the alkyl group may be a linear, branched or cyclic alkyl group, but is preferably a linear or branched alkyl group.
- Specific examples of R 32 include a methyl group, an ethyl group, an n-butyl group, an i-butyl group, a cyclohexyl group, and an n-hexyl group. Of these, i-butyl group, n-butyl group and methyl group are preferable.
- the structural unit (a2) is 5 to 90 mol% in the polymer having the structural unit (a2). It is preferably 20 to 80 mol%.
- the polymer having the structural unit (a2) has the structural unit (a1), the content of the structural unit (a2) in the polymer having the structural unit (a1) and the structural unit (a2) From the viewpoint of chemical resistance, it is preferably 3 to 70 mol%, more preferably 10 to 60 mol%.
- the structural unit (a2) is preferably contained in an amount of 3 to 70 mol%, more preferably 10 to 60 mol%, in all the structural units of Component A, regardless of any embodiment.
- the cured film obtained from the photosensitive resin composition has good transparency and chemical resistance.
- component A may have another structural unit (a3) in addition to the structural units (a1) and / or (a2). These structural units may be contained in the polymer component (1) and / or (2).
- the polymer component has another structural unit (a3) substantially free from the structural unit (a1) and the structural unit (a2). It may be.
- the blending amount of the polymer component is preferably 60% by mass or less, more preferably 40% by mass or less, and still more preferably 20% by mass or less in all polymer components.
- a monomer used as another structural unit (a3) For example, styrenes, (meth) acrylic acid alkyl ester, (meth) acrylic acid cyclic alkyl ester, (meth) acrylic acid aryl ester, unsaturated Dicarboxylic acid diesters, bicyclounsaturated compounds, maleimide compounds, unsaturated aromatic compounds, conjugated diene compounds, unsaturated monocarboxylic acids, unsaturated dicarboxylic acids, unsaturated dicarboxylic acid anhydrides, and other unsaturated compounds be able to.
- the monomer which becomes another structural unit (a3) can be used individually by 1 type or in combination of 2 or more types.
- the other structural unit (a3) include styrene, methyl styrene, hydroxy styrene, ⁇ -methyl styrene, acetoxy styrene, methoxy styrene, ethoxy styrene, chlorostyrene, methyl vinyl benzoate, ethyl vinyl benzoate, 4 -Hydroxybenzoic acid (3-methacryloyloxypropyl) ester, (meth) acrylic acid, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, ( Constitutional unit composed of 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, benzyl (meth) acrylate, isobornyl (meth) acrylate, acrylonitrile, ethylene glycol
- a structural unit derived from a monomer having a styrene or an aliphatic cyclic skeleton is preferable from the viewpoint of electrical characteristics.
- Specific examples include styrene, methylstyrene, hydroxystyrene, ⁇ -methylstyrene, dicyclopentanyl (meth) acrylate, cyclohexyl (meth) acrylate, isobornyl (meth) acrylate, and benzyl (meth) acrylate.
- the other structural unit (a3) a structural unit derived from (meth) acrylic acid alkyl ester is preferable from the viewpoint of adhesion.
- Specific examples include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, and n-butyl (meth) acrylate, and methyl (meth) acrylate is more preferable.
- the content of the structural unit (a3) is preferably 60 mol% or less, more preferably 50 mol% or less, and still more preferably 40 mol% or less.
- 0 mol% may be sufficient, it is preferable to set it as 1 mol% or more, for example, and it is more preferable to set it as 5 mol% or more.
- various properties of the cured film obtained from the photosensitive resin composition are improved.
- the polymer contained in Component A preferably has a structural unit having an acid group as the other structural unit (a3).
- the acid group in the present invention means a proton dissociable group having a pKa smaller than 11.
- the acid group is usually incorporated into the polymer as a structural unit containing an acid group using a monomer capable of forming an acid group. By including such a structural unit containing an acid group in the polymer, the polymer tends to be easily dissolved in an alkaline developer.
- Examples of the acid group used in the present invention include a carboxylic acid group, a sulfonamide group, a phosphonic acid group, a sulfonic acid group, a phenolic hydroxyl group, a sulfonamide group, a sulfonylimide group, and acid anhydride groups of these acid groups, And the group etc. which neutralized these acid groups and made it into salt structure are illustrated, and a carboxylic acid group and / or a phenolic hydroxyl group are preferable.
- An alkali metal salt, alkaline-earth metal salt, and organic ammonium salt can illustrate preferably.
- the structural unit containing an acid group used in the present invention is more preferably a structural unit derived from styrene, a structural unit derived from a vinyl compound, a structural unit derived from (meth) acrylic acid and / or an ester thereof.
- a structural unit derived from styrene a structural unit derived from a vinyl compound
- a structural unit derived from (meth) acrylic acid and / or an ester thereof .
- compounds described in paragraphs 0021 to 0023 and paragraphs 0029 to 0044 of JP2012-88459A can be used, the contents of which are incorporated herein.
- structural units derived from p-hydroxystyrene, (meth) acrylic acid, maleic acid, and maleic anhydride are preferred.
- a polymer having another structural unit (a3) substantially not including the structural unit (a1) and the structural unit (a2) is included. You may go out.
- a resin having a carboxyl group in the side chain is preferable.
- methacrylic acid copolymer acrylic acid copolymer, itaconic acid copolymer, crotonic acid copolymer, maleic acid copolymer, partially esterified maleic acid copolymer, etc.
- side chain examples thereof include acidic cellulose derivatives having a carboxyl group, those obtained by adding an acid anhydride to a polymer having a hydroxyl group, and high molecular polymers having a (meth) acryloyl group in the side chain. “Substantially not contained” means that the weight ratio in the polymer is 1% by mass or less.
- benzyl (meth) acrylate / (meth) acrylic acid copolymer 2-hydroxyethyl (meth) acrylate / benzyl (meth) acrylate / (meth) acrylic acid copolymer, described in JP-A-7-140654 2-hydroxypropyl (meth) acrylate / polystyrene macromonomer / benzyl methacrylate / methacrylic acid copolymer, 2-hydroxy-3-phenoxypropyl acrylate / polymethyl methacrylate macromonomer / benzyl methacrylate / methacrylic acid copolymer, 2 -Hydroxyethyl methacrylate / polystyrene macromonomer / methyl methacrylate / methacrylic acid copolymer, 2-hydroxyethyl methacrylate / polystyrene macromonomer / benzyl methacrylate / methacrylic acid
- Known polymer compounds described in JP-A-2003-233179, JP-A-2009-52020, and the like can be used, and the contents thereof are incorporated herein. These polymers may contain only 1 type and may contain 2 or more types.
- SMA 1000P, SMA 2000P, SMA 3000P, SMA 1440F, SMA 17352P, SMA 2625P, SMA 3840F (above, manufactured by Sartomer), ARUFON UC-3000, ARUFON UC-3510, ARUFON UC-3900, ARUFON UC-3910, ARUFON UC-3920, ARUFON UC-3080 (above, manufactured by Toagosei Co., Ltd.), JONCRYL 690, JONCRYL 678, JONCRYL 67, JONCRYL 586 (above, manufactured by BASF), etc. are used. You can also.
- the structural unit containing an acid group is preferably from 1 to 80 mol%, more preferably from 1 to 50 mol%, still more preferably from 5 to 40 mol%, particularly preferably from 5 to 30 mol%, based on the structural units of all polymer components. Most preferred is 5 to 20 mol%.
- any polymer includes a structural unit containing at least an acid group as the other structural unit (a3).
- -Fifth embodiment- In addition to the polymer component (1) or (2), an embodiment having a polymer having another structural unit (a3) substantially not having the structural unit (a1) and the structural unit (a2). .
- -Sixth embodiment- A mode comprising a combination of two or more of the first to fifth embodiments.
- the molecular weight of the polymer in Component A is a polystyrene-reduced weight average molecular weight, preferably in the range of 1,000 to 200,000, more preferably 2,000 to 50,000. Various characteristics are favorable in the range of said numerical value.
- the ratio (dispersity, Mw / Mn) between the number average molecular weight Mn and the weight average molecular weight Mw is preferably 1.0 to 5.0, more preferably 1.5 to 3.5.
- GPC gel permeation chromatography
- HLC-8020GPC manufactured by Tosoh Corporation
- TSKgel Super HZ MH TSK gel Super HZ4000
- TSKgel SuperHZ200 manufactured by Tosoh Corporation, 4.6 mm ID ⁇ 15 cm
- THF tetrahydrofuran
- radicals used to form at least the structural unit (a1) and the structural unit (a3) can be synthesized by polymerizing a radical polymerizable monomer mixture containing a polymerizable monomer in an organic solvent using a radical polymerization initiator. It can also be synthesized by a so-called polymer reaction.
- the content of component A in the photosensitive resin composition of the present invention is preferably 30 to 99% by mass, preferably 40 to 98% by mass, based on the solid content other than titanium black in the photosensitive resin composition. More preferably, it is 60 to 95% by mass.
- the effect of this invention is show
- solid content of the photosensitive resin composition represents the component except volatile components, such as a solvent.
- the photosensitive resin composition of this invention has a wide development margin by containing the component A.
- the content of the component A in the photosensitive resin composition of the present invention is applied to a solid content other than titanium black of the photosensitive resin composition when applied to an infrared cut filter (particularly a glass substrate) described later. It is preferably 20 to 99% by mass, more preferably 25 to 98% by mass, and further preferably 30 to 95% by mass. The effect of this invention is show
- the crosslinkable group equivalent in the solid content of the photosensitive resin composition is the mass (g) of the solid content when 1 mol of the crosslinkable group is present in the solid content of the composition.
- a certain amount of the solid content of the composition is weighed, and can be determined by measuring the amount of the crosslinkable group contained in the solid content. Specifically, the above measurement is performed using a sample obtained by precipitating titanium black from the photosensitive resin composition of the present invention. About precipitation of titanium black, you may dilute a photosensitive resin composition once with a solvent.
- the crosslinkable group is an epoxy group
- it can be determined by the same method as the measurement of the epoxy equivalent specified in JIS K7236: 2001. In the case of other crosslinkable groups, it can be measured in the same manner.
- the crosslinkable group equivalent in the photosensitive resin composition of the present invention is preferably 1,000 or less, more preferably 500 or less, and more preferably 350 or less, per gram of organic solid content of the photosensitive resin composition. Most preferred.
- the lower limit is not particularly limited, but is preferably 250 or more from the viewpoints of sensitivity and developability.
- the organic solid content of the photosensitive resin composition represents a component excluding a volatile component such as a solvent and an inorganic component such as titanium black.
- the photosensitive resin composition of the present invention contains (Component B) a photoacid generator.
- the photoacid generator (also referred to as “component B”) used in the present invention is preferably a compound that generates an acid in response to an active ray having a wavelength of 300 nm or more, preferably 300 to 450 nm.
- the structure is not limited.
- a photoacid generator that is not directly sensitive to an actinic ray having a wavelength of 300 nm or more can also be used as a sensitizer if it is a compound that reacts with an actinic ray having a wavelength of 300 nm or more and generates an acid when used in combination with a sensitizer. It can be preferably used in combination.
- the photoacid generator used in the present invention is preferably a photoacid generator that generates an acid having a pKa of 4 or less, more preferably a photoacid generator that generates an acid having a pKa of 3 or less, and a pKa of 2 or less. Most preferred is a photoacid generator that generates an acid.
- photoacid generators examples include trichloromethyl-s-triazines, sulfonium salts and iodonium salts (onium salts), quaternary ammonium salts, diazomethane compounds, imide sulfonate compounds, and oxime sulfonate compounds. . Among these, it is preferable to use an oxime sulfonate compound from the viewpoint of insulation and sensitivity. These photoacid generators can be used singly or in combination of two or more.
- trichloromethyl-s-triazines diaryliodonium salts, triarylsulfonium salts, quaternary ammonium salts, and diazomethane derivatives include the compounds described in paragraphs 0083 to 0088 of JP2011-212494A. It can be illustrated.
- oxime sulfonate compound that is, a compound having an oxime sulfonate structure
- a compound containing an oxime sulfonate structure represented by the following formula (B1) can be preferably exemplified, and the contents thereof are incorporated herein.
- R 21 represents an alkyl group or an aryl group, and a wavy line represents a bonding site with another group.
- the alkyl group for R 21 is preferably a linear or branched alkyl group having 1 to 10 carbon atoms.
- the alkyl group represented by R 21 is an aryl group having 6 to 11 carbon atoms, an alkoxy group having 1 to 10 carbon atoms, or a cycloalkyl group (7,7-dimethyl-2-oxonorbornyl group or the like). It may be substituted with a cyclic group, preferably a bicycloalkyl group or the like.
- aryl group for R 21 an aryl group having 6 to 11 carbon atoms is preferable, and a phenyl group or a naphthyl group is more preferable.
- the aryl group of R 21 may be substituted with an alkyl group having 1 to 10 carbon atoms, an alkoxy group having 1 to 10 carbon atoms, or a halogen atom.
- the above compound containing an oxime sulfonate structure represented by the above formula (B1) is also preferably an oxime sulfonate compound represented by the following formula (B2).
- R 42 represents an alkyl group or an aryl group
- X represents an alkyl group, an alkoxy group, or a halogen atom
- m4 represents an integer of 0 to 3
- m4 is 2 or 3. In some cases, multiple Xs may be the same or different.
- the alkyl group as X is preferably a linear or branched alkyl group having 1 to 4 carbon atoms.
- the alkoxy group as X is preferably a linear or branched alkoxy group having 1 to 4 carbon atoms.
- the halogen atom as X is preferably a chlorine atom or a fluorine atom.
- m4 is preferably 0 or 1. In the above formula (B2), m4 is 1, X is a methyl group, the substitution position of X is the ortho position, R 42 is a linear alkyl group having 1 to 10 carbon atoms, 7,7-dimethyl A compound having a -2-oxonorbornylmethyl group or a p-toluyl group is particularly preferable.
- the compound containing an oxime sulfonate structure represented by the above formula (B1) is also preferably an oxime sulfonate compound represented by the following formula (B3).
- R 43 represents an alkyl group or an aryl group
- X 1 represents a halogen atom, a hydroxyl group, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cyano group, or a nitro group.
- n4 represents an integer of 0 to 5.
- R 43 in the above formula (B3) is methyl group, ethyl group, n-propyl group, n-butyl group, n-octyl group, trifluoromethyl group, pentafluoroethyl group, perfluoro-n-propyl group, A perfluoro-n-butyl group, a p-tolyl group, a 4-chlorophenyl group or a pentafluorophenyl group is preferred, and an n-octyl group is particularly preferred.
- X 1 is preferably an alkoxy group having 1 to 5 carbon atoms, and more preferably a methoxy group.
- n4 is preferably an integer of 0 to 2, particularly preferably 0 or 1.
- the compound containing an oxime sulfonate structure represented by the above formula (B1) is also preferably a compound represented by the following formula (OS-1).
- R 101 represents a hydrogen atom, alkyl group, alkenyl group, alkoxy group, alkoxycarbonyl group, acyl group, carbamoyl group, sulfamoyl group, sulfo group, cyano group, aryl group, or hetero Represents an aryl group.
- R102 represents an alkyl group or an aryl group.
- X 101 represents —O—, —S—, —NH—, —NR 105 —, —CH 2 —, —CR 106 H—, or —CR 105 R 107 —, wherein R 105 to R 107 are alkyl groups. Or an aryl group.
- R 121 to R 124 each independently represents a hydrogen atom, a halogen atom, an alkyl group, an alkenyl group, an alkoxy group, an amino group, an alkoxycarbonyl group, an alkylcarbonyl group, an arylcarbonyl group, an amide group, a sulfo group, a cyano group, or Represents an aryl group.
- Two of R 121 to R 124 may be bonded to each other to form a ring.
- R 121 to R 124 are each independently preferably a hydrogen atom, a halogen atom or an alkyl group, and an embodiment in which at least two of R 121 to R 124 are bonded to each other to form an aryl group is also preferable. Can be mentioned. Among these, an embodiment in which R 121 to R 124 are all hydrogen atoms is preferable from the viewpoint of sensitivity. Any of the aforementioned functional groups may further have a substituent.
- the compound represented by the formula (OS-1) is preferably a compound represented by the formula (OS-2) described in paragraphs 0087 to 0089 of JP2012-163937A, for example. This content is incorporated herein.
- the compound having an oxime sulfonate structure represented by the above formula (B1) is represented by the following formula (OS-3), the following formula (OS-4) or the following formula (OS-5). It is preferably an oxime sulfonate compound.
- R 22 , R 25 and R 28 each independently represents an alkyl group, an aryl group or a heteroaryl group
- R 23 , R 26 and R 29 are Each independently represents a hydrogen atom, an alkyl group, an aryl group or a halogen atom
- R 24 , R 27 and R 30 each independently represent a halogen atom, an alkyl group, an alkyloxy group, a sulfonic acid group, an aminosulfonyl group or an alkoxy group.
- X 1 to X 3 each independently represents an oxygen atom or a sulfur atom
- n 1 to n 3 each independently represents 1 or 2
- m 1 to m 3 each independently represents 0 Represents an integer of ⁇ 6)
- the compound containing an oxime sulfonate structure represented by the above formula (B1) is represented by, for example, general formulas (OS-6) to (OS-11) described in paragraph 0117 of JP2012-163937A. It is particularly preferred that the compound is represented by any of the above), the contents of which are incorporated herein.
- oxime sulfonate compounds represented by the above formulas (OS-3) to (OS-5) include the compounds described in paragraphs 0114 to 0120 of JP2011-221494A. The invention is not limited to these.
- the compound containing an oxime sulfonate structure represented by the above formula (B1) is also preferably an oxime sulfonate compound represented by the following formula (B1-4).
- R b1 represents an alkyl group or an aryl group
- R b2 represents an alkyl group, an aryl group, or a heteroaryl group
- R b3 to R b6 each represents a hydrogen atom, alkyl group, an aryl group, a halogen atom.
- R b3 and R b4, R b4 and R b5, or R b5 and R e6 are bonded to may also form a cycloaliphatic or aromatic ring .
- X b is , -O- or -S-.
- R b1 represents an alkyl group or an aryl group.
- the alkyl group is preferably a branched alkyl group or a cyclic alkyl group.
- the alkyl group preferably has 3 to 10 carbon atoms. In particular, when the alkyl group has a branched structure, an alkyl group having 3 to 6 carbon atoms is preferable. When the alkyl group has a cyclic structure, an alkyl group having 5 to 7 carbon atoms is preferable.
- alkyl group examples include propyl group, isopropyl group, n-butyl group, s-butyl group, isobutyl group, tert-butyl group, pentyl group, isopentyl group, neopentyl group, 1,1-dimethylpropyl group, hexyl group. 2-ethylhexyl group, cyclohexyl group, octyl group and the like, preferably isopropyl group, tert-butyl group, neopentyl group, and cyclohexyl group.
- the aryl group preferably has 6 to 12 carbon atoms, more preferably 6 to 8 carbon atoms, and still more preferably 6 to 7 carbon atoms.
- Examples of the aryl group include a phenyl group and a naphthyl group, and a phenyl group is preferable.
- the alkyl group and aryl group represented by R b1 may have a substituent.
- substituents examples include a halogen atom (a fluorine atom, a chlorine atom, a bromine atom, an iodine atom), a linear, branched or cyclic alkyl group (eg, a methyl group, an ethyl group, a propyl group), an alkenyl group, an alkynyl group, Aryl group, acyl group, alkoxycarbonyl group, aryloxycarbonyl group, carbamoyl group, cyano group, carboxyl group, hydroxyl group, alkoxy group, aryloxy group, alkylthio group, arylthio group, heterocyclic oxy group, acyloxy group, amino group, A nitro group, a hydrazino group, a heterocyclic group, etc. are mentioned. Further, these groups may be further substituted. Preferably, they are a halogen atom and a methyl group.
- R b1 is preferably an alkyl group from the viewpoint of transparency, and R b1 has a branched structure having 3 to 6 carbon atoms from the viewpoint of achieving both storage stability and sensitivity.
- An alkyl group, an alkyl group having a cyclic structure having 5 to 7 carbon atoms, or a phenyl group is preferable, and an alkyl group having a branched structure having 3 to 6 carbon atoms or an alkyl group having a cyclic structure having 5 to 7 carbon atoms is more preferable. .
- an isopropyl group, a tert-butyl group, a neopentyl group, and a cyclohexyl group are preferable, and a tert-butyl group and a cyclohexyl group are more preferable.
- R b2 represents an alkyl group, an aryl group, or a heteroaryl group.
- the alkyl group represented by R b2 is preferably a linear, branched or cyclic alkyl group having 1 to 10 carbon atoms.
- Examples of the alkyl group include a methyl group, an ethyl group, a propyl group, an isopropyl group, an n-butyl group, a tert-butyl group, a pentyl group, a neopentyl group, a hexyl group, and a cyclohexyl group. It is a group.
- As the aryl group an aryl group having 6 to 10 carbon atoms is preferable.
- Examples of the aryl group include a phenyl group, a naphthyl group, a p-toluyl group (p-methylphenyl group), and a phenyl group and a p-toluyl group are preferable.
- Examples of the heteroaryl group include a pyrrole group, an indole group, a carbazole group, a furan group, and a thiophene group.
- the alkyl group, aryl group, and heteroaryl group represented by R b2 may have a substituent. As a substituent, it is synonymous with the substituent which the alkyl group and aryl group which Rb1 represents may have.
- R b2 is preferably an alkyl group or an aryl group, more preferably an aryl group, and more preferably a phenyl group.
- As the substituent for the phenyl group a methyl group is preferred.
- R b3 to R b6 each independently represent a hydrogen atom, an alkyl group, an aryl group, or a halogen atom (a fluorine atom, a chlorine atom, a bromine atom, or an iodine atom).
- the alkyl group represented by R b3 to R b6 has the same meaning as the alkyl group represented by R b2 , and the preferred range is also the same.
- the aryl group represented by R b3 to R b6 has the same meaning as the aryl group represented by R b1 , and the preferred range is also the same.
- R b3 to R b6 may combine to form a ring, and the ring forms an alicyclic ring or aromatic ring And a benzene ring is more preferable.
- R b3 to R b6 are a hydrogen atom, an alkyl group, a halogen atom (a fluorine atom, a chlorine atom, a bromine atom), or R b3 and R b4 , R b4 and R b5 , or R b5 and R b6 are bonded.
- Benzene ring is preferably formed, and a hydrogen atom, a methyl group, a fluorine atom, a chlorine atom, a bromine atom, or R b3 and R b4 , R b4 and R b5 , or R b5 and R b6 are bonded It is more preferable that a benzene ring is formed.
- R b3 to R b6 are as follows. (Aspect 1) At least two are hydrogen atoms. (Aspect 2) The number of alkyl groups, aryl groups, or halogen atoms is one or less.
- X b represents —O— or —S—.
- Ts represents a tosyl group (p-toluenesulfonyl group)
- Me represents a methyl group
- Bu represents an n-butyl group
- Ph represents a phenyl group.
- the photoacid generator is preferably used in an amount of 0.1 to 15 parts by mass with respect to 100 parts by mass of Component A in the photosensitive resin composition. It is more preferable to use 5 to 10 parts by mass. Moreover, the component B may be used individually by 1 type, and can also use 2 or more types together. Moreover, when (Component B) photoacid generator in the photosensitive resin composition of the present invention is applied to an infrared cut filter (particularly a glass substrate), with respect to 100 parts by mass of Component A in the photosensitive resin composition It is preferable to use 0.1 to 30 parts by mass, and it is more preferable to use 0.5 to 20 parts by mass.
- the photosensitive resin composition of the present invention contains (Component C) a solvent.
- the photosensitive resin composition of the present invention is preferably prepared as a liquid obtained by dissolving or dispersing essential components and optional components described later in (Component C) solvent.
- solvent used in the photosensitive resin composition of the present invention known solvents can be used, such as ethylene glycol monoalkyl ethers, ethylene glycol dialkyl ethers, ethylene glycol monoalkyl ether acetates, propylene glycol monoalkyl.
- Ethers propylene glycol dialkyl ethers, propylene glycol monoalkyl ether acetates, diethylene glycol dialkyl ethers, diethylene glycol monoalkyl ether acetates, dipropylene glycol monoalkyl ethers, dipropylene glycol dialkyl ethers, dipropylene glycol monoalkyl ether Examples include acetates, esters, ketones, amides, lactones and the like.
- Specific examples of the solvent used in the photosensitive resin composition of the present invention include the solvents described in paragraphs 0174 to 0178 of JP2011-221494A, and the paragraphs 0167 to 0168 of JP2012-194290A. The solvents described are also included, the contents of which are incorporated herein.
- Benzyl alcohol, anisole, benzyl acetate, ethyl benzoate, diethyl oxalate, diethyl maleate, ethylene carbonate, propylene carbonate and the like can also be added.
- These solvents can be used alone or in combination of two or more. It is preferable that the solvent which can be used for this invention is single 1 type, or uses 2 types together.
- Component C is preferably a solvent having a boiling point of 130 ° C. or higher and lower than 160 ° C., a solvent having a boiling point of 160 ° C. or higher, or a mixture thereof.
- Solvents having a boiling point of 130 ° C. or higher and lower than 160 ° C. include propylene glycol monomethyl ether acetate (boiling point 146 ° C.), propylene glycol monoethyl ether acetate (boiling point 158 ° C.), propylene glycol methyl-n-butyl ether (boiling point 155 ° C.), propylene glycol An example is methyl-n-propyl ether (boiling point 131 ° C.).
- Solvents having a boiling point of 160 ° C or higher include ethyl 3-ethoxypropionate (boiling point 170 ° C), diethylene glycol methyl ethyl ether (boiling point 176 ° C), propylene glycol monomethyl ether propionate (boiling point 160 ° C), dipropylene glycol methyl ether acetate.
- the solvent is preferably at least one solvent selected from the group consisting of propylene glycol monoalkyl ether acetates, diethylene glycol dialkyl ethers and esters, and includes propylene glycol monomethyl ether acetate, diethylene glycol methyl ethyl ether and / or Alternatively, ethyl 3-ethoxypropionate is more preferable, and propylene glycol monomethyl ether acetate, diethylene glycol methyl ethyl ether, and ethyl 3-ethoxypropionate are particularly preferable.
- the content of the (component C) solvent in the photosensitive resin composition of the present invention is preferably 10 to 95% by mass, more preferably 50 to 95% by mass in the photosensitive resin composition, More preferably, it is 60 to 90% by mass.
- Titanium Black The photosensitive resin composition of the present invention contains (Component S) titanium black.
- Titanium black in the present invention is black particles having a titanium atom, and specific components are low-order titanium oxide, titanium oxynitride and the like.
- the production method of titanium black includes a method of heating and reducing a mixture of titanium dioxide and metal titanium in a reducing atmosphere, and ultrafine titanium dioxide obtained by high-temperature hydrolysis of titanium tetrachloride in a reducing atmosphere containing hydrogen.
- a method of reducing with titanium a method of reducing titanium dioxide or titanium hydroxide at high temperature in the presence of ammonia
- a method of attaching a vanadium compound to titanium dioxide or titanium hydroxide and reducing at high temperature in the presence of ammonia can be modified as necessary for the purpose of improving dispersibility and suppressing aggregation.
- titanium black particles For example, it is possible to coat titanium black particles with silicon oxide, titanium oxide, germanium oxide, aluminum oxide, magnesium oxide, zirconium oxide, and a water-repellent substance as disclosed in Japanese Patent Application Laid-Open No. 2007-302836. It is also possible to treat the surface of the titanium black particles.
- the shape of titanium black is not particularly limited, but is preferably particulate.
- the particle size of titanium black is not particularly limited, but from the viewpoint of dispersibility and colorability, the average primary particle size is preferably in the range of 3 nm to 2,000 nm, and the average primary particle size is 10 nm or more. A range of 500 nm or less is more preferable, and an average primary particle size is further preferably in a range of 10 nm to 100 nm.
- the particle size of titanium black can be measured by the following method.
- the particle size can be measured by directly observing the particles using a transmission electron microscope, measuring the short axis diameter or the long axis diameter, or using a small-angle X-ray scattering method and a predetermined content contained in the object to be measured. It is known that it can be measured by a method of determining the particle content relative to the particle diameter.
- the specific surface area of titanium black is not particularly limited, but in order for the water repellency after surface treatment of such titanium black with a water repellent to have a predetermined performance, the value measured by the BET method is 5 m 2. / G or more and 150 m 2 / g or less is preferable, and 20 m 2 / g or more and 100 m 2 / g or less is more preferable.
- titanium black examples include, for example, Titanium Black 10S, 12S, 13M, 13M-C, 13R, 13R-N manufactured by Mitsubishi Materials Corporation, and Tilac D manufactured by Ako Kasei Co., Ltd.
- the present invention is not limited to these, and various titanium blacks can be used.
- an extender pigment may be added to the titanium black in the present invention, if necessary.
- extender pigments include barium sulfate, barium carbonate, calcium carbonate, silica, basic magnesium carbonate, alumina white, gloss white, saturn white, and hydrotalcite. These extender pigments can be used alone or in admixture of two or more.
- the amount of extender used is preferably 0 to 100 parts by mass, more preferably 5 to 50 parts by mass, and still more preferably 10 to 40 parts by mass with respect to 100 parts by mass of titanium black. .
- the above-described titanium black and extender pigment can be used by modifying their surfaces with a polymer in some cases.
- the content of titanium black in the photosensitive resin composition of the present invention may be appropriately determined in consideration of the light shielding property and film thickness required for the light shielding color filter obtained by the photosensitive resin composition.
- the total solid content of the photosensitive resin composition of the present invention is preferably 5% by mass or more, more preferably 10% by mass or more, and further preferably 20% by mass or more. It is particularly preferable that the content be at least mass%, most preferably at least 40 mass%, more preferably at most 80 mass%, more preferably at most 70 mass%, and at most 65 mass%. More preferably, it is particularly preferably 60% by mass or less.
- the content of titanium black in the photosensitive resin composition of the present invention is 40 to 70 with respect to the total solid content of the photosensitive resin composition of the present invention.
- the mass is preferably 45% by mass, more preferably 45 to 65% by mass, and particularly preferably 50 to 65% by mass.
- a light-shielding pigment that can be mixed is not particularly limited as long as it has absorbance in the visible light region, and the above-mentioned extender pigment, carbon black, C.I. I. Pigment Blue 1, 2, 15, 15: 1, 15: 2, 15: 3, 15: 4, 15: 6, 16, 22, 60, 64, 66, 79, 80, C.I. I. Pigment Violet 1, 19, 23, 27, 32, 37, 42, C.I. I. Pigment Brown 25, 28, C.I. I. And organic pigments such as Pigment Black 1 and 7.
- Examples of using a mixture of light-shielding pigments other than titanium black include a mixture of titanium black and carbon black in a ratio of 6: 1, a mixture of titanium black and titanium oxide in a ratio of 3: 1, and the like.
- the light-shielding pigment other than titanium black used in combination is preferably used in the range of 0 to 90 parts by mass, more preferably in the range of 0 to 50 parts by mass with respect to 100 parts by mass of titanium black.
- titanium black can also be used as a dispersion prepared by mixing and dispersing in a suitable dispersant and solvent using a mixing device such as a ball mill or a rod mill.
- a mixing device such as a ball mill or a rod mill.
- the solvent used for the preparation of the dispersion include 1-propanol, 2-propanol, 1-butanol, 2-butanol, 2-methyl-2-propanol, in addition to the above-mentioned (Component C) solvent.
- -Alcohols such as pentanol, 2-pentanol, 3-pentanol, 3-methyl-1-butanol, 2-methyl-2-butanol, neopentanol, cyclopentanol, 1-hexanol, cyclohexanol, etc. Can be mentioned. These solvents can be used singly or in combination of two or more.
- Titanium black that can be used in the present invention may be used in the production of a photosensitive resin composition as a titanium black dispersion.
- the titanium black dispersion is preferably adjusted so that the content of titanium black in the dispersion is 5% by mass or more and 99% by mass or less, and more preferably 40% by mass or more and 92% by mass or less. 40 mass% or more and 80 mass% or less is still more preferable.
- the resist using the titanium black dispersion of the present invention is applied to an infrared cut filter (particularly a glass substrate), it is 20 to 99% by mass with respect to the solid content other than titanium black of the photosensitive resin composition. It is preferably 25 to 98% by mass, more preferably 30 to 95% by mass.
- the effect of this invention is show
- the photosensitive resin composition of the present invention preferably contains (Component D) a dispersant.
- a dispersant By containing a dispersing agent, the dispersibility in the resin composition of the component S can be improved more.
- a known dispersant can be used.
- a known pigment dispersant can be appropriately selected and used.
- a polymer dispersant can be preferably used.
- the polymer dispersant is a dispersant having a molecular weight (weight average molecular weight) of 1,000 or more.
- an oligomer or polymer having a polar group at the molecular end or side chain such as an acrylic copolymer, may be mentioned.
- the dispersant is preferably a polymer dispersant having an acid group in the side chain, and more preferably a polymer dispersant having a carboxyl group in the side chain.
- the dispersant is preferably a polymer dispersant having a graft chain in the side chain, and more preferably a polymer dispersant having an acid group and a graft chain in the side chain.
- the graft chain is a polymer chain different from the main chain in the side chain.
- the number of atoms excluding hydrogen atoms per graft chain is preferably 40 to 10,000, and the number of atoms excluding hydrogen atoms per graft chain is 50 to 2,000. More preferably, the number of atoms excluding hydrogen atoms per graft chain is more preferably 60 to 1,000.
- the weight average molecular weight of Exemplified Compounds 1 to 26 in the present invention is preferably 10,000 or more and 300,000 or less, and preferably 15,000 or more and 200,000 or less, from the viewpoint of pattern peeling inhibition during development and developability. More preferably, it is 20,000 or more and 100,000 or less, more preferably 25,000 or more and 50,000 or less.
- the weight average molecular weight of a dispersing agent can be measured by GPC, for example.
- Specific examples of the dispersant used in the photosensitive resin composition of the present invention include the specific resin 9 described in paragraph 0225 of JP2013-249417A, and paragraphs 0039-0140 of JP2007-277514A. (Corresponding US Patent Application Publication No.
- these Exemplified Compounds 1 to 26 are dispersion resins that impart dispersibility to titanium black, and have excellent dispersibility and affinity with a solvent due to graft chains. Therefore, the dispersibility of titanium black and the dispersion stability after aging are excellent. Moreover, when it is set as the photosensitive resin composition, since it has affinity with a solvent, a curing component, or other resin that can be used in combination, a residue is hardly generated by alkali development.
- a dispersing agent may be used individually by 1 type, or may be used together 2 or more types.
- the content of the dispersant in the photosensitive resin composition of the present invention is preferably in the range of 2 to 70% by mass and more preferably in the range of 5 to 50% by mass with respect to the total content of titanium black.
- the photosensitive resin composition of the present invention preferably contains (Component E) a crosslinking agent as required.
- a crosslinking agent By adding a crosslinking agent, the cured film obtained by the photosensitive resin composition of the present invention can be made a stronger film.
- the crosslinking agent is not limited as long as it causes a crosslinking reaction by heat (except for component A). That is, a thermal crosslinking agent is preferably used as the crosslinking agent.
- a compound having two or more epoxy groups or oxetanyl groups in the molecule described below, an alkoxymethyl group-containing crosslinking agent, a compound having at least one ethylenically unsaturated bond, a blocked isocyanate compound, or an alkoxysilane compound Etc. can be added.
- numerator is preferable, and the compound which has 2 or more epoxy groups in a molecule
- the crosslinkable group in the crosslinking agent is at least one selected from the group consisting of an epoxy group, an oxetanyl group, —NH—CH 2 —OR 1 , a (meth) acryloyl group, and a blocked isocyanate group.
- R 1 represents an alkyl group having 1 to 20 carbon atoms.
- the addition amount of the crosslinking agent in the photosensitive resin composition of the present invention is preferably 0 to 50 parts by mass with respect to 100 parts by mass of the solid content other than titanium black in the photosensitive resin composition, preferably 0.1 to The amount is more preferably 30 parts by mass, and further preferably 0.5 to 10 parts by mass. By adding in this range, a cured film excellent in mechanical strength and solvent resistance can be obtained.
- a plurality of crosslinking agents may be used in combination. In that case, the content is calculated by adding all the crosslinking agents.
- JER152, JER157S70, JER157S65, JER806, JER828, JER1007 manufactured by Mitsubishi Chemical Holdings Co., Ltd.
- ADEKA RESIN EP-4000S, EP-4003S, EP-4010S, EP-4011S manufactured by ADEKA
- NC-2000, NC-3000, NC-7300, XD-1000, EPPN-501, EPPN- 502 aboveve, manufactured by ADEKA Corporation
- bisphenol A type epoxy resins bisphenol F type epoxy resins, phenol novolac type epoxy resins and aliphatic epoxy resins are more preferable, and bisphenol A type epoxy resins are particularly preferable.
- Aron oxetane OXT-121, OXT-221, OX-SQ, and PNOX manufactured by Toagosei Co., Ltd.
- the compound containing an oxetanyl group individually or in mixture with the compound containing an epoxy group.
- alkoxymethyl group-containing crosslinking agent alkoxymethylated melamine, alkoxymethylated benzoguanamine, alkoxymethylated glycoluril, alkoxymethylated urea and the like are preferable. These can be obtained by converting the methylol group of methylolated melamine, methylolated benzoguanamine, methylolated glycoluril, or methylolated urea to an alkoxymethyl group, respectively.
- the type of the alkoxymethyl group is not particularly limited, and examples thereof include a methoxymethyl group, an ethoxymethyl group, a propoxymethyl group, and a butoxymethyl group.
- a methyl group is particularly preferred.
- the alkoxymethyl group is preferably —NH—CH 2 —OR 1 .
- R 1 represents an alkyl group having 1 to 20 carbon atoms.
- alkoxymethylated melamine, alkoxymethylated benzoguanamine, and alkoxymethylated glycoluril are mentioned as preferable crosslinkable compounds, and alkoxymethylated glycoluril is particularly preferable from the viewpoint of transparency.
- These alkoxymethyl group-containing crosslinking agents are available as commercial products.
- Cymel 300, 301, 303, 370, 325, 327, 701, 266, 267, 238, 1141, 272, 202, 1156, 1158, 1123, 1170, 1174, UFR65, 300 manufactured by Mitsui Cyanamid Co., Ltd.
- Nicalack MX-750, -032, -706, -708, -40, -31, -270, -280, -290, Nicalack MS-11, Nicarak MW-30HM, -100LM, -390 (above, manufactured by Sanwa Chemical Co., Ltd.) and the like can be preferably used.
- a blocked isocyanate compound can also be preferably employed as a crosslinking agent.
- the blocked isocyanate compound is not particularly limited as long as it is a compound having a blocked isocyanate group, but is preferably a compound having two or more blocked isocyanate groups in one molecule from the viewpoint of curability.
- the blocked isocyanate group in this invention is a group which can produce
- the group which reacted the blocking agent and the isocyanate group and protected the isocyanate group can illustrate preferably.
- the blocked isocyanate group is preferably a group capable of generating an isocyanate group by heat at 90 ° C. to 250 ° C.
- the skeleton of the blocked isocyanate compound is not particularly limited and may be any as long as it has two isocyanate groups in one molecule, and may be aliphatic, alicyclic or aromatic. Polyisocyanate may be used.
- TDI tolylene diisocyanate
- MDI diphenylmethane diisocyanate
- HDI hexamethylene diisocyanate
- IPDI isophorone diisocyanate
- Examples of the matrix structure of the blocked isocyanate compound in the photosensitive resin composition of the present invention include biuret type, isocyanurate type, adduct type, and bifunctional prepolymer type.
- Examples of the blocking agent that forms the block structure of the blocked isocyanate compound include oxime compounds, lactam compounds, phenol compounds, alcohol compounds, amine compounds, active methylene compounds, pyrazole compounds, mercaptan compounds, imidazole compounds, and imide compounds. be able to.
- a blocking agent selected from oxime compounds, lactam compounds, phenol compounds, alcohol compounds, amine compounds, active methylene compounds, and pyrazole compounds is particularly preferable.
- Examples of the oxime compound include aldoxime and ketoxime, and specific examples include acetoxime, formaldoxime, cyclohexane oxime, methyl ethyl ketone oxime, cyclohexanone oxime, and benzophenone oxime.
- Examples of the lactam compound include ⁇ -caprolactam and ⁇ -butyrolactam.
- Examples of the phenol compound include phenol, naphthol, cresol, xylenol, and halogen-substituted phenol.
- Examples of the alcohol compound include methanol, ethanol, propanol, butanol, cyclohexanol, ethylene glycol monoalkyl ether, propylene glycol monoalkyl ether, and alkyl lactate.
- amine compound a primary amine and a secondary amine are mentioned, Any of an aromatic amine, an aliphatic amine, and an alicyclic amine may be sufficient, An aniline, diphenylamine, ethyleneimine, polyethyleneimine etc. can be illustrated.
- Examples of the active methylene compound include diethyl malonate, dimethyl malonate, ethyl acetoacetate, methyl acetoacetate and the like.
- pyrazole compound include pyrazole, methylpyrazole, dimethylpyrazole and the like.
- the mercaptan compound include alkyl mercaptans and aryl mercaptans.
- the blocked isocyanate compound that can be used in the photosensitive resin composition of the present invention is commercially available.
- Coronate AP Stable M Coronate 2503, 2515, 2507, 2513, 2555, Millionate MS-50 (or more, Nippon Polyurethane Industry Co., Ltd.), Takenate B-830, B-815N, B-820NSU, B-842N, B-84N, B-870N, B-874N, B-882N (above, manufactured by Mitsui Chemicals, Inc.) ), Duranate 17B-60PX, 17B-60P, TPA-B80X, TPA-B80E, MF-B60X, MF-B60B, MF-K60X, MF-K60B, E402-B80B, SBN-70D, SBB-70P, K6000 (above , Manufactured by Asahi Kasei Chemicals Corporation, Death Module B 1100, BL1265 MPA / X, BL
- the photosensitive resin composition of the present invention may contain an alkoxysilane compound as a crosslinking agent.
- Preferred examples of the alkoxysilane compound include trialkoxysilane compounds.
- Examples of the alkoxysilane compound include ⁇ -aminopropyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, ⁇ -glycidoxypropyltriacoxysilane, ⁇ -glycidoxypropylalkyldialkoxysilane, and ⁇ -methacryloxy.
- ⁇ -glycidoxypropyltrialkoxysilane and ⁇ -methacryloxypropyltrialkoxysilane are more preferable, ⁇ -glycidoxypropyltrialkoxysilane is more preferable, and 3-glycidoxypropyltrimethoxysilane is particularly preferable. preferable. These can be used alone or in combination of two or more.
- R 1 is a hydrocarbon group having 1 to 20 carbon atoms having no reactive group
- R 2 is an alkyl group having 1 to 3 carbon atoms or a phenyl group
- n is an integer of 1 to 3 is there.
- Specific examples include the following compounds. Ph represents a phenyl group.
- the alkoxysilane compound in the photosensitive resin composition of this invention is not specifically limited to these, A well-known thing can be used. Moreover, when an alkoxysilane compound is used, the adhesiveness of the film
- a (meth) acrylate compound such as a monofunctional (meth) acrylate, a bifunctional (meth) acrylate, a trifunctional or higher (meth) acrylate, or the like is preferably used. It can.
- monofunctional (meth) acrylates include 2-hydroxyethyl (meth) acrylate, carbitol (meth) acrylate, isobornyl (meth) acrylate, 3-methoxybutyl (meth) acrylate, and 2- (meth) acryloyloxyethyl.
- Examples include -2-hydroxypropyl phthalate.
- Examples of the bifunctional (meth) acrylate include ethylene glycol (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, polypropylene glycol di (meth) acrylate, Examples include tetraethylene glycol di (meth) acrylate, bisphenoxyethanol full orange acrylate, and bisphenoxyethanol full orange acrylate.
- Examples of the tri- or higher functional (meth) acrylate include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, tri ((meth) acryloyloxyethyl) phosphate, pentaerythritol tetra (meth) acrylate, Examples include dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate. These compounds having at least one ethylenically unsaturated bond are used singly or in combination of two or more.
- the crosslinking agent of the present invention when adding the compound which has at least 1 ethylenically unsaturated bond, it is preferable to add a radical polymerization initiator and it is more preferable to add a thermal radical polymerization initiator.
- Known radical polymerization initiators can be used.
- it is a compound which has a (meth) acryl group if it is a compound which has a (meth) acryl group, the bridge
- the crosslinking agent of the present invention when applied to an infrared cut filter (particularly a glass substrate), it is preferably 0 to 30% by mass with respect to the solid content other than titanium black of the photosensitive resin composition. More preferably, the content is 1 to 20% by mass, and further preferably 0.5 to 12% by mass. The effect of this invention is show
- the photosensitive resin composition of the present invention may contain (Component F) a basic compound.
- the basic compound can be arbitrarily selected from those used in chemically amplified resists. Examples include aliphatic amines, aromatic amines, heterocyclic amines, quaternary ammonium hydroxides, quaternary ammonium salts of carboxylic acids, and the like. Specific examples thereof include compounds described in paragraphs 0204 to 0207 of JP2011-221494A.
- aliphatic amine examples include trimethylamine, diethylamine, triethylamine, di-n-propylamine, tri-n-propylamine, di-n-pentylamine, tri-n-pentylamine, diethanolamine, triethanolamine, and the like.
- examples include ethanolamine, dicyclohexylamine, and dicyclohexylmethylamine.
- aromatic amine examples include aniline, benzylamine, N, N-dimethylaniline, diphenylamine and the like.
- heterocyclic amine examples include pyridine, 2-methylpyridine, 4-methylpyridine, 2-ethylpyridine, 4-ethylpyridine, 2-phenylpyridine, 4-phenylpyridine, N-methyl-4-phenylpyridine, 4-dimethylaminopyridine, imidazole, benzimidazole, 4-methylimidazole, 2-phenylbenzimidazole, 2,4,5-triphenylimidazole, nicotine, nicotinic acid, nicotinamide, quinoline, 8-oxyquinoline, pyrazine, Pyrazole, pyridazine, purine, pyrrolidine, piperidine, piperazine, morpholine, 4-methylmorpholine, N-cyclohexyl-N ′-[2- (4-morpholinyl) ethyl] thiourea, 1,5-diazabicyclo [4.3.0 ] -5-Nonene, 1,8-di And azabicyclo
- Examples of the quaternary ammonium hydroxide include tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetra-n-butylammonium hydroxide, tetra-n-hexylammonium hydroxide, and the like.
- Examples of the quaternary ammonium salt of carboxylic acid include tetramethylammonium acetate, tetramethylammonium benzoate, tetra-n-butylammonium acetate, tetra-n-butylammonium benzoate and the like.
- heterocyclic amines are preferable, and 2,4,5-triphenylimidazole and / or N-cyclohexyl-N ′-[2- (4-morpholinyl) ethyl] thiourea is particularly preferable.
- the basic compounds that can be used in the present invention may be used singly or in combination of two or more.
- the content of the basic compound in the photosensitive resin composition of the present invention is preferably 0.001 to 5 parts by mass with respect to 100 parts by mass of solids other than titanium black in the photosensitive resin composition. More preferably, the amount is 0.005 to 3 parts by mass.
- the photosensitive resin composition of the present invention may contain (Component G) a surfactant.
- a surfactant any of anionic, cationic, nonionic or amphoteric can be used, but a preferred surfactant is a nonionic surfactant.
- the surfactant used in the composition of the present invention include those described in paragraphs 0201 to 0205 in JP2012-88459A and those described in paragraphs 0185 to 0188 in JP2011-215580A. And these descriptions are incorporated herein.
- nonionic surfactants include polyoxyethylene higher alkyl ethers, polyoxyethylene higher alkyl phenyl ethers, higher fatty acid diesters of polyoxyethylene glycol, silicone-based and fluorine-based surfactants. .
- the following trade names are KP-341, X-22-822 (manufactured by Shin-Etsu Chemical Co., Ltd.), Polyflow No.
- the surfactant includes a structural unit A and a structural unit B represented by the following formula (G-1), and the weight in terms of polystyrene measured by gel permeation chromatography using tetrahydrofuran (THF) as a solvent.
- G-1 the weight in terms of polystyrene measured by gel permeation chromatography using tetrahydrofuran (THF) as a solvent.
- Preferred examples include copolymers having an average molecular weight (Mw) of 1,000 or more and 10,000 or less.
- R 401 and R 403 each independently represent a hydrogen atom or a methyl group
- R 402 represents a linear alkylene group having 1 to 4 carbon atoms
- R 404 represents a hydrogen atom or Represents an alkyl group having 1 to 4 carbon atoms
- L represents an alkylene group having 3 to 6 carbon atoms
- p and q are mass percentages representing a polymerization ratio
- p is 10 mass% to 80 mass%.
- a numerical value is represented, q represents a numerical value of 20% by mass or more and 90% by mass or less, r represents an integer of 1 to 18 and s represents an integer of 1 to 10)
- L is preferably a branched alkylene group represented by the following formula (G-2).
- R 405 in formula (G-2) represents an alkyl group having 1 to 4 carbon atoms, and is preferably an alkyl group having 1 to 3 carbon atoms in terms of compatibility and wettability to the coated surface. Two or three alkyl groups are more preferred.
- the weight average molecular weight (Mw) of the copolymer is more preferably from 1,500 to 5,000.
- the addition amount of the surfactant in the photosensitive resin composition of the present invention is preferably 10 parts by mass or less with respect to 100 parts by mass of solids other than titanium black in the photosensitive resin composition, and is 0.001 to 10 parts.
- the amount is more preferably part by mass, and still more preferably 0.01 to 3 parts by mass.
- the photosensitive resin composition of the present invention preferably contains an antioxidant.
- an antioxidant a well-known antioxidant can be contained. By adding an antioxidant, there is an advantage that coloring of the cured film can be prevented, or a decrease in film thickness due to decomposition can be reduced, and heat resistant transparency is excellent.
- antioxidants include phosphorus antioxidants, amides, hydrazides, hindered amine antioxidants, sulfur antioxidants, phenol antioxidants, ascorbic acids, zinc sulfate, sugars, Examples thereof include nitrates, sulfites, thiosulfates, and hydroxylamine derivatives.
- phenol-based antioxidants amide-based antioxidants, hydrazide-based antioxidants, and sulfur-based antioxidants are particularly preferable from the viewpoint of coloring the cured film and reducing film thickness, with phenol-based antioxidants being the most preferred. preferable.
- phenol-based antioxidants being the most preferred. preferable.
- These may be used individually by 1 type and may mix 2 or more types. Specific examples include the compounds described in JP-A-2005-29515, paragraphs 0026 to 0031, the contents of which are incorporated herein.
- phenolic antioxidants examples include ADK STAB AO-15, ADK STAB AO-18, ADK STAB AO-20, ADK STAB AO-23, ADK STAB AO-30, ADK STAB AO-37, ADK STAB AO-40 and ADK STAB AO.
- ADK STAB AO-51 ADK STAB AO-60
- ADK STAB AO-70 ADK STAB AO-80
- ADK STAB AO-330 ADK STAB AO-412S
- ADK STAB AO-503 ADK STAB A-611, ADK STAB A-612, ADK STAB A -613, ADK STAB PEP-4C, ADK STAB PEP-8, ADK STAB PEP-8W, ADK STAB PEP-24G, ADK STAB PEP-36, ADK STAB PEP-36Z, ADK STAB HP- 0, ADK STAB 2112, ADK STAB 260, ADK STAB 1522, ADK STAB 1178, ADK STAB 1500, ADK STAB 135, ADK STAB 3010, ADK STAB TPP, ADK STAB CDA-1, ADK STAB CDA-6, ADK STAB ZS-27, ADK STAB ZS ZS-91 (above, manufactured by ADEKA Corporation), Irga
- the content of the antioxidant is preferably 0.1 to 10% by mass, and preferably 0.2 to 5% by mass with respect to 100 parts by mass of the solid content other than titanium black in the photosensitive resin composition. More preferred is 0.5 to 4% by mass. By setting it within this range, sufficient transparency of the formed film can be obtained, and the sensitivity at the time of pattern formation can be improved.
- additives other than antioxidants various ultraviolet absorbers described in “New Development of Polymer Additives” (Nikkan Kogyo Shimbun Co., Ltd.), metal deactivators, and the like are used in the present invention. You may add to a resin composition.
- the photosensitive resin composition of the present invention preferably contains a sensitizer in order to promote its decomposition in combination with (Component B) a photoacid generator.
- the sensitizer absorbs actinic rays or radiation and enters an electronically excited state.
- the sensitizer in an electronically excited state comes into contact with the photoacid generator, and effects such as electron transfer, energy transfer, and heat generation occur.
- a photo-acid generator raise
- Examples of preferred sensitizers include compounds belonging to the following compounds and having an absorption wavelength in any of the wavelength ranges from 350 nm to 450 nm.
- Polynuclear aromatics eg, pyrene, perylene, triphenylene, anthracene, 9,10-dibutoxyanthracene, 9,10-diethoxyanthracene, 3,7-dimethoxyanthracene, 9,10-dipropyloxyanthracene
- xanthenes Eg, fluorescein, eosin, erythrosine, rhodamine B, rose bengal
- xanthones eg, xanthone, thioxanthone, dimethylthioxanthone, diethylthioxanthone
- cyanines eg, thiacarbocyanine, oxacarbocyanine
- merocyanines Eg, merocyanine, carbomerocyanine
- rhodocyanins oxonols
- thiazines eg, thionine, methylene blue
- polynuclear aromatics polynuclear aromatics, acridones, styryls, base styryls, and coumarins are preferable, and polynuclear aromatics are more preferable.
- polynuclear aromatics anthracene derivatives are most preferred.
- the addition amount of the sensitizer in the photosensitive resin composition of the present invention is preferably 0 to 1,000 parts by mass with respect to 100 parts by mass of the photoacid generator of the photosensitive resin composition.
- the amount is more preferably part by mass, and further preferably 50 to 200 parts by mass.
- a sensitizer may be used individually by 1 type and can also use 2 or more types together.
- the photosensitive resin composition of the present invention includes an ultraviolet absorber, a metal deactivator, an acid proliferator, a development accelerator, a plasticizer, a thermal radical generator, a heat as necessary.
- Known additives such as acid generators, thickeners, and organic or inorganic suspending agents can be added. As these compounds, for example, the descriptions in paragraphs 0201 to 0224 of JP2012-8859A can be referred to, and the contents thereof are incorporated in the present specification.
- the photosensitive resin composition of the present invention may use an acid proliferating agent for the purpose of improving sensitivity.
- the acid proliferating agent that can be used in the present invention is a compound that can further generate an acid by an acid-catalyzed reaction to increase the acid concentration in the reaction system, and is a compound that exists stably in the absence of an acid. is there.
- Specific examples of such an acid proliferating agent include the acid proliferating agents described in paragraphs 0226 to 0228 of JP2011-221494A, the contents of which are incorporated herein.
- the content of the acid proliferating agent in the photosensitive resin composition is 10 to 1,000 parts by mass with respect to 100 parts by mass of the photoacid generator. From the viewpoint of dissolution contrast between the exposed part and the unexposed part. And more preferably 20 to 500 parts by mass.
- the photosensitive resin composition of the present invention can contain a development accelerator.
- a development accelerator any compound having a development acceleration effect can be used, and the development accelerator may be a compound having at least one structure selected from the group consisting of a carboxyl group, a phenolic hydroxyl group, and an alkyleneoxy group.
- a compound having a carboxyl group or a phenolic hydroxyl group is more preferable, and a compound having a phenolic hydroxyl group is most preferable.
- the description in paragraphs 0171 to 0172 of JP2012-042837A can be referred to, and the contents thereof are incorporated in the present specification.
- a development accelerator may be used individually by 1 type, and can also use 2 or more types together.
- the addition amount of the development accelerator in the photosensitive resin composition of the present invention is 0 to 30 parts by mass with respect to 100 parts by mass of the solid content other than titanium black of the photosensitive resin composition from the viewpoint of sensitivity and residual film ratio.
- 0.1 to 20 parts by mass is more preferable, and 0.5 to 10 parts by mass is most preferable.
- the molecular weight of the development accelerator is preferably from 100 to 2,000, more preferably from 150 to 1,500, still more preferably from 150 to 1,000.
- the resin composition of the present invention may contain a plasticizer.
- the plasticizer include dibutyl phthalate, dioctyl phthalate, didodecyl phthalate, polyethylene glycol, glycerin, dimethyl glycerin phthalate, dibutyl tartrate, dioctyl adipate, and triacetyl glycerin.
- the plasticizer content in the resin composition of the present invention is preferably 0.1 to 30 parts by mass, more preferably 1 to 10 parts by mass with respect to 100 parts by mass of the component A content. .
- thermal radical generators described in paragraphs 0120 to 0121 of JP2012-8223A, and the nitrogen-containing compounds and thermal acid generators described in International Publication No. 2011-136004 may be used. The contents of which are incorporated herein by reference.
- a resin composition can be prepared by preparing a solution in which components are dissolved in a solvent in advance and then mixing them in a predetermined ratio.
- the composition solution prepared as described above can be used after being filtered using, for example, a filter having a pore size of 0.2 ⁇ m.
- a titanium black dispersion containing (component S) titanium black, (component C) solvent, and (component D) dispersant is prepared in advance, and the titanium black dispersion, component A and component B are prepared.
- the resin pattern manufacturing method of the present invention preferably includes the following steps (1) to (4), and more preferably includes the following steps (1) to (5).
- the photosensitive resin composition of the present invention is preferably applied onto a substrate to form a wet film containing a solvent. It is preferable to perform substrate cleaning such as alkali cleaning or plasma cleaning before applying the photosensitive resin resin composition to the substrate, and it is more preferable to treat the substrate surface with hexamethyldisilazane after substrate cleaning. By performing this treatment, the adhesion of the photosensitive resin composition to the substrate is improved.
- the method for treating the substrate surface with hexamethyldisilazane is not particularly limited, and examples thereof include a method in which the substrate is exposed to hexamethyldisilazane vapor.
- the substrate examples include inorganic substrates, resins, resin composite materials, ITO, Cu substrates, polyethylene terephthalate, and plastic substrates such as cellulose triacetate (TAC).
- the inorganic substrate examples include glass, quartz, silicone, silicon nitride, and a composite substrate in which molybdenum, titanium, aluminum, copper, or the like is vapor-deposited on such a substrate.
- Resins include polybutylene terephthalate, polyethylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polystyrene, polycarbonate, polysulfone, polyethersulfone, polyarylate, allyl diglycol carbonate, polyamide, polyimide, polyamideimide, polyetherimide, poly Fluorine resins such as benzazole, polyphenylene sulfide, polycycloolefin, norbornene resin, polychlorotrifluoroethylene, liquid crystal polymer, acrylic resin, epoxy resin, silicone resin, ionomer resin, cyanate resin, crosslinked fumaric acid diester resin, cyclic polyolefin, Is it a synthetic resin such as aromatic ether resin, maleimide-olefin resin, cellulose, episulfide resin, etc.
- all or part of the surface of the substrate is at least one selected from the group consisting of glass, SiO, ITO, IZO, a metal film, and a metal oxide film. It is particularly preferable that all or part of the surface of the substrate is ITO.
- ITO Indium Tin Oxide
- the photosensitive resin composition of the present invention has a very remarkable effect that generation of development residues can be suppressed even when all or part of the surface of the substrate is ITO.
- the coating method on the substrate is not particularly limited, and for example, a method such as an inkjet method, a slit coating method, a spray method, a roll coating method, a spin coating method, a casting coating method, a slit and spin method can be used. Furthermore, it is also possible to apply a so-called pre-wet method as described in JP-A-2009-145395.
- the coating film thickness is not particularly limited, and can be applied with a film thickness according to the application, but it is preferably used in the range of 0.5 to 10 ⁇ m.
- Ink jet method application compared with conventional application methods such as spin coating method and slit coating method, the amount of coating liquid used is greatly reduced, and the influence of mist adhering to the spin coating method is reduced. This is preferable from a comprehensive point of view, for example, generation of foreign matter is suppressed.
- the application conditions by the ink jet method may be appropriately selected depending on the composition of the photosensitive resin composition, the type of coating film to be manufactured, and the like.
- the discharge amount of the liquid photosensitive resin composition and the number of discharges to the same portion may be adjusted.
- what is necessary is just to select suitably the shape and position which apply
- the ink jet recording apparatus that can be used in the ink jet coating method is not particularly limited, and any known ink jet recording apparatus that can achieve the target resolution can be arbitrarily selected and used. That is, if it is a well-known inkjet recording apparatus containing a commercial item, the application
- Examples of the ink jet recording apparatus that can be used in the present invention include an apparatus including a composition supply system and a temperature sensor.
- the ink supply system includes, for example, an original tank containing the photosensitive resin composition of the present invention, a supply pipe, a composition supply tank immediately before the inkjet head, a filter, and a piezo-type inkjet head.
- the piezo-type inkjet head preferably has a multi-size dot of 1 to 100 pl, more preferably 8 to 30 pl, preferably 320 ⁇ 320 to 4,000 ⁇ 4,000 dpi (dot per inch), more preferably 400 ⁇ 400.
- dpi represents the number of dots per 2.54 cm.
- the coating film thickness is not particularly limited, and can be applied with a film thickness according to the application, but it is preferably used in the range of 0.5 to 10 ⁇ m.
- the solvent removal step (2) it is preferable to remove the solvent from the applied film by vacuum (vacuum) and / or heating to form a dry coating film on the substrate.
- the heating conditions for the solvent removal step are preferably 70 to 130 ° C. and about 30 to 300 seconds. When the temperature and time are within the above ranges, the pattern adhesion is good and the residue can be reduced.
- the coating step (1) and the solvent removal step (2) may be performed in this order, simultaneously, or alternately. For example, after all of the inkjet application in the application step (1) is completed, the solvent removal step (2) may be performed, or the substrate is heated, and the photosensitive by the inkjet application method in the application step (1). The solvent may be removed while discharging the conductive resin composition. In particular, it is preferable to perform the solvent removal step (2) after all the inkjet coating in the coating step (1) is completed.
- the photoacid generator is decomposed to generate an acid.
- the acid-decomposable group contained in the coating film component is hydrolyzed to produce an acid group, for example, a carboxyl group or a phenolic hydroxyl group.
- an exposure light source using actinic light a low-pressure mercury lamp, a high-pressure mercury lamp, an ultrahigh-pressure mercury lamp, a chemical lamp, an LED light source, an excimer laser generator, and the like can be used.
- Actinic rays having a wavelength of 300 nm to 450 nm, such as 405 nm), can be preferably used.
- irradiation light can also be adjusted through spectral filters, such as a long wavelength cut filter, a short wavelength cut filter, and a band pass filter, as needed.
- various types of exposure machines such as a mirror projection aligner, a stepper, a scanner, a proximity, a contact, a microlens array, and a laser exposure can be used.
- post-exposure heat treatment Post Exposure Bake (hereinafter also referred to as “PEB”)
- PEB Post Exposure Bake
- PEB can promote the formation of a carboxyl group or a phenolic hydroxyl group from an acid-decomposable group.
- the temperature for performing PEB is preferably 30 ° C. or higher and 130 ° C. or lower, more preferably 40 ° C. or higher and 110 ° C. or lower, and particularly preferably 50 ° C. or higher and 100 ° C. or lower.
- the acid-decomposable group in the present invention has a low activation energy for acid decomposition and is easily decomposed by an acid derived from an acid generator by exposure to produce an acid group, for example, a carboxyl group or a phenolic hydroxyl group.
- a positive image can be formed by development without performing PEB.
- the developing step (4) it is preferable to develop a copolymer having a liberated acid group, for example, a carboxyl group or a phenolic hydroxyl group, using an alkaline developer.
- a positive image is formed by removing an exposed area containing a resin composition having an acid group that easily dissolves in an alkaline developer, such as a carboxyl group or a phenolic hydroxyl group.
- the developer used in the development step preferably contains a basic compound.
- Examples of the basic compound include alkali metal hydroxides such as lithium hydroxide, sodium hydroxide and potassium hydroxide; alkali metal carbonates such as sodium carbonate and potassium carbonate; alkalis such as sodium bicarbonate and potassium bicarbonate Metal bicarbonates; ammonium hydroxides such as tetramethylammonium hydroxide, tetraethylammonium hydroxide and choline hydroxide; aqueous solutions such as sodium silicate and sodium metasilicate can be used.
- An aqueous solution obtained by adding an appropriate amount of a water-soluble organic solvent such as methanol or ethanol or a surfactant to the alkaline aqueous solution can also be used as a developer.
- Preferred examples of the developer include a 0.4% by mass aqueous solution, a 0.5% by mass aqueous solution, a 0.7% by mass aqueous solution, or a 2.38% by mass aqueous solution of tetraethylammonium hydroxide.
- the pH of the developer is preferably 10.0 to 14.0.
- the development time is preferably 30 to 500 seconds, and the development method may be either a liquid piling method or a dipping method. After development, washing with running water can be performed for 30 to 300 seconds to form a desired pattern.
- a rinsing step can also be performed after development. In the rinsing step, the developed substrate and the development residue are removed by washing the developed substrate with pure water or the like.
- a known method can be used as the rinsing method. For example, a shower rinse, a dip rinse, etc. can be mentioned.
- the obtained positive image is heated to thermally decompose the acid-decomposable group to generate an acid group, for example, a carboxyl group or a phenolic hydroxyl group, and a crosslinkable group
- a cured film can be formed by crosslinking with a crosslinking agent or the like.
- This heating is performed using a heating device such as a hot plate or oven at a predetermined temperature, for example, 180 ° C. to 250 ° C. for a predetermined time, for example, 5 to 90 minutes on the hot plate, 30 to 120 minutes for the oven. It is preferable to process.
- heat treatment is preferably performed at 80 to 140 ° C. for 5 to 120 minutes.
- the heat treatment step is performed at a predetermined temperature, for example, 120 ° C. to 250 ° C., more preferably 140 ° C. to 220 ° C. for a predetermined time, for example, a hot plate, when the substrate is mainly composed of glass.
- Heat treatment is preferably performed for 5 to 90 minutes for the above and 30 to 120 minutes for the oven.
- the heat treatment step can be performed after baking at a relatively low temperature (addition of a middle bake step).
- middle baking it is preferable to post-bake at a high temperature of 200 ° C. or higher after heating at 90 to 150 ° C. for 1 to 60 minutes.
- middle baking and post baking can be heated in three or more stages.
- the taper angle of the pattern can be adjusted by devising such middle baking and post baking.
- These heating methods can use well-known heating methods, such as a hotplate, oven, and an infrared heater.
- the entire surface of the patterned substrate was re-exposed with actinic rays (post-exposure), and then post-baked to generate an acid from the photoacid generator present in the unexposed portion, thereby performing a crosslinking step. It can function as a catalyst to promote, and can accelerate the curing reaction of the film.
- the preferred exposure amount in the case of including a post-exposure step preferably 100 ⁇ 3,000mJ / cm 2, particularly preferably 100 ⁇ 500mJ / cm 2.
- the cured film obtained from the photosensitive resin composition of the present invention can also be used as a dry etching resist.
- dry etching processing such as ashing, plasma etching, ozone etching, or the like can be performed as the etching processing.
- the cured film of the present invention is a film obtained by curing the photosensitive resin composition of the present invention.
- the cured film of the present invention can be suitably used as a light-shielding color filter.
- the cured film of the present invention is preferably a film obtained by the method for producing a cured product of the present invention or the resin pattern production method of the present invention, and is a film obtained by the resin pattern production method of the present invention. It is more preferable.
- the cured product of the present invention is a cured product obtained by curing the photosensitive resin composition of the present invention.
- the shape does not have to be a film, and may be any shape.
- the cured product of the present invention may be a cured product in which the hardness is increased by removing at least a part of the solvent from the photosensitive resin composition of the present invention, but from the photosensitive resin composition of the present invention.
- a cured product obtained by removing the solvent and thermosetting is preferable.
- the production method of the cured product of the present invention is not particularly limited, but preferably includes at least the following steps (a) to (c) in this order.
- a coating process for coating the photosensitive resin composition of the present invention on a substrate (B) a solvent removal step of removing the solvent from the applied resin composition; (C) A heat treatment step of heat-treating the resin composition from which the solvent has been removed, or an exposure step of irradiating the resin composition from which the solvent has been removed with actinic rays.
- Process (a) and process (b) are synonymous with the said application
- the heat treatment step in step (c) is the same as the heat treatment step except that the heat treatment target is a resin composition from which the solvent obtained in step (b) has been removed. Preferable embodiments such as temperature, heating time, heating means and the like are also preferable.
- the exposure step in step (c) is the same as the exposure step except that the exposure need not be performed in a pattern. In the exposure step in step (c), it is preferable to expose the entire surface of one surface of the resin composition from which the solvent has been removed. Moreover, it is preferable that the hardened
- the cured product of the present invention includes a color filter in a liquid crystal display device or an organic EL device, an insulating film in the liquid crystal display device, a spacer for keeping the thickness of the liquid crystal layer constant, and a structural member of a MEMS (Micro Electro Mechanical Systems) device It can be suitably used for electronic materials such as antireflection films for various substrates and wirings.
- MEMS Micro Electro Mechanical Systems
- the light-shielding color filter of the present invention is a light-shielding color filter obtained by curing the photosensitive resin composition of the present invention, and is a light-shielding color filter manufactured by the resin pattern manufacturing method of the present invention. preferable.
- the light-shielding color filter of the present invention is formed using the cured film of the present invention.
- the light-shielding color filter formed using the cured film of the present invention is excellent in light-shielding properties.
- the infrared cut filter of the present invention includes a light-shielding film (cured film) obtained by curing the photosensitive resin composition of the present invention.
- the light shielding film provided in the infrared cut filter of the present invention is preferably formed by a resin pattern manufacturing method. Such a light shielding film is excellent in light shielding properties.
- the infrared cut filter should just be a board
- the light-shielding color filter of the present invention is suitably used as a black matrix.
- the film thickness of the black matrix is not particularly limited, but from the viewpoint of obtaining the effect of the present invention more effectively, the film thickness after drying is preferably 0.2 ⁇ m or more and 10 ⁇ m or less, and 0.4 ⁇ m or more and 5 ⁇ m or less. More preferably, it is 0.6 ⁇ m or more and 5 ⁇ m or less.
- the line width of the black matrix is not particularly limited, but is preferably from 0.5 ⁇ m to 500 ⁇ m, more preferably from 0.7 ⁇ m to 20 ⁇ m, and even more preferably from 1.0 ⁇ m to 5 ⁇ m.
- the line width of the light-shielding film according to the present invention is not particularly limited, but is preferably 0.5 ⁇ m or more and 500 ⁇ m or less, more preferably 0.7 ⁇ m or more and 100 ⁇ m or less. More preferably, the thickness is from 0 to 50 ⁇ m.
- the formed colored pattern exhibits high adhesion to the support substrate, and the cured composition is excellent in development resistance. Therefore, it is possible to form a high-resolution pattern that has excellent exposure sensitivity, good adhesion to the substrate of the exposed portion, and gives a desired cross-sectional shape. Therefore, it can be suitably used for solid-state imaging devices and solid-state imaging devices such as liquid crystal display devices and CCDs, and particularly suitable for smartphones having a resolution higher than FHD, high-resolution CCD devices exceeding 5 million pixels, CMOS, and the like. It is.
- the light-shielding color filter of the present invention is preferably applied to a liquid crystal display device, an organic EL display device, and a solid-state imaging device.
- the light shielding film of the infrared cut filter of the present invention is not particularly limited except that it is obtained by curing the photosensitive resin composition of the present invention.
- the infrared cut filter provided with the light-shielding film of the present invention can be suitably used for a solid-state imaging device.
- the solid-state imaging device of the present invention includes the cured product of the present invention.
- the solid-state imaging device of the present invention is not particularly limited except that it has a light-shielding color filter or a light-shielding film formed using the photosensitive resin composition of the present invention, and known solid-state imaging having various structures.
- An apparatus can be mentioned.
- Examples of the infrared cut filter and the solid-state imaging device include those described in claims of Japanese Patent Application Laid-Open Nos. 2014-132333 and 2014-132644.
- the liquid crystal display device of the present invention comprises the cured product of the present invention.
- the liquid crystal display device of the present invention is not particularly limited except that it has a light-shielding color filter or an insulating film formed using the photosensitive resin composition of the present invention, and is a known liquid crystal display device having various structures. Can be mentioned.
- specific examples of TFT (Thin-Film Transistor) included in the liquid crystal display device of the present invention include amorphous silicon-TFT, low-temperature polysilicon-TFT, oxide semiconductor TFT, and the like. Since the cured film of the present invention is excellent in electrical characteristics, it can be preferably used in combination with these TFTs.
- liquid crystal driving methods that can be taken by the liquid crystal display device of the present invention include TN (Twisted Nematic) method, VA (Vertical Alignment) method, IPS (In-Plane-Switching) method, FFS (Fringe Field Switching) method, OCB (OCB) method. Optically Compensated Bend) method.
- the cured film of the present invention can also be used in a COA (Color Filter on Array) type liquid crystal display device.
- the organic insulating film (115) described in JP-A-2005-284291 It can be used as the organic insulating film (212) described in Japanese Unexamined Patent Publication No. 2005-346054.
- the polymer orientation may be supported by a PSA (Polymer Sustained Alignment) technique described in Japanese Patent Application Laid-Open Nos. 2003-149647 and 2011-257734.
- the organic EL display device of the present invention comprises the cured product of the present invention.
- the organic EL display device of the present invention is not particularly limited except that it has a flattening film and an interlayer insulating film formed using the photosensitive resin composition of the present invention, and various known organic materials having various structures.
- An EL display device and a liquid crystal display device can be given.
- specific examples of TFT (Thin-Film Transistor) included in the organic EL display device of the present invention include amorphous silicon-TFT, low-temperature polysilicon-TFT, oxide semiconductor TFT, and the like. Since the cured film of the present invention is excellent in electrical characteristics, it can be preferably used in combination with these TFTs.
- MATHF tetrahydrofuran-2-yl methacrylate (synthetic product)
- MAEVE 1-ethoxyethyl methacrylate (manufactured by Wako Pure Chemical Industries, Ltd.)
- MACHOE 1- (cyclohexyloxy) ethyl methacrylate (synthetic product)
- MATHP Tetrahydro-2H-pyran-2-yl methacrylate (manufactured by Shin-Nakamura Chemical Co., Ltd.)
- PHSEVE 1-ethoxyethyl ether of p-hydroxystyrene (synthetic product)
- PHSTHF tetrahydrofuranyl ether of p-hydroxystyrene (synthetic product)
- PHSt-Bu t-butyl ether of p-hydroxystyrene (synthesized according to a conventional method in which isobuten
- MOI-BM 2- (O- [1′-methylpropylideneamino] carboxyamino) ethyl methacrylate
- MAA Methacrylic acid (manufactured by Wako Pure Chemical Industries, Ltd.)
- MMA Methyl methacrylate (Wako Pure Chemical Industries, Ltd.)
- St Styrene (Wako Pure Chemical Industries, Ltd.)
- DCPM Dicyclopentanyl methacrylate (manufactured by Hitachi Chemical Co., Ltd.)
- HEMA 2-hydroxyethyl methacrylate (manufactured by Wako Pure Chemical Industries, Ltd.)
- PHS p-hydroxystyrene (manufactured by Wako Pure Chemical Industries, Ltd.)
- V-65 2,2′-azobis (2,4-dimethylvaleronitrile) (manufactured by Wako Pure Chemical Industries, Ltd.)
- PGMEA Propylene
- MATHF was synthesized according to the synthesis example described in paragraph 0187 of JP2013-80203A.
- MACHOE was synthesized in the same manner as MATH, except that 2-dihydrofuran was changed to the corresponding compound.
- PHSEVE was synthesized by changing the methacrylic acid in the MAEVE synthesis method to 4-hydroxystyrene.
- PHSTHF was synthesized by changing methacrylic acid in the MATHF synthesis method to 4-hydroxystyrene.
- PGMEA ⁇ Synthesis of Polymer P-1> PGMEA was placed in a three-necked flask and heated to 90 ° C. in a nitrogen atmosphere. In the solution, 0.4 mol equivalent of MATHF, 0.55 mol equivalent of GMA, 0.05 mol equivalent of MAA, and V-65 (corresponding to 4 mol% with respect to 100 mol% in total of all monomer components) were dissolved over 2 hours. It was dripped. After completion of the dropwise addition, the reaction was terminated by stirring for 2 hours. Thereby, a polymer P-1 was obtained. The ratio of PGMEA to the total amount of other components was 60:40. That is, a polymer solution having a solid content concentration of 40% was prepared.
- composition 1 was subjected to a high viscosity dispersion treatment with two rolls to obtain a dispersion.
- the kneader was kneaded for 30 minutes before the high viscosity dispersion treatment.
- composition 2 was added to the obtained dispersion and stirred for 3 hours using a homogenizer under the condition of 3,000 rpm.
- the obtained mixed solution was subjected to dispersion treatment for 4 hours with a disperser (trade name: Dispermat, manufactured by GETZMANN) using zirconia beads having a diameter of 0.3 mm, and a titanium black dispersion A (hereinafter referred to as TB dispersion). Liquid A)) was obtained.
- the collected powder was pulverized in a mortar to obtain titanium black T-1 [dispersed material containing titanium black particles and Si atoms] containing Si atoms and having a powder specific surface area of 73 m 2 / g.
- the components shown in composition 3 below were mixed for 15 minutes using a stirrer (EUROSTAR manufactured by IKA) to obtain dispersion a.
- the polymer compound (X1) described below was synthesized with reference to the description in JP2013-249417A. In the formula of the polymer compound (X1), x was 30% by mass, y was 20% by mass, and z was 50% by mass.
- the weight average molecular weight of the polymer compound (X1) was 30,000, the acid value was 60 mgKOH / g, and the number of graft chain atoms (excluding hydrogen atoms) was 117.
- the obtained dispersion a was subjected to a dispersion treatment under the following conditions using NPM Pilot manufactured by Shinmaru Enterprises Co., Ltd. to obtain a titanium black dispersion B.
- ⁇ Bead diameter ⁇ 0.05mm
- Bead filling rate 65% by volume
- Mill peripheral speed 10m / sec ⁇
- Separator peripheral speed 11m / s ⁇
- Amount of liquid mixture for dispersion treatment 15.0 g ⁇ Circulating flow rate (pump supply amount): 60 kg / hour ⁇ Processing liquid temperature: 20-25 °C ⁇
- Example 1 Preparation of photosensitive resin composition> After mixing and mixing to make a uniform solution with the composition shown in Table 2, it was filtered using a polyethylene filter having a pore size of 0.2 ⁇ m, and the photosensitive resin composition of Example 1 (solid content) : 25%). Various evaluations described later were performed using the obtained photosensitive resin composition. The evaluation results are shown in Table 2 described later. In addition, the numerical value of the compounding quantity of Table 2 represents the mass part of solid content.
- Examples 2 to 15 and Comparative Examples 1 to 7 Photosensitive resin compositions of Examples 2 to 15 and Comparative Examples 1 to 7 were prepared in the same manner as in Example 1 except that the composition in Example 1 was changed to the composition shown in Table 2 below. .
- B-1 DTS-105 (triarylsulfonium salt, manufactured by Midori Chemical Co., Ltd.)
- B-2 CGI1397 (manufactured by BASF Japan Ltd., the following compound)
- B-3 PAI-101 (manufactured by Midori Chemical Co., Ltd., the following compound)
- B-4 The following compound B-5: The following compound
- Crude B-5-2A was purified by silica gel column chromatography to obtain 1.7 g of intermediate B-5-2A.
- B-5-2A (1.7 g) and p-xylene (6 mL) were mixed, and 0.23 g of p-toluenesulfonic acid monohydrate (manufactured by Wako Pure Chemical Industries, Ltd.) was added at 140 ° C. Heated for 2 hours. After allowing to cool, water and ethyl acetate were added to the reaction mixture and the phases were separated.
- W-1 Perfluoroalkyl group-containing nonionic surfactant represented by the following structural formula (F-554, manufactured by DIC Corporation)
- W-2 Megafac F-781F (manufactured by DIC Corporation)
- Z-1 IRGACURE 369 (2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -1-butanone, radical polymerization initiator, manufactured by BASF Japan Ltd.)
- Z-2 Dibutoxyanthracene having the following structure (sensitizer, manufactured by Kawasaki Kasei Kogyo Co., Ltd.) Bu represents a butyl group.
- Example 16 ⁇ Production of color filter> -Formation of black matrix-
- the photosensitive resin composition produced in Example 1 was applied to the washed glass substrate using a slit coater at a coating speed of 120 mm / second.
- heating at 80 ° C. for 120 seconds using a hot plate
- exposure is performed at 50 mJ / cm 2 using a proximity type exposure machine (model number LE5565A, manufactured by Hitachi High-Technologies Corporation). did. Thereafter, the film was shower-developed with a 1.0% developer of potassium hydroxide developer CDK-1 (manufactured by FUJIFILM Electronics Materials Co., Ltd.) for 50 seconds and washed with pure water.
- CDK-1 potassium hydroxide developer
- a post-baking process is performed in a 220 ° C. clean oven for 40 minutes, the color pixel formation region opening is 15 ⁇ m ⁇ 45 ⁇ m, the black matrix thickness is 1.2 ⁇ m, and the black matrix line width is about 5 ⁇ m. Formed.
- the obtained photosensitive coloring composition coating solution CR-1 for red was applied to the black matrix forming surface side of the black matrix substrate. Specifically, as in the case of black matrix formation, the spacing between the slit and the black matrix substrate and the discharge amount are adjusted so that the layer thickness of the photosensitive coloring composition layer after post-baking is about 2.1 ⁇ m. Then, coating was performed at a coating speed of 100 mm / second.
- a green pixel and a blue pixel were formed in the same manner to obtain a color filter.
- the black matrix in the obtained color filter was thin but excellent in light shielding properties and high in surface hardness.
- Example 17 to 30 A color filter was produced in the same manner as in Example 16 except that the photosensitive resin composition produced in Example 1 was changed to the photosensitive resin composition produced in Examples 2 to 15, respectively.
- Each black matrix in the obtained color filter was a thin film but excellent in light shielding properties and high in surface hardness.
- Examples 31 to 36 Photosensitive resin compositions of Examples 31 to 36 were prepared in the same manner as in Example 1, except that the composition in Example 1 was changed to the composition shown in Table 4 below.
- Example 37 to 42 In the photosensitive resin composition of Example 31, the content of titanium black was adjusted by increasing / decreasing the solid content (pigment and dispersant) of the titanium black pigment dispersion and increasing / decreasing the addition amount of the polymer A, which will be described later. In the same manner as in Example 31, except that the concentration was changed to the total solid content in the photosensitive resin composition shown in Table 6 and the amount of the solvent was 25% solid content, titanium black was obtained. 6 types of photosensitive resin compositions having different contents were prepared. The following resolution evaluation was performed using the obtained photosensitive resin composition. The evaluation results are summarized in Table 6.
- a glass substrate (Corning 1737, manufactured by Corning) was ultrasonically washed with 0.5 mass% NaOH water, and then washed with water and dehydrated (200 ° C./20 minutes). Subsequently, a resist solution was spin-coated on the cleaned glass substrate and prebaked at 80 ° C. for 60 seconds using a hot plate. The film thickness is adjusted so that the OD value (absorbance) of the resist film after exposure is 3.
- the resist-coated substrate is applied at an exposure amount of 200 mJ / cm 2 (wavelength 365 nm) using an exposure apparatus UX3100-SR (USHIO INC.) Through a mask having a line-and-space pattern with a line width of 50 ⁇ m. Exposed. After exposure, post-exposure heating (PEB) at 80 ° C. for 60 seconds was performed on a hot plate. After heating after exposure, using tetramethylammonium hydroxide (THAH) 2.38% developer (manufactured by FUJIFILM Electronics Materials Co., Ltd.) at 25 ° C., 30, 40, 50, 60, 70 , And paddle development was performed under each condition for 80 or 90 seconds.
- PEB post-exposure heating
- THAH tetramethylammonium hydroxide
- Example 31 ⁇ Preparation of an infrared cut filter provided with a light shielding part containing titanium black>
- the composition of Example 31 was applied to the incident surface of the infrared cut filter using a coater / developer ACT (manufactured by Tokyo Electron Ltd.) by spin coating, and then heated for 120 seconds using a 100 ° C. hot plate. A coating film was formed by performing treatment (pre-baking). Next, using an i-line stepper exposure apparatus FPA-3000i5 + (manufactured by Canon Inc.), pattern exposure was performed at an exposure amount of 200 mJ / cm 2 through a mask.
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Abstract
Description
更に詳しくは、液晶表示装置、有機EL表示装置、固体撮像装置などに用いられるカラーフィルターのブラックマトリックス(遮光性カラーフィルター)や赤外線カットフィルターの遮光膜の形成に好適な、感光性樹脂組成物及びそれを用いた硬化膜の製造方法に関する。
従来の感光性樹脂組成物としては、特許文献1又は2に記載されたものが知られている。
ブラックマトリックスと着色画素とは重なり部分がある。その重なり部分の盛り上がりが大きいと、表示に悪影響を与えるため、盛り上がりを小さくするために薄膜化が要求されている。また、色の滲みを防止するために、可視光領域の遮光性が要求される。
更に、カラーフィルターの製造においてはブラックマトリックス形成後、着色画素部分を形成する、ITOを形成する等の工程があるため、ブラックマトリックスには表面硬度が要求される。
つまり、薄膜で遮光性に優れる、かつ表面硬度が高いブラックマトリックスが求められている。なお、薄膜で遮光性に優れるとは、光学濃度(OD)値を膜厚で除した「OD/膜厚」の値が大きいことを表す。
以下、上記技術課題の詳細を説明する。
また、表面硬度を大きくするためには、組成物中の硬化成分割合を増やすため、組成物中の着色剤の割合が減り、OD/膜厚が小さくなる傾向にある。
このように、OD/膜厚と表面硬度とはトレードオフ傾向にある。
十分な遮光性(高光学濃度(高OD))を付与するためには、ブラックマトリックスに十分な量の着色剤を持たせる必要がある。従来、着色剤としてカーボンブラックが用いられてきた(特許文献1)。
上記で述べた高OD/膜厚の要求に対応すべく、組成物中のカーボンブラック割合を増やすと、表面硬度が劣るものとなり問題となっていた。
そこで最近では、表面硬度に優れる黒着色剤として、チタンブラックが検討されている(特許文献2)。本発明者らが試したところ特許文献2に記載された組成物は、表面硬度は十分であるものの、OD/膜厚が十分ではないことが分かった。
<1>(成分A)下記(1)及び(2)の少なくとも一方を満たす重合体を含む重合体成分、(成分B)光酸発生剤、(成分C)溶剤、並びに、(成分S)チタンブラック、を含有することを特徴とする感光性樹脂組成物、
(1)(a1)酸基が酸分解性基で保護された基を有する構成単位及び(a2)架橋性基を有する構成単位、を有する重合体、(2)(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体、及び、(a2)架橋性基を有する構成単位を有する重合体、
<2>上記架橋性基が、エポキシ基、オキセタニル基、-NH-CH2-OR1、エチレン性不飽和基、及び、ブロックイソシアネート基よりなる群から選ばれた少なくとも1種である、<1>に記載の感光性樹脂組成物、なお、R1は、炭素数1~20のアルキル基を表す、
<3>感光性樹脂組成物中の架橋性基当量が、有機固形分1gあたり、250~1,000である、<1>又は<2>に記載の感光性樹脂組成物、
<4>(成分D)分散剤を更に含有する、<1>~<3>のいずれか1つに記載の感光性樹脂組成物、
<5>成分Sの含有量が、感光性樹脂組成物の全固形分に対し、40~80質量%である、<1>~<4>のいずれか1つに記載の感光性樹脂組成物、
<6>(成分E)架橋剤を更に含有する、<1>~<5>のいずれか1つに記載の感光性樹脂組成物、
<7>成分Bが、オキシムスルホネート化合物である、<1>~<6>のいずれか1つに記載の感光性樹脂組成物、
<8>少なくとも工程(a)~(c)をこの順に含むことを特徴とする硬化物の製造方法、(a)<1>~<7>のいずれか1つに記載の感光性樹脂組成物を基板上に塗布する塗布工程、(b)塗布された樹脂組成物から溶剤を除去する溶剤除去工程、(c)溶剤が除去された樹脂組成物を熱処理する熱処理工程、又は、溶剤が除去された樹脂組成物に活性光線を照射する露光工程、
<9>少なくとも工程(1)~(4)をこの順に含むことを特徴とする樹脂パターン製造方法、(1)<1>~<7>のいずれか1つに記載の感光性樹脂組成物を基板上に塗布する塗布工程、(2)塗布された樹脂組成物から溶剤を除去する溶剤除去工程、(3)溶剤が除去された樹脂組成物を活性光線によりパターン状に露光する露光工程、(4)露光された樹脂組成物及び未露光の樹脂組成物を水性現像液により現像する現像工程、
<10><8>に記載の硬化物の製造方法、又は、<9>に記載の樹脂パターン製造方法により得られた硬化物、
<11><1>~<7>のいずれか1つに記載の感光性樹脂組成物を硬化してなる硬化膜、
<12>遮光性カラーフィルターである、<11>に記載の硬化膜、
<13><11>又は<12>に記載の硬化膜を有する液晶表示装置、
<14><11>又は<12>に記載の硬化膜を有する有機EL表示装置、
<15><11>又は<12>に記載の硬化膜を有する赤外線カットフィルター、
<16><11>又は<12>に記載の硬化膜を有する固体撮像装置。
なお、本発明において、数値範囲を表す「下限~上限」の記載は、「下限以上、上限以下」を表し、「上限~下限」の記載は、「上限以下、下限以上」を表す。すなわち、上限及び下限を含む数値範囲を表す。
また、本発明において、「(成分A)(1)及び(2)の少なくとも一方を満たす重合体を含む重合体成分」等を、単に「成分A」等ともいい、「(a1)酸基が酸分解性基で保護された基を有する構成単位」等を、単に「構成単位(a1)」等ともいう。
更に、本明細書における基(原子団)の表記において、置換及び無置換を記していない表記は置換基を有さないものと共に置換基を有するものをも包含するものである。例えば「アルキル基」とは、置換基を有さないアルキル基(無置換アルキル基)のみならず、置換基を有するアルキル基(置換アルキル基)をも包含するものである。
また、本発明において、「質量%」と「重量%」とは同義であり、「質量部」と「重量部」とは同義である。
また、本発明において、好ましい態様の組み合わせは、より好ましい。
本発明の感光性樹脂組成物(以下、単に「樹脂組成物」ともいう。)は、(成分A)下記(1)及び(2)の少なくとも一方を満たす重合体を含む重合体成分、(成分B)光酸発生剤、(成分C)溶剤、並びに、(成分S)チタンブラック、を含有することを特徴とする。
(1)(a1)酸基が酸分解性基で保護された基を有する構成単位及び(a2)架橋性基を有する構成単位、を有する重合体
(2)(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体、及び、(a2)架橋性基を有する構成単位を有する重合体
本発明の感光性樹脂組成物は、熱により硬化する性質を有する樹脂組成物であることが好ましい。
また、本発明の感光性樹脂組成物は、ポジ型感光性樹脂組成物であることが好ましく、化学増幅型のポジ型感光性樹脂組成物(化学増幅ポジ型感光性樹脂組成物)であることがより好ましい。
本発明の感光性樹脂組成物は、活性光線に感応する光酸発生剤として1,2-キノンジアジド化合物を含まない方が好ましい。1,2-キノンジアジド化合物は、逐次型光化学反応によりカルボキシ基を生成するが、その量子収率は必ず1以下である。
これに対して、本発明で使用する(成分B)光酸発生剤は、活性光線に感応して生成される酸が、成分A中の保護された酸基の脱保護に対して触媒として作用するので、1個の光量子の作用で生成した酸が、多数の脱保護反応に寄与し、量子収率は1を超え、例えば、10の数乗のような大きい値となり、いわゆる化学増幅の結果として、高感度が得られる。
更に、本発明の感光性樹脂組成物は、カラーフィルターのブラックマトリックス(遮光性カラーフィルター)用感光性樹脂組成物であることが好ましい。
また、本発明の感光性樹脂組成物を硬化させた硬化膜又は硬化物は、各種表示装置における遮光膜又は遮光部材として好適に用いることができる。
以下、本発明の感光性樹脂組成物について詳細に説明する。
本発明の感光性樹脂組成物は、下記(1)及び(2)の少なくとも一方を満たす重合体を含む重合体成分を含有する。
(1)(a1)酸基が酸分解性基で保護された基を有する構成単位及び(a2)架橋性基を有する構成単位を有する重合体
(2)(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体、及び、(a2)架橋性基を有する構成単位を有する重合体
本発明の感光性樹脂組成物は、更に、これら以外の重合体を含んでいてもよい。本発明における成分Aは、特に述べない限り、上記(1)及び/又は(2)に加え、必要に応じて添加される他の重合体を含めたものを意味するものとする。なお、後述する成分Dに該当する化合物は、高分子化合物であっても、成分Aに含まないものとする。
膜強度の観点からは、本発明の感光性樹脂組成物は、成分Aとして、上記(1)を満たす成分を含むことが好ましい。
分子設計の自由度の観点からは、本発明の感光性樹脂組成物は、成分Aとして、上記(2)を満たす成分を含むことが好ましい。
なお、上記(1)を満たす成分を含有する場合であっても、更に、(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体及び/又は(a2)架橋性基を有する構成単位を有する重合体を含有していてもよい。
また、上記(2)を満たす成分を含有する場合であっても、(a1)酸基が酸分解性基で保護された基を有する構成単位及び(a2)架橋性基を有する構成単位を有する重合体に該当するものを少なくとも含有する場合は、上記(1)を満たす成分を含有する場合に該当するものとする。
なお、「(メタ)アクリル酸及び/又はそのエステルに由来する構成単位」を「アクリル系構成単位」ともいう。また、「(メタ)アクリル酸」は、「メタクリル酸及び/又はアクリル酸」を意味するものとする。
成分Aは、(a1)酸基が酸分解性基で保護された基を有する構成単位を少なくとも有する重合体を含む。成分Aが構成単位(a1)を有する重合体を含むことにより、極めて高感度な感光性樹脂組成物とすることができる。
本発明における「酸基が酸分解性基で保護された基」は、酸基及び酸分解性基として公知のものを使用でき、特に限定されない。具体的な酸基としては、カルボキシル基、及び、フェノール性水酸基が好ましく挙げられる。また、酸分解性基としては、酸により比較的分解しやすい基(例えば、後述する式(a1-10)で表される基のエステル構造、テトラヒドロピラニルエステル基、又は、テトラヒドロフラニルエステル基等のアセタール系官能基)や酸により比較的分解しにくい基(例えば、tert-ブチルエステル基等の第三級アルキルエステル基、tert-ブチルカーボネート基等の第三級アルキルカーボネート基)を用いることができる。
以下、酸分解性基で保護された保護カルボキシル基を有する構成単位(a1-1)と、酸分解性基で保護された保護フェノール性水酸基を有する構成単位(a1-2)について、順にそれぞれ説明する。
上記酸分解性基で保護された保護カルボキシル基を有する構成単位(a1-1)は、カルボキシル基を有する構成単位のカルボキシル基が、以下で詳細に説明する酸分解性基によって保護された保護カルボキシル基を有する構成単位である。
上記酸分解性基で保護された保護カルボキシル基を有する構成単位(a1-1)に用いることができる上記カルボキシル基を有する構成単位としては、特に制限はなく公知の構成単位を用いることができる。例えば、不飽和モノカルボン酸、不飽和ジカルボン酸、不飽和トリカルボン酸などの、分子中に少なくとも1個のカルボキシル基を有する不飽和カルボン酸等に由来する構成単位(a1-1-1)や、エチレン性不飽和基と酸無水物由来の構造とを共に有する構成単位(a1-1-2)が挙げられる。
以下、上記カルボキシル基を有する構成単位として用いられる(a1-1-1)分子中に少なくとも1個のカルボキシル基を有する不飽和カルボン酸等に由来する構成単位と、(a1-1-2)エチレン性不飽和基と酸無水物由来の構造とを共に有する構成単位について、それぞれ順に説明する。
上記分子中に少なくとも1個のカルボキシル基を有する不飽和カルボン酸等に由来する構成単位(a1-1-1)として本発明で用いられる不飽和カルボン酸としては以下に挙げるようなものが用いられる。すなわち、不飽和モノカルボン酸としては、例えば、アクリル酸、メタクリル酸、クロトン酸、α-クロロアクリル酸、けい皮酸、2-(メタ)アクリロイロキシエチルコハク酸、2-(メタ)アクリロイロキシエチルヘキサヒドロフタル酸、2-(メタ)アクリロイロキシエチルフタル酸などが挙げられる。また、不飽和ジカルボン酸としては、例えば、マレイン酸、フマル酸、イタコン酸、シトラコン酸、メサコン酸などが挙げられる。また、カルボキシル基を有する構成単位を得るために用いられる不飽和多価カルボン酸は、その酸無水物であってもよい。具体的には、無水マレイン酸、無水イタコン酸、無水シトラコン酸などが挙げられる。また、不飽和多価カルボン酸は、多価カルボン酸のモノ(2-メタクリロイロキシアルキル)エステルであってもよく、例えば、コハク酸モノ(2-アクリロイロキシエチル)、コハク酸モノ(2-メタクリロイロキシエチル)、フタル酸モノ(2-アクリロイロキシエチル)、フタル酸モノ(2-メタクリロイロキシエチル)などが挙げられる。更に、不飽和多価カルボン酸は、その両末端ジカルボキシポリマーのモノ(メタ)アクリレートであってもよく、例えば、ω-カルボキシポリカプロラクトンモノアクリレート、ω-カルボキシポリカプロラクトンモノメタクリレートなどが挙げられる。また、不飽和カルボン酸としては、アクリル酸-2-カルボキシエチルエステル、メタクリル酸-2-カルボキシエチルエステル、マレイン酸モノアルキルエステル、フマル酸モノアルキルエステル、4-カルボキシスチレン等も用いることができる。
中でも、現像性の観点から、上記分子中に少なくとも1個のカルボキシル基を有する不飽和カルボン酸等に由来する構成単位(a1-1-1)を形成するためには、アクリル酸、メタクリル酸、2-(メタ)アクリロイロキシエチルコハク酸、2-(メタ)アクリロイロキシエチルヘキサヒドロフタル酸、2-(メタ)アクリロイロキシエチルフタル酸、又は、不飽和多価カルボン酸の無水物等を用いることが好ましく、アクリル酸、メタクリル酸、2-(メタ)アクリロイロキシエチルヘキサヒドロフタル酸、を用いることがより好ましい。
上記分子中に少なくとも1個のカルボキシル基を有する不飽和カルボン酸等に由来する構成単位(a1-1-1)は、1種単独で構成されていてもよいし、2種以上で構成されていてもよい。
エチレン性不飽和基と酸無水物由来の構造とを共に有する構成単位(a1-1-2)は、エチレン性不飽和基を有する構成単位中に存在する水酸基と酸無水物とを反応させて得られたモノマーに由来する単位であることが好ましい。
上記酸無水物としては、公知のものが使用でき、具体的には、無水マレイン酸、無水コハク酸、無水イタコン酸、無水フタル酸、テトラヒドロ無水フタル酸、ヘキサヒドロ無水フタル酸、無水クロレンド酸等の二塩基酸無水物;無水トリメリット酸、無水ピロメリット酸、ベンゾフェノンテトラカルボン酸無水物、ビフェニルテトラカルボン酸無水物などの酸無水物が挙げられる。これらの中では、現像性の観点から、無水フタル酸、テトラヒドロ無水フタル酸、又は、無水コハク酸が好ましい。
上記酸無水物の水酸基に対する反応率は、現像性の観点から、好ましくは10~100モル%、より好ましくは30~100モル%である。
上記酸分解性基で保護された保護カルボキシル基を有する構成単位(a1-1)に用いることができる上記酸分解性基としては上述の酸分解性基を用いることができる。
これらの酸分解性基の中でもカルボキシル基がアセタールの形で保護された保護カルボキシル基であることが、感光性樹脂組成物の基本物性、特に感度やパターン形状、コンタクトホールの形成性、感光性樹脂組成物の保存安定性の観点から好ましい。更に酸分解性基の中でもカルボキシル基が下記式(a1-10)で表されるアセタールの形で保護された保護カルボキシル基であることが、感度の観点からより好ましい。なお、カルボキシル基が下記式(a1-10)で表されるアセタールの形で保護された保護カルボキシル基である場合、保護カルボキシル基の全体としては、-(C=O)-O-CR101R102(OR103)の構造となっている。
上記直鎖状又は分岐鎖状のアルキル基としては、炭素数1~12であることが好ましく、炭素数1~6であることがより好ましく、炭素数1~4であることが更に好ましい。具体的には、メチル基、エチル基、n-プロピル基、i-プロピル基、n-ブチル基、i-ブチル基、sec-ブチル基、tert-ブチル基、n-ペンチル基、ネオペンチル基、n-ヘキシル基、テキシル基(2,3-ジメチル-2-ブチル基)、n-ヘプチル基、n-オクチル基、2-エチルヘキシル基、n-ノニル基、n-デシル基等を挙げることができる。
上記ハロゲン原子としては、フッ素原子、塩素原子、臭素原子、ヨウ素原子が例示され、これらの中でも、フッ素原子又は塩素原子が好ましい。
また、上記アリール基としては、炭素数6~20のアリール基が好ましく、炭素数6~12のアリール基がより好ましい。具体的には、フェニル基、α-メチルフェニル基、ナフチル基等が例示でき、アリール基で置換されたアルキル基全体、すなわち、アラルキル基としては、ベンジル基、α-メチルベンジル基、フェネチル基、ナフチルメチル基等が例示できる。
上記アルコキシ基としては、炭素数1~6のアルコキシ基が好ましく、炭素数1~4のアルコキシ基がより好ましく、メトキシ基又はエトキシ基が更に好ましい。
また、上記アルキル基がシクロアルキル基である場合、上記シクロアルキル基は置換基として炭素数1~10の直鎖状又は分岐鎖状のアルキル基を有していてもよく、アルキル基が直鎖状又は分岐鎖状のアルキル基である場合には、置換基として炭素数3~12のシクロアルキル基を有していてもよい。
これらの置換基は、上記置換基で更に置換されていてもよい。
R3は、アルキル基又はアリール基を表し、炭素数1~10のアルキル基が好ましく、1~6のアルキル基がより好ましい。
Xは、単結合又はアリーレン基を表し、単結合が好ましい。
L1はカルボニル基が好ましい。
R122~R128は、水素原子が好ましい。
上記酸分解性基で保護された保護フェノール性水酸基を有する構成単位(a1-2)は、フェノール性水酸基を有する構成単位が、以下で詳細に説明する酸分解性基によって保護された保護フェノール性水酸基を有する構成単位である。
上記フェノール性水酸基を有する構成単位としては、ヒドロキシスチレン系構成単位やノボラック系の樹脂における構成単位が挙げられるが、これらの中では、ヒドロキシスチレン又はα-メチルヒドロキシスチレンに由来する構成単位が、感度の観点から好ましい。また、フェノール性水酸基を有する構成単位として、下記式(a1-20)で表される構成単位も、感度の観点から好ましい。
また、R221は単結合又は二価の連結基を表す。単結合である場合には、感度を向上させることができ、更に硬化膜の透明性を向上させることができるので好ましい。R221の二価の連結基としてはアルキレン基が例示でき、炭素数1~12のアルキレン基が好ましく、炭素数1~8のアルキレン基がより好ましく、炭素数1~3のアルキレン基が更に好ましい。R221がアルキレン基である場合の具体例としては、メチレン基、エチレン基、プロピレン基、イソプロピレン基、n-ブチレン基、イソブチレン基、tert-ブチレン基、ペンチレン基、イソペンチレン基、ネオペンチレン基、ヘキシレン基等が挙げられる。中でも、R221が単結合、メチレン基、エチレン基、1,2-プロピレン基、1,3-プロピレン基、又は、2-ヒドロキシ-1,3-プロピレン基であることが好ましい。また、上記二価の連結基は、置換基を有していてもよく、置換基としては、ハロゲン原子、水酸基、アルコキシ基等が挙げられる。また、aは1~5の整数を表すが、本発明の効果の観点や、製造が容易であるという点から、aは1又は2であることが好ましく、aが1であることがより好ましい。
また、ベンゼン環における水酸基の結合位置は、R221と結合している炭素原子を基準(1位)としたとき、4位に結合していることが好ましい。
R222はそれぞれ独立に、ハロゲン原子又は炭素数1~5の直鎖若しくは分岐鎖状のアルキル基を表す。具体的には、フッ素原子、塩素原子、臭素原子、メチル基、エチル基、プロピル基、イソプロピル基、n-ブチル基、イソブチル基、tert-ブチル基、ペンチル基、イソペンチル基、ネオペンチル基等が挙げられる。中でも製造が容易であるという点から、塩素原子、臭素原子、メチル基又はエチル基であることが好ましい。
また、bは0又は1~4の整数を表す。
上記酸分解性基で保護された保護フェノール性水酸基を有する構成単位(a1-2)に用いることができる上記酸分解性基としては、上記酸分解性基で保護された保護カルボキシル基を有する構成単位(a1-1)に用いることができる上記酸分解性基と同様に、公知のものを使用でき、特に限定されない。酸分解性基の中でもアセタールで保護された保護フェノール性水酸基を有する構成単位であることが、感光性樹脂組成物の基本物性、特に感度やパターン形状、感光性樹脂組成物の保存安定性、コンタクトホールの形成性の観点から好ましい。更に、酸分解性基の中でもフェノール性水酸基が上記式(a1-10)で表されるアセタールの形で保護された保護フェノール性水酸基であることが、感度の観点からより好ましい。なお、フェノール性水酸基が上記式(a1-10)で表されるアセタールの形で保護された保護フェノール性水酸基である場合、保護フェノール性水酸基の全体としては、-Ar-O-CR101R102(OR103)の構造となっている。なお、Arはアリーレン基を表す。
これらの中で、4-ヒドロキシフェニルメタクリレートの1-アルコキシアルキル保護体、4-ヒドロキシフェニルメタクリレートのテトラヒドロピラニル保護体が透明性の観点から好ましい。
上記構成単位(a1)を有する重合体が、実質的に、構成単位(a2)を有しない場合、構成単位(a1)は、該構成単位(a1)を有する重合体中、20~100モル%が好ましく、30~90モル%がより好ましい。
上記構成単位(a1)を有する重合体が、下記構成単位(a2)を有する場合、単構成単位(a1)は、該構成単位(a1)と構成単位(a2)とを有する重合体中、感度の観点から3~70モル%が好ましく、10~60モル%がより好ましい。また、特に上記構成単位(a1)が、カルボキシル基がアセタールの形で保護された保護カルボキシル基を有する構成単位である場合、20~50モル%が好ましい。
なお、本発明において、「構成単位」の含有量をモル比で規定する場合、当該「構成単位」は「モノマー単位」と同義であるものとする。また、本発明において当該「モノマー単位」は、高分子反応等により重合後に修飾されていてもよい。以下においても同様である。
成分Aは、架橋性基を有する構成単位(a2)を有する重合体を含有する。上記架橋性基は、加熱処理で硬化反応を起こす基であれば特に限定はされない。好ましい架橋性基を有する構成単位の態様としては、エポキシ基、オキセタニル基、-NH-CH2-O-R(Rは水素原子又は炭素数1~20のアルキル基を表す。)で表される基、エチレン性不飽和基、及び、ブロックイソシアネート基よりなる群から選ばれた少なくとも1つを含む構成単位が挙げられ、エポキシ基、オキセタニル基、-NH-CH2-O-R(Rは水素原子又は炭素数1~20のアルキル基を表す。)で表される基、(メタ)アクリロイル基、及び、ブロックイソシアネート基よりなる群から選ばれた少なくとも1種であることが好ましく、エポキシ基、オキセタニル基、及び、-NH-CH2-O-R(Rは水素原子又は炭素数1~20のアルキル基を表す。)で表される基よりなる群から選ばれた少なくとも1種であることがより好ましい。その中でも、本発明の感光性樹脂組成物は、上記成分Aが、エポキシ基及びオキセタニル基のうち少なくとも1つを含む構成単位を含むことがより好ましい。より詳細には、以下のものが挙げられる。
成分Aは、エポキシ基及び/又はオキセタニル基を有する構成単位(構成単位(a2-1))を有する重合体を含有することが好ましい。3員環の環状エーテル基はエポキシ基とも呼ばれ、4員環の環状エーテル基はオキセタニル基とも呼ばれる。
上記エポキシ基及び/又はオキセタニル基を有する構成単位(a2-1)は、1つの構成単位中にエポキシ基又はオキセタニル基を少なくとも1つ有していればよく、1つ以上のエポキシ基及び1つ以上オキセタニル基、2つ以上のエポキシ基、又は、2つ以上のオキセタニル基を有していてもよく、特に限定されないが、エポキシ基及び/又はオキセタニル基を合計1~3つ有することが好ましく、エポキシ基及び/又はオキセタニル基を合計1又は2つ有することがより好ましく、エポキシ基又はオキセタニル基を1つ有することが更に好ましい。
オキセタニル基を有する構成単位を形成するために用いられるラジカル重合性単量体の具体例としては、例えば、特開2001-330953号公報の段落0011~0016に記載のオキセタニル基を有する(メタ)アクリル酸エステルなどが挙げられ、これらの内容は本願明細書に組み込まれる。
上記エポキシ基及び/又はオキセタニル基を有する構成単位(a2-1)を形成するために用いられるラジカル重合性単量体の具体例としては、メタクリル酸エステル構造を含有するモノマー、アクリル酸エステル構造を含有するモノマーであることが好ましい。
上記架橋性基を有する構成単位(a2)の1つとして、エチレン性不飽和基を有する構成単位(a2-2)が挙げられる(以下、「構成単位(a2-2)」ともいう。)。上記エチレン性不飽和基を有する構成単位(a2-2)としては、側鎖にエチレン性不飽和基を有する構成単位が好ましく、末端にエチレン性不飽和基を有し、炭素数3~16の側鎖を有する構成単位がより好ましい。
本発明で用いる共重合体は、-NH-CH2-O-R(Rは水素原子又は炭素数1~20のアルキル基を表す。)で表される基を有する構成単位(a2-3)も好ましい。構成単位(a2-3)を有することで、緩やかな加熱処理で硬化反応を起こすことができ、諸特性に優れた硬化膜を得ることができる。ここで、Rは炭素数1~20のアルキル基が好ましく、炭素数1~9のアルキル基がより好ましく、炭素数1~4のアルキル基が更に好ましい。また、アルキル基は、直鎖、分岐又は環状のアルキル基のいずれであってもよいが、直鎖又は分岐のアルキル基であることが好ましい。構成単位(a2)は、下記式(a2-30)で表される基を有する構成単位であることがより好ましい。
R32の具体例としては、メチル基、エチル基、n-ブチル基、i-ブチル基、シクロヘキシル基、及び、n-ヘキシル基を挙げることができる。中でも、i-ブチル基、n-ブチル基、メチル基が好ましい。
上記構成単位(a2)を有する重合体が、実質的に、構成単位(a1)を有しない場合、構成単位(a2)は、該構成単位(a2)を有する重合体中、5~90モル%が好ましく、20~80モル%がより好ましい。
上記構成単位(a2)を有する重合体が、上記構成単位(a1)を有する場合、構成単位(a2)の含有量は、該構成単位(a1)と構成単位(a2)を有する重合体中、薬品耐性の観点から3~70モル%が好ましく、10~60モル%がより好ましい。
本発明では、更に、いずれの態様にかかわらず、成分Aの全構成単位中、構成単位(a2)を3~70モル%含有することが好ましく、10~60モル%含有することがより好ましい。
上記の数値の範囲内であると、感光性樹脂組成物から得られる硬化膜の透明性及び薬品耐性が良好となる。
本発明において、成分Aは、上記構成単位(a1)及び/又は(a2)に加えて、これら以外の他の構成単位(a3)を有していてもよい。これらの構成単位は、上記重合体成分(1)及び/又は(2)が含んでいてもよい。また、上記重合体成分(1)又は(2)とは別に、実質的に構成単位(a1)及び構成単位(a2)を含まずに他の構成単位(a3)を有する重合体成分を有していてもよい。上記重合体成分(1)又は(2)とは別に、実質的に構成単位(a1)及び構成単位(a2)を有さずに他の構成単位(a3)を有する重合体成分を含む場合、重合体成分の配合量は、全重合体成分中、60質量%以下であることが好ましく、40質量%以下であることがより好ましく、20質量%以下であることが更に好ましい。
本発明で用いられる酸基としては、カルボン酸基、スルホンアミド基、ホスホン酸基、スルホン酸基、フェノール性水酸基、スルホンアミド基、スルホニルイミド基、並びに、これらの酸基の酸無水物基、及び、これらの酸基を中和し塩構造とした基等が例示され、カルボン酸基及び/又はフェノール性水酸基が好ましい。上記塩としては、特に制限はないが、アルカリ金属塩、アルカリ土類金属塩、及び、有機アンモニウム塩が好ましく例示できる。
本発明で用いられる酸基を含む構成単位は、スチレンに由来する構成単位や、ビニル化合物に由来する構成単位、(メタ)アクリル酸及び/又はそのエステルに由来する構成単位であることがより好ましい。例えば、特開2012-88459号公報の段落0021~0023及び段落0029~0044記載の化合物を用いることができ、この内容は本願明細書に組み込まれる。中でも、p-ヒドロキシスチレン、(メタ)アクリル酸、マレイン酸、無水マレイン酸に由来する構成単位が好ましい。
このような重合体としては、側鎖にカルボキシル基を有する樹脂が好ましい。例えば、特開昭59-44615号、特公昭54-34327号、特公昭58-12577号、特公昭54-25957号、特開昭59-53836号、特開昭59-71048号の各公報に記載されているような、メタクリル酸共重合体、アクリル酸共重合体、イタコン酸共重合体、クロトン酸共重合体、マレイン酸共重合体、部分エステル化マレイン酸共重合体等、並びに側鎖にカルボキシル基を有する酸性セルロース誘導体、水酸基を有するポリマーに酸無水物を付加させたもの等が挙げられ、更に側鎖に(メタ)アクリロイル基を有する高分子重合体も好ましいものとして挙げられる。実質的に含まないとは重合体中の重量割合が1質量%以下であることをいう。
その他にも、特開平7-207211号公報、特開平8-259876号公報、特開平10-300922号公報、特開平11-140144号公報、特開平11-174224号公報、特開2000-56118号公報、特開2003-233179号公報、特開2009-52020号公報等に記載の公知の高分子化合物を使用することができ、これらの内容は本願明細書に組み込まれる。
これらの重合体は、1種類のみ含んでいてもよいし、2種類以上含んでいてもよい。
-第1の実施形態-
重合体成分(1)が、更に、1種又は2種以上のその他の構成単位(a3)を有する態様。
-第2の実施形態-
重合体成分(2)の(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体が、更に、1種又は2種以上のその他の構成単位(a3)を有する態様。
-第3の実施形態-
重合体成分(2)の(a2)架橋性基を有する構成単位を有する重合体が、更に、1種又は2種以上のその他の構成単位(a3)を有する態様。
-第4の実施形態-
上記第1~第3の実施形態のいずれかにおいて、その他の構成単位(a3)として、少なくとも酸基を含む構成単位をいずれかの重合体に有する態様。
-第5の実施形態-
上記重合体成分(1)又は(2)とは別に、更に、実質的に構成単位(a1)及び構成単位(a2)を有さずに他の構成単位(a3)を有する重合体を有する態様。
-第6の実施形態-
上記第1~第5の実施形態の2以上の組み合わせからなる態様。
成分Aにおける重合体の分子量は、ポリスチレン換算重量平均分子量で、好ましくは1,000~200,000、より好ましくは2,000~50,000の範囲である。上記の数値の範囲内であると、諸特性が良好である。数平均分子量Mnと重量平均分子量Mwとの比(分散度、Mw/Mn)は1.0~5.0が好ましく、1.5~3.5がより好ましい。
なお、本発明における重量平均分子量や数平均分子量の測定は、ゲル浸透クロマトグラフィ(GPC)法により測定することが好ましい。本発明におけるゲル浸透クロマトグラフィ法による測定は、HLC-8020GPC(東ソー(株)製)を用い、カラムとしてTSKgel Super HZ M-H、TSK gel Super HZ4000、TSKgel SuperHZ200(東ソー(株)製、4.6mmID×15cm)を、溶離液としてTHF(テトラヒドロフラン)を用いることが好ましい。
また、成分Aにおける重合体の合成法についても、様々な方法が知られているが、一例を挙げると、少なくとも上記構成単位(a1)及び上記構成単位(a3)を形成するために用いられるラジカル重合性単量体を含むラジカル重合性単量体混合物を有機溶剤中、ラジカル重合開始剤を用いて重合することにより合成することができる。また、いわゆる高分子反応で合成することもできる。
また、本発明の感光性樹脂組成物は、成分Aを含有することにより、現像マージンが広い。
更に、本発明の感光性樹脂組成物中における成分Aの含有量は、後述する赤外線カットフィルター(特にガラス基板)に塗布する場合、感光性樹脂組成物のチタンブラック以外の固形分に対して、20~99質量%であることが好ましく、25~98質量%であることがより好ましく、30~95質量%であることが更に好ましい。含有量がこの範囲であると、本発明の効果がより奏される。
感光性樹脂組成物の固形分中の架橋性基当量について説明する。
固形分中の架橋性基当量とは、組成物の固形分中に架橋性基が1molある場合の固形分の質量(g)である。組成物の固形分を一定量はかり取り、その固形分中に含まれる架橋性基量を測定することで求めることができる。
具体的には、本発明の感光性樹脂組成物よりチタンブラックを沈降させたものを試料とし、上記の測定を行う。チタンブラックの沈降については、一旦、感光性樹脂組成物を溶剤により希釈し行ってもよい。
架橋性基がエポキシ基である場合には、JIS K7236:2001に規定されるエポキシ当量の測定と同様の方法で求めることができる。また、他の架橋性基の場合も同様にして測定できる。
本発明の感光性樹脂組成物における架橋性基当量は、硬化膜強度の観点から、感光性樹脂組成物の有機固形分1gあたり、1,000以下が好ましく、500以下がより好ましく、350以下が最も好ましい。下限値については、特に限定はないが、感度、現像性の観点から、250以上が好ましい。なお、感光性樹脂組成物の有機固形分とは、溶剤などの揮発性成分、及び、チタンブラックなどの無機成分を除いた成分を表す。
本発明の感光性樹脂組成物は、(成分B)光酸発生剤を含有する。本発明で使用される光酸発生剤(「成分B」ともいう。)としては、波長300nm以上、好ましくは波長300~450nmの活性光線に感応し、酸を発生する化合物が好ましいが、その化学構造に制限されるものではない。また、波長300nm以上の活性光線に直接感応しない光酸発生剤についても、増感剤と併用することによって波長300nm以上の活性光線に感応し、酸を発生する化合物であれば、増感剤と組み合わせて好ましく用いることができる。本発明で使用される光酸発生剤としては、pKaが4以下の酸を発生する光酸発生剤が好ましく、pKaが3以下の酸を発生する光酸発生剤がより好ましく、pKaが2以下の酸を発生する光酸発生剤が最も好ましい。
R21のアルキル基としては、炭素数1~10の、直鎖状又は分岐状アルキル基が好ましい。R21のアルキル基は、炭素数6~11のアリール基、炭素数1~10のアルコキシ基、又は、シクロアルキル基(7,7-ジメチル-2-オキソノルボルニル基などの有橋式脂環基を含む、好ましくはビシクロアルキル基等)で置換されてもよい。
R21のアリール基としては、炭素数6~11のアリール基が好ましく、フェニル基又はナフチル基がより好ましい。R21のアリール基は、炭素数1~10のアルキル基、炭素数1~10のアルコキシ基又はハロゲン原子で置換されてもよい。
Xとしてのアルコキシ基は、炭素数1~4の直鎖状又は分岐状アルコキシ基が好ましい。
Xとしてのハロゲン原子は、塩素原子又はフッ素原子が好ましい。
m4は、0又は1が好ましい。上記式(B2)中、m4が1であり、Xがメチル基であり、Xの置換位置がオルト位であり、R42が炭素数1~10の直鎖状アルキル基、7,7-ジメチル-2-オキソノルボルニルメチル基、又は、p-トルイル基である化合物が特に好ましい。
X1としては、炭素数1~5のアルコキシ基が好ましく、メトキシ基がより好ましい。
n4としては、0~2の整数が好ましく、0又は1が特に好ましい。
X101は-O-、-S-、-NH-、-NR105-、-CH2-、-CR106H-、又は、-CR105R107-を表し、R105~R107はアルキル基、又は、アリール基を表す。
R121~R124はそれぞれ独立に、水素原子、ハロゲン原子、アルキル基、アルケニル基、アルコキシ基、アミノ基、アルコキシカルボニル基、アルキルカルボニル基、アリールカルボニル基、アミド基、スルホ基、シアノ基、又は、アリール基を表す。R121~R124のうち2つは、それぞれ互いに結合して環を形成してもよい。
R121~R124としてはそれぞれ独立に、水素原子、ハロゲン原子、又は、アルキル基が好ましく、また、R121~R124のうち少なくとも2つが互いに結合してアリール基を形成する態様もまた、好ましく挙げられる。中でも、R121~R124がいずれも水素原子である態様が感度の観点から好ましい。
既述の官能基は、いずれも、更に置換基を有していてもよい。
アルキル基の炭素数は、好ましくは3~10である。特にアルキル基が分岐構造を有する場合、炭素数3~6のアルキル基が好ましく、環状構造を有する場合、炭素数5~7のアルキル基が好ましい。アルキル基としては、例えば、プロピル基、イソプロピル基、n-ブチル基、s-ブチル基、イソブチル基、tert-ブチル基、ペンチル基、イソペンチル基、ネオペンチル基、1,1-ジメチルプロピル基、ヘキシル基、2-エチルヘキシル基、シクロヘキシル基、オクチル基などが挙げられ、好ましくは、イソプロピル基、tert-ブチル基、ネオペンチル基、シクロヘキシル基である。
アリール基の炭素数は、好ましくは6~12であり、より好ましくは6~8であり、更に好ましくは6~7である。上記アリール基としては、フェニル基、ナフチル基などが挙げられ、好ましくは、フェニル基である。
Rb1が表すアルキル基及びアリール基は、置換基を有していてもよい。置換基としては、例えばハロゲン原子(フッ素原子、塩素原子、臭素原子、ヨウ素原子)、直鎖、分岐又は環状のアルキル基(例えばメチル基、エチル基、プロピル基など)、アルケニル基、アルキニル基、アリール基、アシル基、アルコキシカルボニル基、アリールオキシカルボニル基、カルバモイル基、シアノ基、カルボキシル基、水酸基、アルコキシ基、アリールオキシ基、アルキルチオ基、アリールチオ基、ヘテロ環オキシ基、アシルオキシ基、アミノ基、ニトロ基、ヒドラジノ基、ヘテロ環基などが挙げられる。また、これらの基によって更に置換されていてもよい。好ましくは、ハロゲン原子、メチル基である。
かさ高い置換基の中でも、イソプロピル基、tert-ブチル基、ネオペンチル基、シクロヘキシル基が好ましく、tert-ブチル基、シクロヘキシル基がより好ましい。
アリール基としては、炭素数6~10のアリール基が好ましい。上記アリール基としては、フェニル基、ナフチル基、p-トルイル基(p-メチルフェニル基)などが挙げられ、好ましくは、フェニル基、p-トルイル基である。
ヘテロアリール基としては、例えば、ピロール基、インドール基、カルバゾール基、フラン基、チオフェン基などが挙げられる。
Rb2が表すアルキル基、アリール基、及びヘテロアリール基は、置換基を有していてもよい。置換基としては、Rb1が表すアルキル基及びアリール基が有していてもよい置換基と同義である。
Rb2は、アルキル基又はアリール基が好ましく、アリール基がより好ましく、フェニル基がより好ましい。フェニル基の置換基としてはメチル基が好ましい。
Rb3~Rb6のうち、Rb3とRb4、Rb4とRb5、又は、Rb5とRb6が結合して環を形成してもよく、環としては、脂環又は芳香環を形成していることが好ましく、ベンゼン環がより好ましい。
Rb3~Rb6は、水素原子、アルキル基、ハロゲン原子(フッ素原子、塩素原子、臭素原子)、又は、Rb3とRb4、Rb4とRb5、若しくは、Rb5とRb6が結合してベンゼン環を構成していることが好ましく、水素原子、メチル基、フッ素原子、塩素原子、臭素原子、又は、Rb3とRb4、Rb4とRb5、若しくは、Rb5とRb6が結合してベンゼン環を構成していることがより好ましい。
Rb3~Rb6の好ましい態様は以下の通りである。
(態様1)少なくとも2つは水素原子である。
(態様2)アルキル基、アリール基、又は、ハロゲン原子の数は、1つ以下である。
(態様3)Rb3とRb4、Rb4とRb5、又は、Rb5とRb6が結合してベンゼン環を構成している。
(態様4)上記態様1と2を満たす態様、及び/又は、上記態様1と3を満たす態様。
また、本発明の感光性樹脂組成物中における(成分B)光酸発生剤は、赤外線カットフィルター(特にガラス基板)に塗布する場合、感光性樹脂組成物中の成分A100質量部に対して、0.1~30質量部使用することが好ましく、0.5~20質量部使用することがより好ましい。
本発明の感光性樹脂組成物は、(成分C)溶剤を含有する。本発明の感光性樹脂組成物は、必須成分と、更に後述の任意の成分を(成分C)溶剤に溶解又は分散した液として調製されることが好ましい。
本発明の感光性樹脂組成物に使用される溶剤としては、公知の溶剤を用いることができ、エチレングリコールモノアルキルエーテル類、エチレングリコールジアルキルエーテル類、エチレングリコールモノアルキルエーテルアセテート類、プロピレングリコールモノアルキルエーテル類、プロピレングリコールジアルキルエーテル類、プロピレングリコールモノアルキルエーテルアセテート類、ジエチレングリコールジアルキルエーテル類、ジエチレングリコールモノアルキルエーテルアセテート類、ジプロピレングリコールモノアルキルエーテル類、ジプロピレングリコールジアルキルエーテル類、ジプロピレングリコールモノアルキルエーテルアセテート類、エステル類、ケトン類、アミド類、ラクトン類等が例示できる。また、本発明の感光性樹脂組成物に使用される溶剤の具体例としては特開2011-221494号公報の段落0174~0178に記載の溶剤、特開2012-194290号公報の段落0167~0168に記載の溶剤も挙げられ、これらの内容は本願明細書に組み込まれる。
これら溶剤は、1種単独で又は2種以上を混合して使用することができる。本発明に用いることができる溶剤は、1種単独、又は、2種を併用することが好ましい。
沸点130℃以上160℃未満の溶剤としては、プロピレングリコールモノメチルエーテルアセテート(沸点146℃)、プロピレングリコールモノエチルエーテルアセテート(沸点158℃)、プロピレングリコールメチル-n-ブチルエーテル(沸点155℃)、プロピレングリコールメチル-n-プロピルエーテル(沸点131℃)が例示できる。
沸点160℃以上の溶剤としては、3-エトキシプロピオン酸エチル(沸点170℃)、ジエチレングリコールメチルエチルエーテル(沸点176℃)、プロピレングリコールモノメチルエーテルプロピオネート(沸点160℃)、ジプロピレングリコールメチルエーテルアセテート(沸点213℃)、3-メトキシブチルエーテルアセテート(沸点171℃)、ジエチレングリコールジエチエルエーテル(沸点189℃)、ジエチレングリコールジメチルエーテル(沸点162℃)、プロピレングリコールジアセテート(沸点190℃)、ジエチレングリコールモノエチルエーテルアセテート(沸点220℃)、ジプロピレングリコールジメチルエーテル(沸点175℃)、1,3-ブチレングリコールジアセテート(沸点232℃)、シクロヘキサノン(沸点156℃)、シクロペンタノン(131℃)が例示できる。
これらの中でも、溶剤としては、プロピレングリコールモノアルキルエーテルアセテート類、ジエチレングリコールジアルキルエーテル類及びエステル類よりなる群から選ばれた少なくとも1種の溶剤が好ましく、プロピレングリコールモノメチルエーテルアセテート、ジエチレングリコールメチルエチルエーテル及び/又は3-エトキシプロピオン酸エチルがより好ましく、プロピレングリコールモノメチルエーテルアセテート、ジエチレングリコールメチルエチルエーテル及び3-エトキシプロピオン酸エチルが特に好ましい。
本発明の感光性樹脂組成物は、(成分S)チタンブラックを含有する。
本発明におけるチタンブラックとは、チタン原子を有する黒色粒子で、具体的な成分は低次酸化チタンや酸窒化チタン等である。
また、チタンブラック粒子は、分散性向上、凝集性抑制などの目的で、必要に応じ、表面を修飾することが可能である。例えば、酸化ケイ素、酸化チタン、酸化ゲルマニウム、酸化アルミニウム、酸化マグネシウム、酸化ジルコニウムでチタンブラック粒子を被覆することが可能であり、また、特開2007-302836号公報に示されるような撥水性物質でチタンブラック粒子の表面を処理することも可能である。
チタンブラックの粒子径は、特に制限はないが、分散性、着色性の観点から、平均1次粒子径が3nm以上2,000nm以下の範囲であることが好ましく、平均1次粒子径が10nm以上500nm以下の範囲であることがより好ましく、平均1次粒子径が10nm以上100nm以下の範囲であることが更に好ましい。
チタンブラックの粒子径は、以下の方法により測定することができる。
粒径の測定方法としては、透過型電子顕微鏡を用いて粒子を直接観察し、短軸径や長軸径を計測する方法や、小角エックス線散乱法を用いて被測定物中に含有する所定の粒子径に対する粒子含有率を定める方法により、測定できることが知られている。
また、遮光性カラーフィルター及び赤外線カットフィルターに使用する場合、本発明の感光性樹脂組成物におけるチタンブラックの含有量は、本発明の感光性樹脂組成物の全固形分に対して、40~70質量%であることが好ましく、45~65質量%であることがより好ましく、50~65質量%であることが特に好ましい。上記範囲であると、薄膜でありながら遮光性に優れ、表面硬度が高い硬化物が得られ、更に解像性に優れる。
このような混合可能な遮光用顔料としては、可視光領域に吸光度を有するものであれば特に限定はされず、上記した体質顔料、カーボンブラック、C.I.Pigment Blue 1,2,15,15:1,15:2,15:3,15:4,15:6,16,22,60,64,66,79,80、C.I.Pigment Violet 1,19,23,27,32,37,42、C.I.Pigment Brown 25,28、C.I.Pigment Black 1,7等の有機顔料等を挙げることができる。
チタンブラック以外の遮光用顔料を混合して使用する例として、チタンブラックとカーボンブラックとを6:1で混合した物、チタンブラックと酸化チタンとを3:1で混合した物などが挙げられる。
混合して使用するチタンブラック以外の遮光用顔料は、チタンブラック100質量部に対して、0~90質量部の範囲で用いることが好ましく、0~50質量部の範囲で用いることがより好ましい。
上記分散液の調製に使用される溶剤としては、例えば、上述した(成分C)溶剤のほか、1-プロパノール、2-プロパノール、1-ブタノール、2-ブタノール、2-メチル-2-プロパノール、1-ペンタノール、2-ペンタノール、3-ペンタノール、3-メチル-1-ブタノール、2-メチル-2-ブタノール、ネオペンタノール、シクロペンタノール、1-ヘキサノール、シクロヘキサノール等のアルコール類等を挙げることができる。
これらの溶剤は、1種単独又は2種以上を混合して使用することができる。
上記チタンブラック分散液は、分散液中のチタンブラックの含有量が5質量%以上99質量%以下となるように調整されることが好ましく、40質量%以上92質量%以下であることがより好ましく、40質量%以上80質量%以下であることが更に好ましい。
また、本発明のチタンブラック分散液を用いたレジストを、赤外線カットフィルター(特にガラス基板)に塗布する場合、感光性樹脂組成物のチタンブラック以外の固形分に対して、20~99質量%であることが好ましく、25~98質量%であることがより好ましく、30~95質量%であることが更に好ましい。含有量がこの範囲であると、本発明の効果がより奏される。
本発明の感光性樹脂組成物は、(成分D)分散剤を含有することが好ましい。分散剤を含有することにより、成分Sの樹脂組成物中における分散性をより向上させることができる。
分散剤としては、公知の分散剤を用いることができ、例えば、公知の顔料分散剤を適宜選択して用いることができる。
また、分散剤としては、高分子分散剤を好ましく用いることができる。なお、高分子分散剤とは、分子量(重量平均分子量)が1,000以上の分散剤である。
分散剤としては、側鎖に酸基を有する高分子分散剤であることが好ましく、側鎖にカルボキシル基を有する高分子分散剤であることがより好ましい。
また、分散剤としては、側鎖にグラフト鎖を有する高分子分散剤であることが好ましく、側鎖に酸基とグラフト鎖とを有する高分子分散剤であることがより好ましい。なお、グラフト鎖とは、側鎖に有する主鎖とは異なるポリマー鎖のことである。グラフト鎖としては、グラフト鎖1本あたりの水素原子を除いた原子数が40~10,000であることが好ましく、グラフト鎖1本あたりの水素原子を除いた原子数が50~2,000であることがより好ましく、グラフト鎖1本あたりの水素原子を除いた原子数が60~1,000であることが更に好ましい。
また、本発明の感光性樹脂組成物に用いられる分散剤の具体例としては、特開2013-249417号公報の段落0225に記載の特定樹脂9、特開2007-277514号公報の段落0039~0140(対応する米国特許出願公開第2010/0233595号明細書段落0053~0180)に記載の高分子化合物、特開2007-277514号公報の段落0266~0348(対応する米国特許出願公開第2010/0233595号明細書の段落0389~0429)に記載の実施例で合成された化合物C-1~C-57、特開2014-177613号公報に記載の高分子化合物(B)、及び、特開2014-177614号公報に記載の高分子化合物(B)等が挙げられる。
本発明の感光性樹脂組成物における分散剤の含有量は、チタンブラックの総含有量に対して、2~70質量%の範囲が好ましく、5~50質量%の範囲がより好ましい。
本発明の感光性樹脂組成物は、必要に応じ、(成分E)架橋剤を含有することが好ましい。架橋剤を添加することにより、本発明の感光性樹脂組成物により得られる硬化膜をより強固な膜とすることができる。
架橋剤としては、熱によって架橋反応が起こるものであれば制限はない(ただし、成分Aを除く。)。すなわち、架橋剤としては熱架橋剤が好適に使用される。例えば、以下に述べる分子内に2個以上のエポキシ基又はオキセタニル基を有する化合物、アルコキシメチル基含有架橋剤、少なくとも1個のエチレン性不飽和結合を有する化合物、ブロックイソシアネート化合物、又は、アルコキシシラン化合物等を添加することができる。中でも、分子内に2個以上のエポキシ基又はオキセタニル基を有する化合物が好ましく、分子内に2個以上のエポキシ基を有する化合物がより好ましい。
また、架橋剤における架橋性基としては、エポキシ基、オキセタニル基、-NH-CH2-OR1、(メタ)アクリロイル基、及び、ブロックイソシアネート基よりなる群から選ばれた少なくとも1種であることが好ましい。なお、R1は、炭素数1~20のアルキル基を表す。
分子内に2個以上のエポキシ基を有する化合物の具体例としては、ビスフェノールA型エポキシ樹脂、ビスフェノールF型エポキシ樹脂、フェノールノボラック型エポキシ樹脂、クレゾールノボラック型エポキシ樹脂、脂肪族エポキシ樹脂等を挙げることができる。
これらは1種単独又は2種以上を組み合わせて使用することができる。
また、オキセタニル基を含む化合物は、単独で又はエポキシ基を含む化合物と混合して使用することが好ましい。
アルコキシメチル基含有架橋剤としては、アルコキシメチル化メラミン、アルコキシメチル化ベンゾグアナミン、アルコキシメチル化グリコールウリル及びアルコキシメチル化尿素等が好ましい。これらは、それぞれメチロール化メラミン、メチロール化ベンゾグアナミン、メチロール化グリコールウリル、又は、メチロール化尿素のメチロール基をアルコキシメチル基に変換することにより得られる。このアルコキシメチル基の種類については特に限定されるものではなく、例えば、メトキシメチル基、エトキシメチル基、プロポキシメチル基、ブトキシメチル基等を挙げることができるが、アウトガスの発生量の観点から、メトキシメチル基が特に好ましい。
また、上記アルコキシメチル基としては、-NH-CH2-OR1が好ましく挙げられる。なお、R1は、炭素数1~20のアルキル基を表す。
これらの架橋性化合物のうち、アルコキシメチル化メラミン、アルコキシメチル化ベンゾグアナミン、アルコキシメチル化グリコールウリルが好ましい架橋性化合物として挙げられ、透明性の観点から、アルコキシメチル化グリコールウリルが特に好ましい。
これらアルコキシメチル基含有架橋剤は、市販品として入手可能であり、例えば、サイメル300、301、303、370、325、327、701、266、267、238、1141、272、202、1156、1158、1123、1170、1174、UFR65、300(以上、三井サイアナミッド(株)製)、ニカラックMX-750、-032、-706、-708、-40、-31、-270、-280、-290、ニカラックMS-11、ニカラックMW-30HM、-100LM、-390、(以上、(株)三和ケミカル製)などを好ましく使用することができる。
本発明の感光性樹脂組成物では、架橋剤として、ブロックイソシアネート化合物も好ましく採用できる。ブロックイソシアネート化合物は、ブロックイソシアネート基を有する化合物であれば特に制限はないが、硬化性の観点から、1分子内に2以上のブロックイソシアネート基を有する化合物であることが好ましい。
なお、本発明におけるブロックイソシアネート基とは、熱によりイソシアネート基を生成することが可能な基であり、例えば、ブロック剤とイソシアネート基とを反応させイソシアネート基を保護した基が好ましく例示できる。また、上記ブロックイソシアネート基は、90℃~250℃の熱によりイソシアネート基を生成することが可能な基であることが好ましい。
また、ブロックイソシアネート化合物としては、その骨格は特に限定されるものではなく、1分子中にイソシアネート基を2個有するものであればどのようなものでもよく、脂肪族、脂環族又は芳香族のポリイソシアネートであってもよいが、例えば、2,4-トリレンジイソシアネート、2,6-トリレンジイソシアネート、イソホロンジイソシアネート、1,6-ヘキサメチレンジイソシアネート、1,3-トリメチレンジイソシアネート、1,4-テトラメチレンジイソシアネート、2,2,4-トリメチルヘキサメチレンジイソシアネート、2,4,4-トリメチルヘキサメチレンジイソシアネート、1,9-ノナメチレンジイソシアネート、1,10-デカメチレンジイソシアネート、1,4-シクロヘキサンジイソシアネート、2,2’-ジエチルエーテルジイソシアネート、ジフェニルメタン-4,4’-ジイソシアネート、o-キシレンジイソシアネート、m-キシレンジイソシアネート、p-キシレンジイソシアネート、メチレンビス(シクロヘキシルイソシアネート)、シクロヘキサン-1,3-ジメチレンジイソシアネート、シクロヘキサン-1,4-ジメチレレンジイソシアネート、1,5-ナフタレンジイソシアネート、p-フェニレンジイソシアネート、3,3’-メチレンジトリレン-4,4’-ジイソシアネート、4,4’-ジフェニルエーテルジイソシアネート、テトラクロロフェニレンジイソシアネート、ノルボルナンジイソシアネート、水素化1,3-キシリレンジイソシアネート、水素化1,4-キシリレンジイソシアネート等のイソシアネート化合物及びこれらの化合物から派生するプレポリマー型の骨格の化合物を好適に用いることができる。これらの中でも、トリレンジイソシアネート(TDI)やジフェニルメタンジイソシアネート(MDI)、ヘキサメチレンジイソシアネート(HDI)、イソホロンジイソシアネート(IPDI)が特に好ましい。
上記ブロックイソシアネート化合物のブロック構造を形成するブロック剤としては、オキシム化合物、ラクタム化合物、フェノール化合物、アルコール化合物、アミン化合物、活性メチレン化合物、ピラゾール化合物、メルカプタン化合物、イミダゾール系化合物、イミド系化合物等を挙げることができる。これらの中でも、オキシム化合物、ラクタム化合物、フェノール化合物、アルコール化合物、アミン化合物、活性メチレン化合物、ピラゾール化合物から選ばれるブロック剤が特に好ましい。
上記ラクタム化合物としては、ε-カプロラクタム、γ-ブチロラクタム等が例示できる。
上記フェノール化合物としては、フェノール、ナフトール、クレゾール、キシレノール、ハロゲン置換フェノール等が例示できる。
上記アルコール化合物としては、メタノール、エタノール、プロパノール、ブタノール、シクロヘキサノール、エチレングリコールモノアルキルエーテル、プロピレングリコールモノアルキルエーテル、乳酸アルキル等が例示できる。
上記アミン化合物としては、1級アミン及び2級アミンが挙げられ、芳香族アミン、脂肪族アミン、脂環族アミンいずれでもよく、アニリン、ジフェニルアミン、エチレンイミン、ポリエチレンイミン等が例示できる。
上記活性メチレン化合物としては、マロン酸ジエチル、マロン酸ジメチル、アセト酢酸エチル、アセト酢酸メチル等が例示できる。
上記ピラゾール化合物としては、ピラゾール、メチルピラゾール、ジメチルピラゾール等が例示できる。
上記メルカプタン化合物としては、アルキルメルカプタン、アリールメルカプタン等が例示できる。
本発明の感光性樹脂組成物は、架橋剤として、アルコキシシラン化合物を含有してもよい。アルコキシシラン化合物としては、トリアルコキシシラン化合物が好ましく挙げられる。
アルコキシシラン化合物としては、例えば、γ-アミノプロピルトリメトキシシラン、γ-アミノプロピルトリエトキシシラン、γ-グリシドキシプロピルトリアコキシシラン、γ-グリシドキシプロピルアルキルジアルコキシシラン、γ-メタクリロキシプロピルトリアルコキシシラン、γ-メタクリロキシプロピルアルキルジアルコキシシラン、γ-クロロプロピルトリアルコキシシラン、γ-メルカプトプロピルトリアルコキシシラン、β-(3,4-エポキシシクロヘキシル)エチルトリアルコキシシラン、ビニルトリアルコキシシランが挙げられる。これらのうち、γ-グリシドキシプロピルトリアルコキシシランやγ-メタクリロキシプロピルトリアルコキシシランがより好ましく、γ-グリシドキシプロピルトリアルコキシシランが更に好ましく、3-グリシドキシプロピルトリメトキシシランが特に好ましい。これらは1種単独又は2種以上を組み合わせて使用することができる。
(R1)4-n-Si-(OR2)n
式中、R1は反応性基を有さない炭素数1~20の炭化水素基であり、R2は炭素数1~3のアルキル基又はフェニル基であり、nは1~3の整数である。
具体例として以下の化合物を挙げることができる。なお、Phはフェニル基を表す。
また、アルコキシシラン化合物を用いると、表面硬度向上効果の他に、本発明の感光性樹脂組成物により形成された膜と基板との密着性を向上できる。
少なくとも1個のエチレン性不飽和結合を有する化合物としては、単官能(メタ)アクリレート、2官能(メタ)アクリレート、3官能以上の(メタ)アクリレートなどの(メタ)アクリレート化合物を好適に用いることができる。
単官能(メタ)アクリレートとしては、例えば、2-ヒドロキシエチル(メタ)アクリレート、カルビトール(メタ)アクリレート、イソボルニル(メタ)アクリレート、3-メトキシブチル(メタ)アクリレート、2-(メタ)アクリロイルオキシエチル-2-ヒドロキシプロピルフタレートなどが挙げられる。
2官能(メタ)アクリレートとしては、例えば、エチレングリコール(メタ)アクリレート、1,6-ヘキサンジオールジ(メタ)アクリレート、1,9-ノナンジオールジ(メタ)アクリレート、ポリプロピレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、ビスフェノキシエタノールフルオレンジアクリレート、ビスフェノキシエタノールフルオレンジアクリレートなどが挙げられる。
3官能以上の(メタ)アクリレートとしては、例えばトリメチロールプロパントリ(メタ)アクリレート、ペンタエリスリトールトリ(メタ)アクリレート、トリ((メタ)アクリロイロキシエチル)フォスフェート、ペンタエリスリトールテトラ(メタ)アクリレート、ジペンタエリスリトールペンタ(メタ)アクリレート、ジペンタエリスリトールヘキサ(メタ)アクリレートなどが挙げられる。
これらの少なくとも1個のエチレン性不飽和結合を有する化合物は、1種単独又は2種以上を組み合わせて用いられる。
また、少なくとも1個のエチレン性不飽和結合を有する化合物を加える場合には、ラジカル重合開始剤を添加することが好ましく、熱ラジカル重合開始剤を添加することがより好ましい。ラジカル重合開始剤としては、公知のものを用いることができる。
また、(メタ)アクリル基を有する化合物であれば、マイケル付加反応による架橋も可能である。
また、本発明の架橋剤は、赤外線カットフィルター(特にガラス基板)に塗布する場合、感光性樹脂組成物のチタンブラック以外の固形分に対して、0~30質量%であることが好ましく、0.1~20質量%であることがより好ましく、0.5~12質量%であることが更に好ましい。含有量がこの範囲であると、本発明の効果がより奏される。
本発明の感光性樹脂組成物は、(成分F)塩基性化合物を含有してもよい。
(成分F)塩基性化合物としては、化学増幅レジストで用いられるものの中から任意に選択して使用することができる。例えば、脂肪族アミン、芳香族アミン、複素環式アミン、第四級アンモニウムヒドロキシド、カルボン酸の第四級アンモニウム塩等が挙げられる。これらの具体例としては、特開2011-221494号公報の段落0204~0207に記載の化合物が挙げられる。
芳香族アミンとしては、例えば、アニリン、ベンジルアミン、N,N-ジメチルアニリン、ジフェニルアミンなどが挙げられる。
複素環式アミンとしては、例えば、ピリジン、2-メチルピリジン、4-メチルピリジン、2-エチルピリジン、4-エチルピリジン、2-フェニルピリジン、4-フェニルピリジン、N-メチル-4-フェニルピリジン、4-ジメチルアミノピリジン、イミダゾール、ベンズイミダゾール、4-メチルイミダゾール、2-フェニルベンズイミダゾール、2,4,5-トリフェニルイミダゾール、ニコチン、ニコチン酸、ニコチン酸アミド、キノリン、8-オキシキノリン、ピラジン、ピラゾール、ピリダジン、プリン、ピロリジン、ピペリジン、ピペラジン、モルホリン、4-メチルモルホリン、N-シクロヘキシル-N’-[2-(4-モルホリニル)エチル]チオ尿素、1,5-ジアザビシクロ[4.3.0]-5-ノネン、1,8-ジアザビシクロ[5.3.0]-7-ウンデセンなどが挙げられる。
第四級アンモニウムヒドロキシドとしては、例えば、テトラメチルアンモニウムヒドロキシド、テトラエチルアンモニウムヒドロキシド、テトラ-n-ブチルアンモニウムヒドロキシド、テトラ-n-ヘキシルアンモニウムヒドロキシドなどが挙げられる。
カルボン酸の第四級アンモニウム塩としては、例えば、テトラメチルアンモニウムアセテート、テトラメチルアンモニウムベンゾエート、テトラ-n-ブチルアンモニウムアセテート、テトラ-n-ブチルアンモニウムベンゾエートなどが挙げられる。
これらの中でも、複素環式アミンが好ましく、2,4,5-トリフェニルイミダゾール、及び/又は、N-シクロヘキシル-N’-[2-(4-モルホリニル)エチル]チオ尿素が特に好ましい。
本発明の感光性樹脂組成物における塩基性化合物の含有量は、感光性樹脂組成物中のチタンブラック以外の固形分100質量部に対し、0.001~5質量部であることが好ましく、0.005~3質量部であることがより好ましい。
本発明の感光性樹脂組成物は、(成分G)界面活性剤を含有してもよい。
(成分G)界面活性剤としては、アニオン系、カチオン系、ノニオン系又は両性のいずれでも使用することができるが、好ましい界面活性剤は、ノニオン界面活性剤である。本発明の組成物に用いられる界面活性剤としては、例えば、特開2012-88459号公報の段落0201~0205に記載のものや、特開2011-215580号公報の段落0185~0188に記載のものを用いることができ、これらの記載は本願明細書に組み込まれる。
ノニオン系界面活性剤の例としては、ポリオキシエチレン高級アルキルエーテル類、ポリオキシエチレン高級アルキルフェニルエーテル類、ポリオキシエチレングリコールの高級脂肪酸ジエステル類、シリコーン系、フッ素系界面活性剤を挙げることができる。また、以下商品名で、KP-341、X-22-822(信越化学工業(株)製)、ポリフローNo.99C(共栄社化学(株)製)、エフトップ(三菱マテリアル電子化成(株)製)、メガファック(DIC(株)製)、フロラードノベックFC-4430(住友スリーエム(株)製)、サーフロンS-242(AGCセイミケミカル社製)、PolyFoxPF-6320(OMNOVA社製)、SH-8400(東レ・ダウコーニングシリコーン(株)製)、フタージェントFTX-218G(ネオス社製)等の各シリーズを挙げることができる。
また、界面活性剤として、下記式(G-1)で表される構成単位A及び構成単位Bを含み、テトラヒドロフラン(THF)を溶媒とした場合のゲルパーミエーションクロマトグラフィで測定されるポリスチレン換算の重量平均分子量(Mw)が1,000以上10,000以下である共重合体を好ましい例として挙げることができる。
本発明の感光性樹脂組成物における界面活性剤の添加量は、感光性樹脂組成物中のチタンブラック以外の固形分100質量部に対し10質量部以下であることが好ましく、0.001~10質量部であることがより好ましく、0.01~3質量部であることが更に好ましい。
本発明の感光性樹脂組成物は、酸化防止剤を含有することが好ましい。酸化防止剤としては、公知の酸化防止剤を含有することができる。酸化防止剤を添加することにより、硬化膜の着色を防止できる、又は、分解による膜厚減少を低減でき、また、耐熱透明性に優れるという利点がある。
このような酸化防止剤としては、例えば、リン系酸化防止剤、アミド類、ヒドラジド類、ヒンダードアミン系酸化防止剤、イオウ系酸化防止剤、フェノール系酸化防止剤、アスコルビン酸類、硫酸亜鉛、糖類、亜硝酸塩、亜硫酸塩、チオ硫酸塩、ヒドロキシルアミン誘導体等を挙げることができる。これらの中では、硬化膜の着色、膜厚減少の観点から特にフェノール系酸化防止剤、アミド系酸化防止剤、ヒドラジド系酸化防止剤、イオウ系酸化防止剤が好ましく、フェノール系酸化防止剤が最も好ましい。これらは1種単独で用いてもよいし、2種以上を混合してもよい。
具体例としては、特開2005-29515号公報の段落0026~0031に記載の化合物を挙げることができ、これらの内容は本願明細書に組み込まれる。
また、酸化防止剤以外の添加剤として、「高分子添加剤の新展開」((株)日刊工業新聞社)に記載の各種紫外線吸収剤や、金属不活性化剤等を本発明の感光性樹脂組成物に添加してもよい。
本発明の感光性樹脂組成物は、(成分B)光酸発生剤との組み合わせにおいて、その分解を促進させるために、増感剤を含有することが好ましい。増感剤は、活性光線又は放射線を吸収して電子励起状態となる。電子励起状態となった増感剤は、光酸発生剤と接触して、電子移動、エネルギー移動、発熱などの作用が生じる。これにより光酸発生剤は化学変化を起こして分解し、酸を生成する。好ましい増感剤の例としては、以下の化合物類に属しており、かつ350nmから450nmの波長域のいずれかに吸収波長を有する化合物を挙げることができる。
これら増感剤の中でも、多核芳香族類、アクリドン類、スチリル類、ベーススチリル類、クマリン類が好ましく、多核芳香族類がより好ましい。多核芳香族類の中でもアントラセン誘導体が最も好ましい。
また、増感剤は、1種単独で使用してもよいし、2種以上を併用することもできる。
本発明の感光性樹脂組成物には、上記成分に加えて、必要に応じて、紫外線吸収剤、金属不活性化剤や、酸増殖剤、現像促進剤、可塑剤、熱ラジカル発生剤、熱酸発生剤、増粘剤、及び、有機又は無機の沈殿防止剤などの公知の添加剤を加えることができる。また、これらの化合物としては、例えば特開2012-88459号公報の段落0201~0224の記載も参酌でき、これらの内容は本願明細書に組み込まれる。
本発明の感光性樹脂組成物は、感度向上を目的に、酸増殖剤を用いてもよい。
本発明に用いることができる酸増殖剤は、酸触媒反応によって更に酸を発生して反応系内の酸濃度を上昇させることができる化合物であり、酸が存在しない状態では安定に存在する化合物である。
このような酸増殖剤の具体例としては、特開2011-221494号公報の段落0226~0228に記載の酸増殖剤が挙げられ、この内容は本願明細書に組み込まれる。
本発明の感光性樹脂組成物は、現像促進剤を含有することができる。
現像促進剤としては、現像促進効果のある任意の化合物を使用できるが、カルボキシル基、フェノール性水酸基、及び、アルキレンオキシ基よりなる群から選ばれた少なくとも1種の構造を有する化合物であることが好ましく、カルボキシル基又はフェノール性水酸基を有する化合物がより好ましく、フェノール性水酸基を有する化合物が最も好ましい。
現像促進剤としては、特開2012-042837号公報の段落0171~0172の記載を参酌でき、この内容は本願明細書に組み込まれる。
本発明の感光性樹脂組成物における現像促進剤の添加量は、感度と残膜率の観点から、感光性樹脂組成物のチタンブラック以外の固形分100質量部に対し、0~30質量部が好ましく、0.1~20質量部がより好ましく、0.5~10質量部であることが最も好ましい。
また、現像促進剤の分子量は、100~2,000が好ましく、150~1,500がより好ましく、150~1,000が更に好ましい。
本発明の樹脂組成物は、可塑剤を含有してもよい。
可塑剤としては、例えば、ジブチルフタレート、ジオクチルフタレート、ジドデシルフタレート、ポリエチレングリコール、グリセリン、ジメチルグリセリンフタレート、酒石酸ジブチル、アジピン酸ジオクチル、トリアセチルグリセリンなどが挙げられる。
本発明の樹脂組成物における可塑剤の含有量は、成分Aの含有量100質量部に対して、0.1~30質量部であることが好ましく、1~10質量部であることがより好ましい。
各成分を所定の割合でかつ任意の方法で混合し、撹拌溶解して感光性樹脂組成物を調製する。例えば、成分を、それぞれ予め溶剤に溶解させた溶液とした後、これらを所定の割合で混合して樹脂組成物を調製することもできる。以上のように調製した組成物溶液は、例えば孔径0.2μmのフィルター等を用いてろ過した後に、使用に供することもできる。
なお、本発明において、(成分S)チタンブラック、(成分C)溶剤、及び、(成分D)分散剤を含有するチタンブラック分散物を予め調製し、チタンブラック分散物と、成分A及び成分B、並びに、任意の成分とを添加し感光性樹脂組成物を調製することが特に好ましい。
次に、本発明の樹脂パターン製造方法を説明する。
本発明の樹脂パターン製造方法は、以下の(1)~(4)の工程を含むことが好ましく、以下の(1)~(5)の工程を含むことがより好ましい。
(1)本発明の感光性樹脂組成物を基板上に塗布する塗布工程;
(2)塗布された樹脂組成物から溶剤を除去する溶剤除去工程;
(3)溶剤が除去された樹脂組成物を活性光線によりパターン状に露光する露光工程;
(4)露光された樹脂組成物及び未露光の樹脂組成物を水性現像液により現像する現像工程;
(5)現像された樹脂組成物を熱処理する熱処理工程。
以下に各工程を順に説明する。
上記の基板としては、無機基板、樹脂、樹脂複合材料、ITO、Cu基板、ポリエチレンテレフタレート、セルローストリアセテート(TAC)などのプラスチック基板が挙げられる。
無機基板としては、例えばガラス、石英、シリコーン、シリコンナイトライド、及び、それらのような基板上にモリブデン、チタン、アルミ、銅などを蒸着した複合基板が挙げられる。
樹脂としては、ポリブチレンテレフタレート、ポリエチレンテレフタレート、ポリエチレンナフタレート、ポリブチレンナフタレート、ポリスチレン、ポリカーボネート、ポリスルホン、ポリエーテルスルホン、ポリアリレート、アリルジグリコールカーボネート、ポリアミド、ポリイミド、ポリアミドイミド、ポリエーテルイミド、ポリベンズアゾール、ポリフェニレンサルファイド、ポリシクロオレフィン、ノルボルネン樹脂、ポリクロロトリフルオロエチレン等のフッ素樹脂、液晶ポリマー、アクリル樹脂、エポキシ樹脂、シリコーン樹脂、アイオノマー樹脂、シアネート樹脂、架橋フマル酸ジエステル樹脂、環状ポリオレフィン、芳香族エーテル樹脂、マレイミド-オレフィン樹脂、セルロース、エピスルフィド樹脂等の合成樹脂からなる基板が挙げられる。
これらの基板は、上記の形態のまま用いられる場合は少なく、最終製品の形態によって、例えばTFT素子のような多層積層構造が形成されている場合が通常である。
本発明者らが鋭意検討した結果、基板の表面の全部又は一部がITO(酸化インジウムスズ、Indium Tin Oxide)である場合、ITO上への現像残渣の発生が特に顕著であることを見いだした。本発明の感光性樹脂組成物は、基板の表面の全部又は一部がITOである場合であっても、現像残渣の発生を抑制することができるという、極めて顕著な効果を有するものである。
塗布膜厚は特に限定されるものではなく、用途に応じた膜厚で塗布することができるが、0.5~10μmの範囲で使用されることが好ましい。
例えば、インクジェット方式による塗布条件は、感光性樹脂組成物の組成や、製造する塗膜の種類などによって適宜選択すればよい。塗布膜の厚さを調節するためには、液状の感光性樹脂組成物の吐出量や同一部分への吐出回数を調整すればよい。また、感光性樹脂組成物を塗布する形状や位置についても、所望に応じ、適宜選択すればよい。インクジェット方式の塗布に用いられる装置としては、特に制限はなく、公知のインクジェット塗布装置を適用すればよい。
具体的には、オンデマンドインクジェット塗布装置IJ-DESK-S、IJ-DESK-H((株)ピーエムティー製)、ダイマディックス・マテリアル・プリンターDMP2831、DMP-3000(FUJIFILM Dimatix社製)などが挙げられる。
インク供給系は、例えば、本発明の感光性樹脂組成物を含む元タンク、供給配管、インクジェットヘッド直前の組成物供給タンク、フィルター、ピエゾ型のインクジェットヘッドからなる。ピエゾ型のインクジェットヘッドは、好ましくは1~100pl、より好ましくは8~30plのマルチサイズドットを、好ましくは320×320~4,000×4,000dpi(dot per inch)、より好ましくは400×400~1,600×1,600dpi、更に好ましくは720×720dpiの解像度で吐出できるよう駆動することができる。なお、本発明でいうdpiとは、2.54cm当たりのドット数を表す。
塗布膜厚は特に限定されるものではなく、用途に応じた膜厚で塗布することができるが、0.5~10μmの範囲で使用されることが好ましい。
なお、(1)の塗布工程と(2)の溶剤除去工程とは、この順に行っても、同時に行っても、交互に繰り返してもよい。例えば、(1)の塗布工程におけるインクジェット塗布が全て終了した後、(2)の溶剤除去工程を行ってもよいし、基板を加熱しておき、(1)の塗布工程におけるインクジェット塗布方式による感光性樹脂組成物の吐出を行いながら溶剤除去を行ってもよい。
中でも、(1)の塗布工程におけるインクジェット塗布が全て終了した後、(2)の溶剤除去工程を行うことが好ましい。
活性光線による露光光源としては、低圧水銀灯、高圧水銀灯、超高圧水銀灯、ケミカルランプ、LED光源、エキシマレーザー発生装置などを用いることができ、g線(436nm)、i線(365nm)、h線(405nm)などの波長300nm以上450nm以下の波長を有する活性光線が好ましく使用できる。また、必要に応じて長波長カットフィルター、短波長カットフィルター、バンドパスフィルターのような分光フィルターを通して照射光を調整することもできる。
露光装置としては、ミラープロジェクションアライナー、ステッパー、スキャナー、プロキシミティ、コンタクト、マイクロレンズアレイ、レーザー露光など各種方式の露光機を用いることができる。
酸触媒の生成した領域において、上記の加水分解反応を加速させるために、露光後加熱処理:Post Exposure Bake(以下、「PEB」ともいう。)を行うことができる。PEBにより、酸分解性基からのカルボキシル基又はフェノール性水酸基の生成を促進させることができる。PEBを行う場合の温度は、30℃以上130℃以下であることが好ましく、40℃以上110℃以下がより好ましく、50℃以上100℃以下が特に好ましい。
但し、本発明における酸分解性基は、酸分解の活性化エネルギーが低く、露光による酸発生剤由来の酸により容易に分解し、酸基、例えば、カルボキシル基又はフェノール性水酸基を生じるため、必ずしもPEBを行うことなく、現像によりポジ画像を形成することもできる。
現像工程で使用する現像液には、塩基性化合物が含まれることが好ましい。塩基性化合物としては、例えば、水酸化リチウム、水酸化ナトリウム、水酸化カリウムなどのアルカリ金属水酸化物類;炭酸ナトリウム、炭酸カリウムなどのアルカリ金属炭酸塩類;重炭酸ナトリウム、重炭酸カリウムなどのアルカリ金属重炭酸塩類;テトラメチルアンモニウムヒドロキシド、テトラエチルアンモニウムヒドロキシド、コリンヒドロキシド等のアンモニウムヒドロキシド類;ケイ酸ナトリウム、メタケイ酸ナトリウムなどの水溶液を使用することができる。また、上記アルカリ類の水溶液にメタノールやエタノールなどの水溶性有機溶剤や界面活性剤を適当量添加した水溶液を現像液として使用することもできる。
好ましい現像液として、テトラエチルアンモニウムヒドロキシドの0.4質量%水溶液、0.5質量%水溶液、0.7質量%水溶液、又は、2.38質量%水溶液を挙げることができる。
現像液のpHは、好ましくは10.0~14.0である。
現像時間は、好ましくは30~500秒間であり、また、現像の手法は液盛り法、ディップ法等のいずれでもよい。現像後は、流水洗浄を30~300秒間行い、所望のパターンを形成させることができる。
現像の後に、リンス工程を行うこともできる。リンス工程では、現像後の基板を純水などで洗うことで、付着している現像液除去、現像残渣除去を行う。リンス方法は公知の方法を用いることができる。例えばシャワーリンスやディップリンスなどを挙げることができる。
また、熱処理工程(ポストベーク)は、基板がガラスを主成分とするものである場合、所定の温度、例えば120℃~250℃、より好ましくは140℃~220℃で所定の時間、例えばホットプレート上なら5~90分間、オーブンならば30~120分間、加熱処理をすることが好ましい。
熱処理工程(ポストベーク)の前に、比較的低温でベークを行った後に熱処理工程を行うこともできる(ミドルベーク工程の追加)。ミドルベークを行う場合は、90~150℃で1~60分加熱した後に、200℃以上の高温でポストベークすることが好ましい。また、ミドルベーク、ポストベークを3段階以上の多段階に分けて加熱することもできる。このようなミドルベーク、ポストベークの工夫により、パターンのテーパー角を調整することができる。これらの加熱は、ホットプレート、オーブン、赤外線ヒーターなど、公知の加熱方法を使用することができる。
なお、ポストベークに先立ち、パターンを形成した基板に活性光線により全面再露光(ポスト露光)した後、ポストベークすることにより未露光部分に存在する光酸発生剤から酸を発生させ、架橋工程を促進する触媒として機能させることができ、膜の硬化反応を促進することができる。ポスト露光工程を含む場合の好ましい露光量としては、100~3,000mJ/cm2が好ましく、100~500mJ/cm2が特に好ましい。
本発明の硬化膜は、本発明の感光性樹脂組成物を硬化して得られた膜である。
本発明の硬化膜は、遮光性カラーフィルターとして好適に用いることができる。また、本発明の硬化膜は、本発明の硬化物の製造方法又は本発明の樹脂パターン製造方法により得られた膜であることが好ましく、本発明の樹脂パターン製造方法により得られた膜であることがより好ましい。
本発明の硬化物は、本発明の感光性樹脂組成物を硬化して得られた硬化物であり、上記のように、その形状は、膜でなくともよく、任意の形状であればよい。
また、本発明の硬化物は、少なくとも、本発明の感光性樹脂組成物から少なくとも一部の溶剤を除去して硬度が上昇した硬化物であればよいが、本発明の感光性樹脂組成物から溶剤を除去し、熱硬化して得られた硬化物であることが好ましい。
本発明の硬化物の製造方法は、特に制限はないが、少なくとも以下の工程(a)~(c)をこの順に含むことが好ましい。
(a)本発明の感光性樹脂組成物を基板上に塗布する塗布工程;
(b)塗布された樹脂組成物から溶剤を除去する溶剤除去工程;
(c)溶剤が除去された樹脂組成物を熱処理する熱処理工程、又は、溶剤が除去された樹脂組成物に活性光線を照射する露光工程。
工程(c)における熱処理工程は、熱処理する対象が工程(b)で得られた溶剤が除去された樹脂組成物であること以外は、上記熱処理工程と同様の工程であり、上記熱処理工程における加熱温度、加熱時間、加熱手段等の好ましい態様も同様に好ましい。
また、工程(c)における露光工程は、露光をパターン状に行わなくともよいこと以外は、上記露光工程と同様の工程である。工程(c)における露光工程は、溶剤が除去された樹脂組成物の一方の面の全面に対し露光することが好ましい。
また、本発明の硬化物は、本発明の樹脂パターン製造方法により得られた硬化物であることが好ましい。
本発明の遮光性カラーフィルターは、本発明の感光性樹脂組成物を硬化して得られた遮光性カラーフィルターであり、本発明の樹脂パターン製造方法により製造された遮光性カラーフィルターであることが好ましい。
本発明の遮光性カラーフィルターは、本発明の硬化膜を用いて形成されたものである。本発明の硬化膜を用いて形成された遮光性カラーフィルターは、遮光性に優れる。
本発明の赤外線カットフィルターは、本発明の感光性樹脂組成物を硬化して得られた遮光膜(硬化膜)を備えている。本発明の赤外線カットフィルターに設けられる遮光膜は、樹脂パターン製造方法により形成されることが好ましい。かかる遮光膜は、遮光性に優れる。
なお、赤外線カットフィルターは、赤外線カット機能を有する基板であればよく、基板としてはガラス基板(ガラスを主成分とする基板)が好ましい。本発明の遮光膜によれば、ガラス基板の場合でも、十分な密着性を得ることができ、高い解像性を達成することができる。
ブラックマトリクスの膜厚としては特に限定はないが、本発明による効果をより効果的に得る観点からは、乾燥後の膜厚で、0.2μm以上10μm以下が好ましく、0.4μm以上5μm以下がより好ましく、0.6μm以上5μm以下が更に好ましい。
ブラックマトリックスの線幅としては、特に限定はないが、0.5μm以上500μm以下が好ましく、0.7μm以上20μm以下がより好ましく、1.0μm以上5μm以下が更に好ましい。
赤外線カットフィルター(特にガラス基板)に塗布する場合、本発明による遮光膜の線幅としては、特に限定はないが、0.5μm以上500μm以下が好ましく、0.7μm以上100μm以下がより好ましく、1.0μm以上50μm以下が更に好ましい。
従って、液晶表示装置やCCD等の固体撮像素子及び固体撮像装置に好適に用いることができ、特にFHD以上の解像度をもつスマートフォンや500万画素を超えるような高解像度のCCD素子やCMOS等に好適である。すなわち、本発明の遮光性カラーフィルターは、液晶表示装置、有機EL表示装置及び固体撮像装置に適用されることが好ましい。
また、本発明の赤外線カットフィルターの遮光膜は、本発明の感光性樹脂組成物を硬化して得られたものである以外、特に制限はない。本発明の遮光膜を備えた赤外線カットフィルターは、固体撮像装置に好適に用いることができる。
本発明の固体撮像装置は、本発明の硬化物を具備することを特徴とする。
本発明の固体撮像装置としては、本発明の感光性樹脂組成物を用いて形成される遮光性カラーフィルターや遮光膜等を有すること以外は特に制限されず、様々な構造をとる公知の固体撮像装置を挙げることができる。
赤外線カットフィルター及び固体撮像装置としては、例えば、特開2014-132333号公報や特開2014-132644号公報の請求項に記載のものが挙げられる。
本発明の液晶表示装置は、本発明の硬化物を具備することを特徴とする。
本発明の液晶表示装置としては、本発明の感光性樹脂組成物を用いて形成される遮光性カラーフィルターや絶縁膜を有すること以外は特に制限されず、様々な構造をとる公知の液晶表示装置を挙げることができる。
例えば、本発明の液晶表示装置が具備するTFT(Thin-Film Transistor)の具体例としては、アモルファスシリコン-TFT、低温ポリシリコン-TFT、酸化物半導体TFT等が挙げられる。本発明の硬化膜は電気特性に優れるため、これらのTFTに組み合わせて好ましく用いることができる。
また、本発明の液晶表示装置が取りうる液晶駆動方式としてはTN(Twisted Nematic)方式、VA(Vertical Alignment)方式、IPS(In-Plane-Switching)方式、FFS(Fringe Field Switching)方式、OCB(Optically Compensated Bend)方式などが挙げられる。
パネル構成においては、COA(Color Filter on Array)方式の液晶表示装置でも本発明の硬化膜を用いることができ、例えば、特開2005-284291号公報に記載の有機絶縁膜(115)や、特開2005-346054号公報に記載の有機絶縁膜(212)として用いることができる。
また、本発明の液晶表示装置が取りうる液晶配向膜の具体的な配向方式としてはラビング配向法、光配向法などが挙げられる。また、特開2003-149647号公報や特開2011-257734号公報に記載のPSA(Polymer Sustained Alignment)技術によってポリマー配向支持されていてもよい。
本発明の有機EL表示装置は、本発明の硬化物を具備することを特徴とする。
本発明の有機EL表示装置としては、本発明の感光性樹脂組成物を用いて形成される平坦化膜や層間絶縁膜を有すること以外は特に制限されず、様々な構造をとる公知の各種有機EL表示装置や液晶表示装置を挙げることができる。
例えば、本発明の有機EL表示装置が具備するTFT(Thin-Film Transistor)の具体例としては、アモルファスシリコン-TFT、低温ポリシリコン-TFT、酸化物半導体TFT等が挙げられる。本発明の硬化膜は電気特性に優れるため、これらのTFTに組み合わせて好ましく用いることができる。
MATHF:メタクリル酸テトラヒドロフラン-2-イル(合成品)
MAEVE:メタクリル酸1-エトキシエチル(和光純薬工業(株)製)
MACHOE:1-(シクロヘキシルオキシ)エチルメタクリレート(合成品)
MATHP:メタクリル酸テトラヒドロ-2H-ピラン-2-イル(新中村化学工業(株)製)
PHSEVE:p-ヒドロキシスチレンの1-エトキシエチルエーテル(合成品)
PHSTHF:p-ヒドロキシスチレンのテトラヒドロフラニルエーテル(合成品)
PHSt-Bu:p-ヒドロキシスチレンのt-ブチルエーテル(p-ヒドロキシスチレンに酸触媒下イソブテンを作用させる定法に沿って合成した。)
GMA:グリシジルメタクリレート(和光純薬工業(株)製)
OXE-30:メタクリル酸(3-エチルオキセタン-3-イル)メチル(大阪有機化学工業(株)製)
NBMA:n-ブトキシメチルアクリルアミド(三菱レイヨン(株)製)
GMA-MAA付加物:グリシジルメタクリレート(和光純薬工業(株)製)とアクリル酸(和光純薬工業(株)製)との付加反応を利用する定法に沿って合成した。
MOI-BM:メタクリル酸2-(O-[1’-メチルプロピリデンアミノ]カルボキシアミノ)エチル(昭和電工(株)製カレンズMOI-BM)
MAA:メタクリル酸(和光純薬工業(株)製)
MMA:メタクリル酸メチル(和光純薬工業(株)製)
St:スチレン(和光純薬工業(株)製)
DCPM:ジシクロペンタニルメタクリレート(日立化成工業(株)製)
HEMA:メタクリル酸2-ヒドロキシエチル(和光純薬工業(株)製)
PHS:p-ヒドロキシスチレン(和光純薬工業(株)製)
V-65:2,2’-アゾビス(2,4-ジメチルバレロニトリル)(和光純薬工業(株)製)
PGMEA:プロピレングリコールモノメチルエーテルアセテート(昭和電工(株)製メトキシプロピルアセテート)
また、MACHOEは、2-ジヒドロフランを対応する化合物に変更した以外、上記MATHFと同様の方法で合成した。
PHSEVEは、MAEVE合成法のメタクリル酸を4-ヒドロキシスチレンに変更し合成した。
PHSTHFは、MATHF合成法のメタクリル酸を4-ヒドロキシスチレンに変更し合成した。
3つ口フラスコにPGMEAを入れ、窒素雰囲気下において90℃に昇温した。その溶液にMATHF0.4モル当量、GMA0.55モル当量、MAA0.05モル当量、V-65(全単量体成分の合計100mol%に対して4mol%に相当)を溶解させ、2時間かけて滴下した。滴下終了後2時間撹拌し、反応を終了させた。それにより重合体P-1を得た。なお、PGMEAとその他の成分の合計量との比を60:40とした。すなわち、固形分濃度40%の重合体溶液を調製した。
使用するモノマーの種類等を下記表1に示す通りに変更した以外は、重合体P-1の合成と同様にして、他の重合体をそれぞれ合成した。
<特定樹脂1の合成>
三口フラスコに、ε-カプロラクトン 600.0部、2-エチル-1-ヘキサノール 22.8部を導入し、窒素を吹き込みながら、撹拌溶解した。モノブチル錫オキシド 0.1部を加え、100℃に加熱した。8時間後、ガスクロマトグラフィーにて、原料が消失したのを確認後、80℃まで冷却した。2,6-ジ-t-ブチル-4-メチルフェノール 0.1部を添加した後、2-メタクリロイルオキシエチルイソシアネート 27.2部を添加した。5時間後、1H-NMRにて原料が消失したのを確認後、室温(25℃)まで冷却し、固体状の前駆体M1を200部得た。化学構造がM1であることは、1H-NMR、IR、質量分析により確認した。
下記組成1を二本ロールにて高粘度分散処理を施し、分散物を得た。なお、高粘度分散処理の前にニーダーで30分混練した。
・チタンブラック:35部
(平均一次粒径75nm、三菱マテリアルズ(株)製13M-C)
・プロピレングリコールモノメチルエーテルアセテート(PGMEA):65部
・特定樹脂1のプロピレングリコールモノメチルエーテルアセテート30質量%溶液:30部
-チタンブラックT-1の作製-
平均粒径15nmの酸化チタンMT-150A(商品名:テイカ(株)製)を100g、BET表面積300m2/gのシリカ粒子AEROGIL(登録商標)300/30(エボニック製)を25g、及び、分散剤Disperbyk190(商品名:ビックケミー社製)を100g秤量し、イオン電気交換水71gを加えてクラボウ(株)製MAZERSTAR KK-400Wを使用して、公転回転数1,360rpm、自転回転数1,047rpmにて20分間処理することにより均一な混合物水溶液を得た。この水溶液を石英容器に充填し、小型ロータリーキルン((株)モトヤマ製)を用いて酸素雰囲気中で920℃に加熱した後、窒素で雰囲気を置換し、同温度でアンモニアガスを100mL/minで5時間流すことにより窒化還元処理を実施した。終了後回収した粉末を乳鉢で粉砕し、Si原子を含み、粉末状の比表面積73m2/gのチタンブラックT-1〔チタンブラック粒子及びSi原子を含む被分散体〕を得た。
下記組成3に示す成分を、撹拌機(IKA社製EUROSTAR)を使用して、15分間混合し、分散物aを得た。
なお、以下に記載の高分子化合物(X1)は、特開2013-249417号公報の記載を参照して合成した。なお、高分子化合物(X1)の式中、xは30質量%、yは20質量%、zは50質量%であった。また、高分子化合物(X1)の重量平均分子量は30,000であり、酸価は60mgKOH/gであり、グラフト鎖の原子数(水素原子を除く。)は117であった。
・上記のようにして得られたチタンブラックT-1:25質量部
・高分子化合物(X1)のプロピレングリコールモノメチルエーテルアセテート30質量%溶液:25質量部
・プロピレングリコールモノメチルエーテルアセテート(PGMEA)(溶剤):50質量部
(分散条件)
・ビーズ径:φ0.05mm
・ビーズ充填率:65体積%
・ミル周速:10m/sec
・セパレーター周速:11m/s
・分散処理する混合液量:15.0g
・循環流量(ポンプ供給量):60kg/hour
・処理液温度:20~25℃
・冷却水:水道水 5℃
・ビーズミル環状通路内容積:2.2L
・パス回数:84パス
下記組成のカーボンブラック分散液を用いた。
・カーボンブラック(デグッサ社製、Nipex35):13.1%
・下記分散剤1:0.65%
・ポリマー(ベンジルメタクリレート/メタクリル酸=72/28モル比のランダム共重合物、分子量3.7万):6.72%
・プロピレングリコールモノメチルエーテルアセテート:79.53%
<感光性樹脂組成物の調製>
表2に記載の組成にて、配合し混合して均一な溶液とした後、0.2μmのポアサイズを有するポリエチレン製フィルターを用いてろ過して、実施例1の感光性樹脂組成物(固形分量:25%)を調製した。得られた感光性樹脂組成物を用い、後述する各種評価を行った。評価結果を後述の表2に示す。なお、表2の配合量の数値は固形分の質量部を表す。
実施例1における組成を、下記表2に記載の組成に変更した以外は、実施例1と同様の方法により、実施例2~15及び比較例1~7の感光性樹脂組成物をそれぞれ調製した。
得られた実施例1~15及び比較例1~7の各感光性樹脂組成物を用い、以下の評価を行った。評価結果を表3に示す。
実施例及び比較例において得られた各感光性樹脂組成物を、ガラス基板に任意の回転数でスピンコートし、溶剤除去後、250℃で1時間焼成して焼成膜(ベタ膜)をそれぞれ作製した。かかる焼成膜のOD値(Optical Density)を透過濃度計(BMT-1(サカタインクスエンジニアリング社製))にて測定した。また、膜厚を測定し、OD値を膜厚で除した数値(OD値/μm)を評価値とした。
評価値のランクは以下の通りである。
A・・・4.0以上
B・・・3.5以上4.0未満(これ以上が実用レベルである。)
C・・・3.0以上3.5未満
D・・・2.5以上3.0未満
E・・・2.5未満
光学濃度評価と同様に焼成膜を作製後、鉛筆硬度試験(JIS K5600-5-4(ISO/DIN 15184))を実施し、その鉛筆硬度を評価値とした。評価値のランクは以下の通りである。
A・・・5H以上
B・・・3~4H
C・・・1~2H(これ以上が実用レベルである。)
D・・・B~HB
E・・・2B以下
B-1:DTS-105(トリアリールスルホニウム塩、みどり化学(株)製)
B-2:CGI1397(BASFジャパン(株)製、下記の化合物)
B-3:PAI-101(みどり化学(株)製、下記の化合物)
B-4:下記の化合物
B-5:下記の化合物
特開2013-182077号公報の段落0239の記載の方法にしたがって合成した。
1-アミノ-2-ナフトール塩酸塩(東京化成工業(株)製)4.0gをN-メチルピロリドン(和光純薬工業(株)製)16gに懸濁させ、炭酸水素ナトリウム(和光純薬工業(株)製)3.4gを添加後、4,4-ジメチル-3-オキソ吉草酸メチル(和光純薬工業(株)製)4.9gを滴下し、窒素雰囲気下120℃で2時間加熱した。放冷後、反応混合液に水、酢酸エチルを添加して分液し、有機相を硫酸マグネシウムで乾燥し、ろ過、濃縮して粗B-5-2Aを得た。粗B-5-2Aをシリカゲルカラムクロマトグラフィー精製して、中間体B-5-2Aを1.7g得た。
B-5-2A(1.7g)とp-キシレン(6mL)を混合し、p-トルエンスルホン酸一水和物(和光純薬工業(株)製)0.23gを添加して140℃で2時間加熱した。放冷後、反応混合液に水、酢酸エチルを添加して分液し、有機相を硫酸マグネシウムで乾燥後、ろ過、濃縮して粗B-5-2Bを得た。
テトラヒドロフラン(THF)(2mL)と粗B-5-2B全量を混合し、氷冷下2M塩酸/THF溶液6.0mL、次いで亜硝酸イソペンチル(和光純薬工業(株)製)(0.84g)を滴下し、室温(25℃)まで昇温後2時間撹拌した。得られた反応混合物に水、酢酸エチルを添加して分液し、有機層を水で洗浄後、硫酸マグネシウムで乾燥し、ろ過、濃縮して中間体粗B-5-2Cを得た。
中間体粗B-5-2C全量をアセトン(10mL)と混合し、氷冷下でトリエチルアミン(和光純薬工業(株)製)(1.2g)、p-トルエンスルホニルクロリド(東京化成工業(株)製)(1.4g)を添加後、室温まで昇温して1時間撹拌した。得られた反応混合液に水、酢酸エチルを添加して分液し、有機相を硫酸マグネシウムで乾燥後、ろ過、濃縮して粗B-5を得た。粗B-5を冷メタノールでリスラリー後、ろ過、乾燥してB-5(1.2g)を得た。
なお、B-5の1H-NMRスペクトル(300MHz、CDCl3)は、δ=8.5-8.4(m,1H),8.0-7.9(m,4H),7.7-7.6(m,2H),7.6-7.5(m,1H),7.4(d.2H),2.4(s,3H),1.4(s,9H)であった。
C-2:PGME(プロピレングリコールモノメチルエーテル)(ダイセル化学(株)製)
C-3:シクロヘキサノン(三協化学(株)製)
C-4:シクロペンタノン(東京化成工業(株)製)
C-5:エチル-3-エトキシプロピオネート(長瀬産業(株)製、製品名エチル-3エトキシプロピオネート)
S-1:上記チタンブラック分散液A
S-2:上記カーボンブラック分散液
S-3:上記チタンブラック分散液B
E-1:γ-メタクリロキシプロピルトリメトキシシラン(KBM-503、信越化学工業(株)製)
E-2:ビス(トリエトキシシリルプロピル)テトラスルフィド(KBE-846、信越化学工業(株)製)
E-3:JER157S65(フェノールノボラック型エポキシ樹脂、(株)三菱ケミカルホールディングス製)
E-4:セロキサイド2021P(3’,4’-エポキシシクロヘキシルメチル 3,4-エポキシシクロヘキサンカルボキシレート、(株)ダイセル製)
E-5:デュラネート17B-60P(ブロックイソシアネート化合物、旭化成ケミカルズ(株)製)
E-6:DPHA(ジペンタエリスリトールヘキサアクリレート、日本化薬(株)製KAYARAD DPHA)
E-7:γ-メタクリロキシプロピルメチルジメトキシシラン(KBM-502、信越化学工業(株)製)
E-8:3-グリシドキシプロピルトリメトキシシラン(KBM-403、信越化学工業(株)製)
F-4:ジアザビシクロノネン(東京化成工業(株)製)
F-5:N-シクロヘキシル-N’-[2-(4-モルホリニル)エチル]チオ尿素(CMTU、下記化合物、東洋化成工業(株)製)
F-6:N,N-ジブチルアニリン(東京化成工業(株)製)
F-7:N,N-ジシクロヘキシルメチルアミン(和光純薬工業(株)製)
W-2:Megafac F-781F(DIC(株)製)
Z-2:下記構造のジブトキシアントラセン(増感剤、川崎化成工業(株)製)なお、Buはブチル基を表す。
<カラーフィルターの作製>
-ブラックマトリックスの形成-
実施例1で作製した感光性樹脂組成物を、洗浄したガラス基板にスリットコーターを用いて、塗布速度120mm/秒で塗布した。
次いで、ホットプレートを用いて、80℃で120秒間加熱(プリベーク処理)を行った後、プロキシミティ方式露光機(型番LE5565A、(株)日立ハイテクノロジーズ製)を用いて、50mJ/cm2で露光した。
その後、水酸化カリウム系現像液CDK-1(富士フイルムエレクトロニクスマテリアルズ(株)製)の1.0%現像液で50秒間シャワー現像し、純水で洗浄した。
次いで220℃のクリーンオーブンで40分間ポストベーク処理し、着色画素形成領域の開口が15μm×45μmで、ブラックマトリックスの厚みが1.2μmで、ブラックマトリックスの線幅が約5μmの格子状ブラックマトリックス基板を形成した。
特開2009-199066号公報の段落0173~0185に記載された方法にしたがって、赤色用感光性着色組成物塗布液CR-1、緑色用感光性着色組成物塗布液CG-1、及び、青色用感光性着色組成物塗布液CB-1を調製した。
得られた赤色用感光性着色組成物塗布液CR-1を、前記ブラックマトリックス基板のブラックマトリックス形成面側に、塗布した。具体的には、ブラックマトリックス形成の場合と同様に、ポストベーク後の感光性着色組成物層の層厚が約2.1μmとなるようにスリットとブラックマトリックス基板間との間隔、吐出量を調節して、塗布速度100mm/秒で塗布した。
次いで、ホットプレートを用いて、100℃で120秒間加熱を行った後、プロキシミティ方式露光機を用いて、90mJ/cm2で露光した。
その後、水酸化カリウム系現像液CDK-1(富士フイルムエレクトロニクスマテリアルズ(株)製)の1.0%現像液でシャワー圧を0.2MPaに設定して、45秒現像し、純水で洗浄した。
次いで220℃のクリーンオーブンで30分間ポストベーク処理し、熱処理済みの赤色画素を形成した。
得られたカラーフィルターにおけるブラックマトリックスは、薄膜でありながら遮光性に優れ、かつ表面硬度が高いものであった。
実施例1で作製した感光性樹脂組成物を実施例2~15で作製した感光性樹脂組成物にそれぞれ変更した以外は、実施例16と同様にして、カラーフィルターをそれぞれ作製した。
得られたカラーフィルターにおけるブラックマトリックスはそれぞれ、薄膜でありながら遮光性に優れ、かつ表面硬度が高いものであった。
実施例1における組成を、下記表4に記載の組成に変更した以外は、実施例1と同様の方法により、実施例31~36の感光性樹脂組成物をそれぞれ調製した。
上記実施例31~36の組成物について、実施例1の組成物に対して行った試験と同様の方法にて鉛筆硬度試験(JIS K5600-5-4(ISO/DIN 15184))を実施し、その鉛筆硬度を評価値とした。評価値のランクは以下の通りである。
A・・・5H以上
B・・・3~4H
C・・・1~2H(これ以上が実用レベルである。)
D・・・B~HB
E・・・2B以下
評価結果を表5に示す。
なお、いずれの組成物も、遮光性に優れた硬化膜が得られた。
実施例31の感光性樹脂組成物において、チタンブラックの含有量を、チタンブラック顔料分散液の固形分(顔料及び分散剤)の増減、及び、重合体Aの添加量の増減で調整し、後述する表6に記載の感光性樹脂組成物中の全固形分に対する濃度に変更して、更に溶剤の量は固形分25%となるようにした以外は、実施例31と同様にして、チタンブラックの含有量の異なる6種の感光性樹脂組成物をそれぞれ調製した。
得られた感光性樹脂組成物を使用して、下記解像性評価を行った。評価結果をまとめて表6に示す。
ガラス基板(コーニング1737、コーニング社製)を0.5質量%NaOH水で超音波洗浄した後、水洗、脱水ベーク(200℃/20分)を行った。
続いて、洗浄したガラス基板上にレジスト液をスピン塗布し、ホットプレートにて80℃60秒のプリベークを行った。なお、露光後におけるレジスト膜のOD値(吸光度)が3となるよう膜厚を調整している。
その後、線幅50μmのラインアンドスペースパターンを有するマスクを通じ、露光装置UX3100-SR(ウシオ電機(株)製)を使用して、200mJ/cm2(波長365nm)の露光量で上記レジスト塗布基板を露光した。
露光後、ホットプレートにて80℃60秒の露光後加熱(PEB)を行った。
露光後加熱の後、テトラメチルアンモニウムヒドロキシド(THAH)2.38%の現像液(富士フイルムエレクトロニクスマテリアルズ(株)製)を使用して、25℃で、30、40、50、60、70、80又は90秒間の各条件によりパドル現像を行った。その後、流水で30秒間リンスした。
現像後の上記レジスト塗布基板を、200℃5分(ホットプレート)でポストベークした。
評価基準を以下に示す。
A:60秒以内の現像で解像(50μmの細線の抜けが得られる。)する。
B:90秒以内の現像で解像する。
C:90秒以内の現像でも解像しない。
上記実施例31の組成物を、赤外線カットフィルターの入射面にスピンコート法によりコーター・デベロッパーACT(東京エレクトロン(株)製)を用いて塗布した後、100℃のホットプレートを用いて120秒間加熱処理(プリベーク)を行うことにより、塗布膜を形成した。次いで、i線ステッパー露光装置FPA-3000i5+(キヤノン(株)製)を使用して、マスクを通して200mJ/cm2の露光量でパターン露光した。
その後、照射された塗布膜が形成されている赤外線カットフィルターに対して、コーター・デベロッパーACTを使用して、現像液としてテトラメチルアンモニウムヒドロキサイドの0.3質量%水溶液を用いて、室温にて60秒間パドル現像した。現像後、スピンシャワーにて20秒間純水でリンスを行い、更に純水にて水洗を行った後、200℃のホットプレートを用いて300秒間加熱処理(ポストベーク)を行うことにより、赤外線カットフィルター上に7.0mm×5.0mm、幅0.7mmの額縁パターンの黒色層を形成し、額縁パターン付き赤外線カットフィルターを作製した。
得られた赤外線カットフィルターにおける黒色層は、遮光性に優れ、かつ表面硬度が高いものであり、また、製造時の解像性にも優れるものであった。
Claims (16)
- (成分A)下記(1)及び(2)の少なくとも一方を満たす重合体を含む重合体成分、
(1)(a1)酸基が酸分解性基で保護された基を有する構成単位及び(a2)架橋性基を有する構成単位、を有する重合体、
(2)(a1)酸基が酸分解性基で保護された基を有する構成単位を有する重合体、及び、(a2)架橋性基を有する構成単位を有する重合体、
(成分B)光酸発生剤、
(成分C)溶剤、並びに、
(成分S)チタンブラック、を含有することを特徴とする
感光性樹脂組成物。 - 前記架橋性基が、エポキシ基、オキセタニル基、-NH-CH2-OR1、エチレン性不飽和基、及び、ブロックイソシアネート基よりなる群から選ばれた少なくとも1種である、請求項1に記載の感光性樹脂組成物。
なお、R1は、炭素数1~20のアルキル基を表す。 - 感光性樹脂組成物中の架橋性基当量が、有機固形分1gあたり、250~1,000である、請求項1又は2に記載の感光性樹脂組成物。
- (成分D)分散剤を更に含有する、請求項1~3のいずれか1項に記載の感光性樹脂組成物。
- 成分Sの含有量が、感光性樹脂組成物の全固形分に対し、40~80質量%である、請求項1~4のいずれか1項に記載の感光性樹脂組成物。
- (成分E)架橋剤を更に含有する、請求項1~5のいずれか1項に記載の感光性樹脂組成物。
- 成分Bが、オキシムスルホネート化合物である、請求項1~6のいずれか1項に記載の感光性樹脂組成物。
- 少なくとも工程(a)~(c)をこの順に含むことを特徴とする硬化物の製造方法。
(a)請求項1~7のいずれか1項に記載の感光性樹脂組成物を基板上に塗布する塗布工程
(b)塗布された樹脂組成物から溶剤を除去する溶剤除去工程
(c)溶剤が除去された樹脂組成物を熱処理する熱処理工程、又は、溶剤が除去された樹脂組成物に活性光線を照射する露光工程 - 少なくとも工程(1)~(4)をこの順に含むことを特徴とする樹脂パターン製造方法。
(1)請求項1~7のいずれか1項に記載の感光性樹脂組成物を基板上に塗布する塗布工程
(2)塗布された樹脂組成物から溶剤を除去する溶剤除去工程
(3)溶剤が除去された樹脂組成物を活性光線によりパターン状に露光する露光工程
(4)露光された樹脂組成物及び未露光の樹脂組成物を水性現像液により現像する現像工程 - 請求項8に記載の硬化物の製造方法、又は、請求項9に記載の樹脂パターン製造方法により得られた硬化物。
- 請求項1~7のいずれか1項に記載の感光性樹脂組成物を硬化してなる硬化膜。
- 遮光性カラーフィルターである、請求項11に記載の硬化膜。
- 請求項11又は12に記載の硬化膜を有する液晶表示装置。
- 請求項11又は12に記載の硬化膜を有する有機EL表示装置。
- 請求項11又は12に記載の硬化膜を有する赤外線カットフィルター。
- 請求項11又は12に記載の硬化膜を有する固体撮像装置。
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