WO2016052323A1 - ディスプレイ用支持基板、それを用いたカラーフィルターおよびその製造方法、有機el素子およびその製造方法、ならびにフレキシブル有機elディスプレイ - Google Patents
ディスプレイ用支持基板、それを用いたカラーフィルターおよびその製造方法、有機el素子およびその製造方法、ならびにフレキシブル有機elディスプレイ Download PDFInfo
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- WO2016052323A1 WO2016052323A1 PCT/JP2015/077070 JP2015077070W WO2016052323A1 WO 2016052323 A1 WO2016052323 A1 WO 2016052323A1 JP 2015077070 W JP2015077070 W JP 2015077070W WO 2016052323 A1 WO2016052323 A1 WO 2016052323A1
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- H—ELECTRICITY
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- H10K2102/301—Details of OLEDs
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions
- the present invention relates to a display support substrate, a color filter using the same, a manufacturing method thereof, an organic EL element and a manufacturing method thereof, and a flexible organic EL display.
- Organic film is more flexible than glass, has the characteristics of being hard to break and lightweight. Recently, studies for making a display flexible by forming a substrate of a flat panel display using an organic film have become active.
- the resin used for the organic film includes polyester, polyamide, polyimide, polycarbonate, polyethersulfone, acrylic, epoxy, and the like.
- polyimide has excellent mechanical properties such as high mechanical strength, wear resistance, dimensional stability, chemical resistance, and excellent electrical properties such as insulation, in addition to high heat resistance compared to other resins. Because of this, development of flexible substrates using polyimide films is underway.
- the flexible substrate examples include display substrates such as a flexible TFT (Thin Film Transistor) substrate, a flexible organic EL element substrate, and a flexible color filter substrate.
- the color filter is a member necessary for color display of an organic electroluminescence display device or a liquid crystal display device using white light as a light source.
- a three-color filter in which three colored pixels, that is, a red colored pixel, a green colored pixel, and a blue colored pixel are finely patterned, is generally used. In the three-color filter, white is obtained by additive color mixture of three colored pixels of red, green, and blue.
- the flat panel display substrate and color filter substrate exemplified above are required to have high light transmittance in the visible light region. Also, in order to prevent deterioration in alignment accuracy due to heating when forming display elements and light receiving elements such as TFTs and color filters, it is required that the coefficient of linear thermal expansion (CTE) is low and the substrate does not warp. In addition, low birefringence is required in order to prevent color misregistration when viewed from an oblique direction and to suppress external light reflection when a circularly polarizing film is used.
- CTE coefficient of linear thermal expansion
- a polyimide composed of fluorine-containing and / or alicyclic acid dianhydride and fluorine-containing and / or alicyclic diamine is disclosed (for example, patent document). 1 to 4).
- a shape retention layer is laminated on the opposite side of the high CTE layer laminated on the low CTE layer, and it occurs on both sides of the low CTE layer.
- a method for canceling the stress to suppress the warpage of the substrate is disclosed (for example, see Patent Document 5).
- the polyimide produced by the specific method using the specific acid dianhydride and diamine is disclosed as a flexible substrate which makes low CTE and low birefringence compatible. (For example, see Patent Document 6)
- an organic EL element when an organic EL element is produced using such a polyimide resin, it is common to form a silicon oxide or nitride as a gas barrier film on the polyimide.
- the CTE of silicon oxide and nitride is as low as about 3.5 ppm / ° C. Therefore, in such a case, in addition to the above-described problems, cracks and wrinkles occur in the gas barrier film in the subsequent heating process due to the CTE difference between the polyimide resin and the gas barrier film, and the organic EL element is likely to deteriorate. There is a problem.
- Patent Document 6 discloses a method for obtaining a polyimide film that achieves both low CTE and low birefringence using a specific technique using a specific acid anhydride and diamine, but the monomer is limited. Therefore, there is a problem that the degree of freedom in polymer design is slightly low.
- low-molecular compounds imidizing agent, dehydration catalyst
- these compounds may cause degassing in the heating process at the time of module production and may cause defects. .
- An object of the present invention is to provide a display supporting substrate.
- the present invention is a display support substrate having a film B containing a polysiloxane resin on at least one side of a film A containing a polyimide resin, wherein the film B contains inorganic oxide particles. It is a substrate.
- a support substrate for a display can be provided.
- the present invention is a display support substrate having a film B containing a polysiloxane resin on at least one surface of a film A containing a polyimide resin, wherein the film B contains inorganic oxide particles. It is.
- the structure having the film B containing the polysiloxane resin on at least one surface of the film A containing the polyimide resin used for the display support substrate of the present invention is referred to as a “resin laminate”.
- the display support substrate includes not only a substrate that supports the display itself, but also any support substrate that is used for members constituting the display.
- any support substrate that is used for members constituting the display For example, black matrix, support substrate for color filter having colored pixels, support substrate for organic EL element having TFT, electrode, organic layer, etc., support substrate for electronic paper having electrode, ink layer, etc., electrode, phosphor, etc.
- the films containing the polyimide resin has a film containing the polysiloxane resin (film B), and the film containing the polysiloxane resin is an inorganic oxide. Since the material particles are included, even if the CTE of the polyimide is large, the CTE can be lowered as a laminate.
- the display support substrate preferably has a linear expansion coefficient of 40 ppm / ° C. or less. In this case, as described later, a color filter is formed on the side of the display support substrate opposite to the side in contact with the support substrate.
- a gas barrier layer is formed to form an EL element, a high-definition color filter or an organic EL element in which deterioration of the element is suppressed without deterioration of processing accuracy and generation of cracks in the gas barrier layer is produced. Is possible.
- the reflection can be suppressed preferentially, and the visibility of the display can be improved.
- the thickness of the film A is preferably 5.0 ⁇ m or more and 20 ⁇ m or less, and the thickness of the film B is 0.2 ⁇ m or more and 3.0 ⁇ m or less. Preferably there is. From the viewpoint of transparency, the thickness of the entire laminate is preferably 5.0 ⁇ m or more and 20 ⁇ m or less.
- the film thickness of the film A is more preferably 5.0 ⁇ m or more and 15 ⁇ m or less, and further preferably 5 ⁇ m or more and 10 ⁇ m or less. By being in the said range, the transmission color tone of the support substrate for a display becomes more favorable.
- the film thickness of the film B is more preferably 0.4 ⁇ m or more as the lower limit, and further preferably 2.0 ⁇ m or less as the upper limit. By being within the above film thickness range, it is possible to produce a resin film laminate having a lower CTE, no warping of the substrate, and particularly excellent transparency and crack resistance.
- the film thickness can be measured by observing the cross section with a scanning electron microscope (SEM).
- SEM scanning electron microscope
- five measurement points are determined at intervals of 1 mm in the cross-sectional direction of the laminate, and the thickness of each layer is measured.
- the transparency of the resin laminate in the present invention is not particularly limited, but when the substrate is required to be transparent like a color filter or a see-through display, the resin laminate is preferably transparent.
- transparent as used herein means that the visible light transmittance at a wavelength of 400 nm is 65% or more in the resin laminate. By being transparent in the visible light region, it can be effectively used for flexible display substrates and the like that require high transparency. More preferably, the visible light transmittance at a wavelength of 400 nm is 75% or more.
- the visible light transmittance can be measured by forming the resin film laminate of the present invention on a glass substrate and using an ultraviolet-visible spectrophotometer.
- the polyimide resin contained in the film A is not particularly limited, and generally, a polyimide resin represented by the following general formula (11) can be used. This can be obtained by, for example, imide ring closure (imidation reaction) of a polyimide precursor resin represented by the following general formula (12). It does not specifically limit as a method of imidation reaction, Thermal imidation and chemical imidation are mentioned. Among these, thermal imidization is preferable from the viewpoint of heat resistance of the polyimide resin film and transparency in the visible light region.
- R 2 represents a tetravalent organic group
- R 3 represents a divalent organic group
- X 1 and X 2 each independently represent a hydrogen atom, a monovalent organic group having 1 to 10 carbon atoms, or a monovalent alkylsilyl group having 1 to 10 carbon atoms.
- Polyimide precursor resins such as polyamic acid, polyamic acid ester, and polyamic acid silyl ester can be synthesized by a reaction between a diamine compound and an acid dianhydride or a derivative thereof.
- the derivatives include tetracarboxylic acids of the acid dianhydrides, mono-, di-, tri-, or tetra-esters of the tetracarboxylic acids, acid chlorides, and the like, and specifically include methyl groups, ethyl groups, and n-propyl.
- the reaction method of the polymerization reaction is not particularly limited as long as the target polyimide precursor resin can be produced, and a known reaction method can be used.
- a predetermined amount of all the diamine component and solvent are charged and dissolved in a reactor, and then a predetermined amount of acid dianhydride component is charged and stirred at room temperature to 80 ° C. for 0.5 to 30 hours. The method of doing is mentioned.
- the acid dianhydride is not particularly limited, and examples thereof include aromatic acid dianhydrides, alicyclic acid dianhydrides, and aliphatic acid dianhydrides.
- Aromatic dianhydrides include 4,4′-oxydiphthalic anhydride, pyromellitic dianhydride, 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride, 2,2-bis ( 4- (3,4-dicarboxyphenoxy) phenyl) propane dianhydride, 2,3,3 ′, 4′-biphenyltetracarboxylic dianhydride, 2,2 ′, 3,3′-biphenyltetracarboxylic acid Dianhydride, 3,3 ′, 4,4′-terphenyltetracarboxylic dianhydride, 3,3 ′, 4,4′-oxyphthalic dianhydride, 2,3,3 ′, 4′-oxyphthale Acid dianhydride, 2,3,2 ′, 3′-oxyphthalic dianhydride, diphenylsulfone-3,3 ′, 4,4′-tetracarboxylic dianhydride, benzophenone-3,3 ′,
- Examples of the alicyclic acid dianhydride include 1,2,3,4-cyclobutanetetracarboxylic dianhydride, 1,2,4,5-cyclohexanetetracarboxylic dianhydride, 1,2,3,4- Cyclopentanetetracarboxylic dianhydride, 1,2,3,4-tetramethyl-1,2,3,4-cyclobutanetetracarboxylic dianhydride, 1,2-dimethyl-1,2,3,4- Cyclobutanetetracarboxylic dianhydride, 1,3-dimethyl-1,2,3,4-cyclobutanetetracarboxylic dianhydride, 1,2,3,4-cycloheptanetetracarboxylic dianhydride, 2,3 , 4,5-tetrahydrofurantetracarboxylic dianhydride, 3,4-dicarboxy-1-cyclohexylsuccinic dianhydride, 2,3,5-tricarboxycyclopentylacetic dianhydride, 3,4
- aliphatic dianhydride examples include 1,2,3,4-butanetetracarboxylic dianhydride, 1,2,3,4-pentanetetracarboxylic dianhydride, and derivatives thereof. It is not limited to these.
- aromatic acid dianhydrides alicyclic acid dianhydrides, or aliphatic acid dianhydrides can be used alone or in combination of two or more.
- pyromellitic dianhydride, 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride, 3,3 ′ from the viewpoint of being commercially available and easy to obtain and from the viewpoint of reactivity 4,4′-oxyphthalic dianhydride, 2,2-bis (3,4-dicarboxyphenyl) hexafluoropropane dianhydride, 2,2′-bis [(dicarboxyphenoxy) phenyl] propane dianhydride 2,3,6,7-naphthalenetetracarboxylic dianhydride, 1,2,4,5-cyclohexanetetracarboxylic dianhydride, 3,3 ′, 4,4′-dicyclohexyltetracarboxylic dianhydride Anhydride, 1,2,3,4-cyclobutanetetracarboxylic dianhydride, 4,4'-oxydiphthalic anhydride, 2,2-bis (4- (3,4-dicarboxyphenoxy)
- the diamine is not particularly limited, and examples thereof include aromatic diamine compounds, alicyclic diamine compounds, and aliphatic diamine compounds.
- aromatic diamine compounds examples include 3,4'-diaminodiphenyl ether, 4,4'-diaminodiphenyl ether, 3,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, 3,3'-diaminodiphenyl sulfone, 4'-diaminodiphenylsulfone, 4,4'-diaminodiphenylsulfone, 3,4'-diaminodiphenylsulfide, 4,4'-diaminodiphenylsulfide, 1,4-bis (4-aminophenoxy) benzene, benzidine 2,2'-bis (trifluoromethyl) benzidine, 3,3'-bis (trifluoromethyl) benzidine, 2,2'-dimethylbenzidine, 3,3'-dimethylbenzidine, 2,2'3,3 '-Tetramethylbenzidine, 2,2'-d
- Examples of the alicyclic diamine compound include cyclobutane diamine, isophorone diamine, bicyclo [2,2,1] heptane bismethylamine, tricyclo [3,3,1,13,7] decane-1,3-diamine, 1,2 -Cyclohexyl diamine, 1,3-cyclohexyl diamine, 1,4-cyclohexyl diamine, trans-1,4-diaminocyclohexane, 4,4'-diaminodicyclohexyl methane, 3,3'-dimethyl-4,4'- Diaminodicyclohexylmethane, 3,3′-diethyl-4,4′-diaminodicyclohexylmethane, 3,3 ′, 5,5′-tetramethyl-4,4′-diaminodicyclohexylmethane, 3,3 ′, 5,5 '-Tetraethyl-4,4'-di
- Aliphatic diamine compounds include ethylenediamine, 1,3-diaminopropane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,7-diaminoheptane, 1,8-diaminooctane
- Alkylene diamines such as 1,9-diaminononane and 1,10-diaminodecane
- ethylene glycol diamines such as bis (aminomethyl) ether, bis (2-aminoethyl) ether, bis (3-aminopropyl) ether
- siloxanes such as 1,3-bis (3-aminopropyl) tetramethyldisiloxane, 1,3-bis (4-aminobutyl) tetramethyldisiloxane, ⁇ , ⁇ -bis (3-aminopropyl) polydimethylsiloxane
- diamine
- aromatic diamines alicyclic diamines, or aliphatic diamines can be used alone or in combination of two or more.
- the polyimide resin of the display support substrate used for color filters, touch screens, etc. is required to have heat resistance, low water absorption and high transparency in the visible light region. It is preferable that the component has a trifluoromethyl group or an alicyclic monomer component as a bulky fluorine substituent. That is, it is preferable that the polyimide resin has at least one group selected from a trifluoromethyl group and an alicyclic hydrocarbon group. Moreover, it is preferable to have a trifluoromethyl group in the acid dianhydride or diamine component in order to impart low water absorption.
- the trifluoromethyl group-containing monomer and the alicyclic monomer component may be used for either the acid dianhydride and the diamine component, or may be used for one of them, but may be used for the diamine component from the viewpoint of availability of the monomer. preferable.
- it has at least one group selected from a trifluoromethyl group or an alicyclic hydrocarbon group with respect to the total amount of diamine residues contained in the polyimide resin. It is preferable that 50 mol% or more of diamine residues are contained.
- ODPA 4,4′-oxydiphthalic anhydride
- BPDA 4,4′-biphenyltetracarboxylic dianhydride
- 6FDA 4,4 ′-(hexafluoro) Isopropylidene) diphthalic anhydride
- BSAA 2,2-bis (4- (3,4-dicarboxyphenoxy) phenyl) propane dianhydride
- CBDA 1,2,4,5-cyclohexanetetracarboxylic dianhydride
- PMDA-H 1,2,4,5-cyclohexanetetracarboxylic dianhydride
- diamine examples include 2,2-bis [3- (3-aminobenzamido) -4-hydroxyphenyl] hexafluoropropane (HFHA), trans-1,4-diaminocyclohexane (t-DACH), 2,2 ′. It preferably contains bis (trifluoromethyl) benzidine (TFMB).
- the polyimide resin of the support substrate for display used in the organic EL element is required to have heat resistance and low water absorption.
- acid dianhydrides in this case, 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride (BPDA), 4,4′-oxydiphthalic anhydride (ODPA), 1,2,4,5 -Cyclohexanetetracarboxylic dianhydride (PMDA-H), 2,2-bis (4- (3,4-dicarboxyphenoxy) phenyl) propane dianhydride (BSAA), 4,4 '-(hexafluoroisopropyl It is preferable to include (redene) diphthalic anhydride (6FDA) and 1,2,3,4-cyclobutanetetracarboxylic dianhydride (CBDA).
- 6FDA diphthalic anhydride
- CBDA 1,2,3,4-cyclobutanetetracarboxylic dianhydride
- diamine examples include 4,4′-diaminodiphenyl ether and p-phenylenediamine.
- 3,3′-dimethylbenzidine, 2,2-bis [3- (3-aminobenzamido) -4-hydroxyphenyl] hexafluoropropa (HFHA) they are preferable to include hexane trans-1,4 Jiaminoshikuro, 2,2'-bis (trifluoromethyl) benzidine (TFMB).
- TFMB trifluoromethyl benzidine
- ODPA 4,4′-oxydiphthalic anhydride
- BPDA 4,4′-biphenyltetracarboxylic dianhydride
- BSAA 2,2-bis (4- (3,4-Dicarboxyphenoxy) phenyl) propane dianhydride
- ODPA 4,4′-oxydiphthalic anhydride
- 6FDA 4,4 ′-(hexafluoroisopropylidene) diphthalic anhydride
- CBDA 1,2,3,4-cyclobutanetetracarboxylic dianhydride
- diamines examples include 2,2-bis [3- (3-aminobenzamide) -4-hydroxyphenyl] hexafluoropropane (HFHA), trans-1,4-diaminocyclohexane, 2,2′-bis (trifluoro).
- HFHA 2,2-bis [3- (3-aminobenzamide) -4-hydroxyphenyl] hexafluoropropane
- TFMB methyl
- Particularly preferred polyimide resins include polyimides having as a main component at least one of repeating structural units represented by the general formulas (1) to (3).
- R 1 is at least one group represented by (4) to (9).
- the main component means that the structural units represented by the general formulas (1) to (3) have 50 mol% or more of the total structural units of the polymer.
- the structure represented by the general formulas (1) to (3) at the diamine portion of the polyimide it is possible to improve the low water absorption, transparency and heat resistance of the polyimide resin.
- the aromatic or alicyclic acid anhydride represented by the general formulas (4) to (9) in the acid anhydride portion a polyimide resin having high heat resistance and good flexibility can be obtained. Is possible.
- a polyimide resin a polyimide mainly composed of a repeating structural unit represented by the general formula (10) can be given.
- R 1 is at least one group represented by (4) to (9).
- the main component means that the structural unit represented by the general formula (10) has 50 mol% or more of the total structural unit of the polymer.
- the polyimide and the polyimide precursor resin may be sealed at both ends with a terminal sealing agent in order to adjust the molecular weight to a preferable range.
- a terminal sealing agent examples include monoamines and monohydric alcohols.
- the terminal blocking agent that reacts with the diamine compound include acid anhydrides, monocarboxylic acids, monoacid chloride compounds, monoactive ester compounds, dicarbonates, and vinyl ethers.
- various organic groups can be introduce
- Monoamines used for the acid anhydride group end-capping agent include 5-amino-8-hydroxyquinoline, 4-amino-8-hydroxyquinoline, 1-hydroxy-8-aminonaphthalene, 1-hydroxy-7-amino.
- Examples of the monohydric alcohol used as the acid anhydride group terminal blocking agent include methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-pentanol, 3 -Pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 1-octanol, 2-octanol, 3-octanol, 1-nonanol, 2-nonanol, 1- Decanol, 2-decanol, 1-undecanol, 2-undecanol, 1-dodecanol, 2-dodecanol, 1-tridecanol, 2-tridecanol, 1-tetradecanol, 2-tetradecanol, 1-pentadecanol, 2- Pentadecanol, 1-hexadecanol, 2 He
- Examples of the acid anhydride, monocarboxylic acid, monoacid chloride compound and monoactive ester compound used as an amino group terminal blocking agent include phthalic anhydride, maleic anhydride, nadic anhydride, cyclohexanedicarboxylic anhydride, 3- Acid anhydrides such as hydroxyphthalic anhydride, 2-carboxyphenol, 3-carboxyphenol, 4-carboxyphenol, 2-carboxythiophenol, 3-carboxythiophenol, 4-carboxythiophenol, 1-hydroxy-8- Carboxynaphthalene, 1-hydroxy-7-carboxynaphthalene, 1-hydroxy-6-carboxynaphthalene, 1-hydroxy-5-carboxynaphthalene, 1-hydroxy-4-carboxynaphthalene, 1-hydroxy-3-carboxynaphthalene, 1 Hydroxy-2-carboxynaphthalene, 1-mercapto-8-carboxynaphthalene, 1-mercapto-7-carboxynaphthalene, 1-mer
- dicarbonate compound used as the amino group terminal blocking agent examples include di-tert-butyl dicarbonate, dibenzyl dicarbonate, dimethyl dicarbonate, and diethyl dicarbonate.
- vinyl ether compounds used as amino-group end-capping agents include tert-butyl chloroformate, n-butyl chloroformate, isobutyl chloroformate, benzyl chloroformate, allyl chloroformate, ethyl chloroformate, and isopropyl chloroformate.
- Isocyanates such as chloroformates, butyl isocyanate, 1-naphthyl isocyanate, octadecyl isocyanate, phenyl isocyanate, butyl vinyl ether, cyclohexyl vinyl ether, ethyl vinyl ether, 2-ethylhexyl vinyl ether, isobutyl vinyl ether, isopropyl vinyl ether, n -Propyl vinyl ether, tert-butyl vinyl ether, benzyl vinyl ether and the like.
- Examples of other compounds used as the amino group-end blocking agent include benzyl chloroformate, benzoyl chloride, fluorenylmethyl chloroformate, 2,2,2-trichloroethyl chloroformate, allyl chloroformate, methanesulfonic acid chloride, Examples thereof include p-toluenesulfonic acid chloride and phenyl isocyanate.
- the introduction ratio of the acid anhydride group terminal sealing agent is preferably in the range of 0.1 to 60 mol%, particularly preferably 0.5 to 50 mol%, relative to the acid dianhydride component.
- the introduction ratio of the amino group terminal blocking agent is preferably in the range of 0.1 to 100 mol%, particularly preferably 0.5 to 70 mol%, relative to the diamine component.
- a plurality of different end groups may be introduced by reacting a plurality of end-capping agents.
- the end-capping agent introduced into the polyimide precursor resin or the polyimide resin can be easily detected by the following method. For example, by dissolving a polymer having an end capping agent dissolved in an acidic solution and decomposing it into an amine component and an acid anhydride component, which are constituent units of the polymer, this is measured by gas chromatography (GC) or NMR measurement, The end capping agent can be easily detected.
- the polymer in which the end-capping agent is introduced can be easily detected directly by pyrolysis gas chromatograph (PGC), infrared spectrum, 1 H NMR spectrum measurement and 13 C NMR spectrum measurement.
- PPC pyrolysis gas chromatograph
- the film A may contain a thermal crosslinking agent.
- a thermal crosslinking agent an epoxy compound, a compound having at least two alkoxymethyl groups or methylol groups are preferable. By having at least two of these groups, a crosslinked structure is formed by a condensation reaction with the resin and the same kind of molecules, and the mechanical strength and chemical resistance of the cured film after heat treatment can be improved.
- Preferred examples of the epoxy compound include, for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, propylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, polymethyl (glycidyloxypropyl), epoxy group-containing silicone such as siloxane, etc.
- the present invention is not limited to these at all.
- Epicron 850-S Epicron HP-4032, Epicron HP-7200, Epicron HP-820, Epicron HP-4700, Epicron EXA-4710, Epicron HP-4770, Epicron EXA-859CRP, Epicron EXA-1514 Epicron EXA-4880, Epicron EXA-4850-150, Epicron EXA-4850-1000, Epicron EXA-4816, Epicron EXA-4822 (trade name, manufactured by Dainippon Ink & Chemicals, Inc.), Recare Resin BEO-60E, Recare Resin BPO-20E, Rica Resin HBE-100, Portugal Resin DME-100 (above trade name, Shin Nippon Rika Co., Ltd.), EP-4003S, EP-4000S (above trade name, Adeka Co., Ltd.), PG-10 CG-500, EG-200 (above trade name, manufactured by Osaka Gas Chemical Co., Ltd.), NC-3000, NC-6000 (above trade name, manufactured by Nippon Meth
- Examples of the compound having at least two alkoxymethyl groups or methylol groups include DML-PC, DML-PEP, DML-OC, DML-OEP, DML-34X, DML-PTBP, DML-PCHP, DML-OCHP, and DML.
- the thermal crosslinking agent is preferably contained in an amount of 0.01 to 50 parts by weight with respect to 100 parts by weight of the resin.
- a coupling agent such as a silane coupling agent or a titanium coupling agent can be added to improve adhesion to the substrate.
- the coupling agent is preferably contained in an amount of 0.1 to 10 parts by weight with respect to 100 parts by weight of the resin.
- the film A may contain an inorganic filler.
- the inorganic filler include silica fine particles, alumina fine particles, titania fine particles, zirconia fine particles, and the like.
- the shape of the inorganic filler is not particularly limited, and examples thereof include a spherical shape, an elliptical shape, a flat shape, a rod shape, and a fiber shape.
- the contained inorganic filler preferably has a small particle size in order to prevent light scattering.
- the average particle diameter is 0.5 to 100 nm, preferably in the range of 0.5 to 30 nm, and the inorganic filler is preferably contained in 1 to 100 parts by weight with respect to 100 parts by weight of the resin.
- the polysiloxane resin contained in the film B is not particularly limited.
- the polysiloxane resin composition used for forming the film B is non-photosensitive or positive photosensitive, those having a phenyl group or a naphthyl group are preferable from the viewpoint of storage stability of the coating liquid, and from the viewpoint of chemical resistance. Those having an epoxy group or amino group are preferred.
- the polysiloxane resin composition used for forming the film B is negative photosensitive, those having a phenyl group or a naphthyl group are preferable from the viewpoint of storage stability of the coating liquid, and from the viewpoint of curability, Those having a (meth) acrylic group or vinyl group are preferred, and those having a carboxyl group or a phenolic hydroxyl group are preferred from the viewpoint of pattern processability.
- a method for synthesizing a polysiloxane resin a method of hydrolyzing and condensing an organosilane compound is common.
- organosilane compound used for the synthesis of polysiloxane include methyltrimethoxysilane, methyltriethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, hexyltrimethoxysilane, octadecyltrimethoxysilane, octadecyltriethoxysilane, and phenyl.
- the hydrolysis reaction conditions of the organosilane compound may be appropriately set. For example, after adding an acid catalyst and water to the organosilane compound in a solvent over 1 to 180 minutes, the reaction is performed at room temperature to 110 ° C. for 1 to 180 minutes. It is preferable to make it. By performing the hydrolysis reaction under such conditions, a rapid reaction can be suppressed.
- the reaction temperature is preferably 30 to 105 ° C.
- the hydrolysis reaction is preferably performed in the presence of an acid catalyst.
- the acid catalyst an acidic aqueous solution containing formic acid, acetic acid or phosphoric acid is preferable.
- the content of these acid catalysts is preferably 0.1 to 5 parts by weight with respect to 100 parts by weight of the total organosilane compound used during the hydrolysis reaction. By making content of an acid catalyst into the said range, it can control easily so that a hydrolysis reaction may progress sufficiently and necessary.
- As conditions for the condensation reaction it is preferable to obtain a silanol compound by hydrolysis of an organosilane compound, and then heat the reaction solution as it is at 50 ° C. to the boiling point of the solvent for 1 to 100 hours. In order to increase the degree of polymerization of the polysiloxane, reheating or a base catalyst may be added. Further, after the hydrolysis reaction, an appropriate amount of the produced alcohol or the like may be distilled and removed by heating and / or decompression as necessary, and an optional solvent may be added thereafter.
- the weight average molecular weight (Mw) of the polysiloxane resin contained in the film B is preferably 1000 to 100,000 in terms of polystyrene measured by GPC. By setting Mw within the above range, coating characteristics and solubility in a developing solution when forming a pattern are improved.
- the film B containing a polysiloxane resin contains inorganic oxide particles.
- the CTE of the film B can be lowered, and by forming the film B on at least one of the films A, the CTE of the resin laminate can be lowered.
- the number average particle diameter of the inorganic oxide particles is preferably 1 to 200 nm, and more preferably 1 to 70 nm in order to obtain a cured film with high transmittance.
- the number average particle diameter of the inorganic oxide particles can be calculated as follows. The surface of the film B is observed using a SEM (scanning electron microscope) at a magnification of 10,000 times, and the image of the particles is linked to an image analyzer (for example, QTM900 manufactured by Cambridge Instrument). Data is acquired by changing the observation location, and when the total number of particles reaches 5000 or more, the following numerical processing is performed, and the number average diameter d obtained thereby is defined as the average particle diameter (diameter).
- di is the equivalent circular diameter of the particle (the diameter of a circle having the same area as the cross-sectional area of the particle), and N is the number.
- inorganic oxides are exemplified and are not particularly limited, but preferably silicon oxide (silica), hollow silica, aluminum oxide (alumina), titanium oxide, antimony oxide, zinc oxide, tin oxide, zirconium oxide. Etc. are used. Of these, silicon dioxide is preferred from the viewpoints of transparency when dispersed in a polysiloxane resin, CTE reduction, price, and availability.
- inorganic oxides are appropriately selected from one or more.
- the form of the inorganic oxide to be added is not particularly limited, but a form such as powder or sol is preferable.
- the inorganic oxide particles can be pulverized or dispersed using a disperser such as a bead mill by procuring an appropriate nanoparticle powder.
- a disperser such as a bead mill by procuring an appropriate nanoparticle powder.
- commercially available nanoparticle powders include REA200, RA200SH, RA200H (silica; manufactured by Nippon Aerosil Co., Ltd.), T-BTO-020RF (barium titanate; manufactured by Toda Kogyo Co., Ltd.), UEP-100 (zirconium oxide; 1st rare element chemical industry) or STR-100N (titanium oxide; Sakai Chemical Industry Co., Ltd.). It can also be procured as a dispersion.
- “through rear” 4110 which is a hollow silica particle having a number average particle diameter of 60 nm may be mentioned.
- silicon oxide-titanium oxide particles include “OPTRAIK” (registered trademark) TR-502, “OPTRAIK” TR-503, “OPTRAIK” TR-504, “OPTRAIK” TR-513, “OPTRAIK” “TR-520", “Optlake” TR-527, “Optlake” TR-528, “Optlake” TR-529, “Optlake” TR-544 or “Optlake” TR-550 Kogyo Co., Ltd.).
- SZR-M or SZR-K both manufactured by Sakai Chemical Co
- the content of the inorganic oxide particles is not particularly limited, but is preferably in the range of 20 to 80% by weight in the film B. Further, from the viewpoint of crack resistance, 20 to 65% by weight is more preferable. When the content is within this range, the occurrence of cracks in the film B is further suppressed, and the CTE of the laminate is further reduced.
- the solid content concentration of the polysiloxane resin composition used for forming the film B is preferably 5 to 35 wt% because the film thickness can be easily controlled.
- the polysiloxane resin composition may contain a photosensitizer.
- a resin laminate composed of the films A and B can be obtained by patterning in a single exposure and development. More specifically, the photosensitive polysiloxane resin composition for forming the film B ′ is applied on the film A ′ (a film containing the polyimide precursor resin), and the pattern processing is performed by exposing, developing and curing. Membrane A and membrane B can be obtained.
- the photosensitive resin composition is a positive type
- a quinonediazide compound is preferable as the component imparting photosensitivity.
- a mixture of a quinonediazide compound and an alkali-soluble resin forms a positive type by exposure and alkali development.
- quinonediazide compound a compound in which naphthoquinonediazidesulfonic acid is ester-bonded to a compound having a phenolic hydroxyl group is preferable, and hydrogen or the following formula (13) The compound which has a substituent represented by these is used.
- R 4 to R 6 may be the same or different and each represents an alkyl group having 1 to 10 carbon atoms, a carboxyl group, a phenyl group or a substituted phenyl group, or R 4 and R 5 , R 4 And R 6 or R 5 and R 6 may form a ring.
- R 4 to R 6 may be the same or different and each is a substituted or unsubstituted alkyl group having 1 to 10 carbon atoms, a carboxyl group, a phenyl group, or a substituted phenyl group. Indicates one of the following. Examples of the alkyl group include methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, t-butyl group, n-hexyl group, cyclohexyl group, n-heptyl group, and n-octyl group.
- examples of the ring formed by R 4 and R 5 , R 4 and R 6, or R 5 and R 6 include a cyclopentane ring, a cyclohexane ring, an adamantane ring, and a fluorene ring.
- the quinonediazide compound can be synthesized by a known esterification reaction between a compound having a phenolic hydroxyl group and naphthoquinonediazidesulfonic acid chloride.
- Examples of the compound having a phenolic hydroxyl group include the following compounds (manufactured by Honshu Chemical Industry Co., Ltd.).
- naphthoquinone diazide sulfonic acid examples include 4-naphthoquinone diazide sulfonic acid and 5-naphthoquinone diazide sulfonic acid. Since 4-naphthoquinonediazide sulfonic acid ester compound has absorption in the i-line (wavelength 365 nm) region, it is suitable for i-line exposure. Further, the 5-naphthoquinonediazide sulfonic acid ester compound has absorption in a wide wavelength range and is therefore suitable for exposure in a wide wavelength range.
- a 4-naphthoquinone diazide sulfonic acid ester compound or a 5-naphthoquinone diazide sulfonic acid ester compound depending on the wavelength to be exposed.
- a mixture of 4-naphthoquinone diazide sulfonic acid ester compound and 5-naphthoquinone diazide sulfonic acid ester compound may be used.
- the molecular weight of the naphthoquinone diazide compound is preferably 300 to 1500, and more preferably 350 to 1200. If the molecular weight of the naphthoquinone diazide compound is greater than 1500, pattern formation may not be possible with an addition amount of 4 to 10% by weight. On the other hand, when the molecular weight of the naphthoquinone diazide compound is less than 300, the colorless transparency may be lowered.
- the photosensitive polysiloxane composition is a negative type
- a photopolymerization initiator and a polyfunctional monomer are preferable as the component imparting photosensitivity.
- the photopolymerization initiator that is a component imparting photosensitivity is preferably one that decomposes and / or reacts with light (including ultraviolet rays and electron beams) to generate radicals.
- Examples of the photopolymerization initiator that decomposes and / or reacts with light to generate radicals include 2-methyl- [4- (methylthio) phenyl] -2-morpholinopropan-1-one, 2-dimethylamino- 2- (4-Methylbenzyl) -1- (4-morpholin-4-yl-phenyl) -butan-1-one, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone -1,2,4,6-trimethylbenzoylphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, bis (2,6-dimethoxybenzoyl)-(2,4,4-trimethyl Pentyl)
- ⁇ -aminoalkylphenone compounds acylphosphine oxide compounds, oxime ester compounds, benzophenone compounds having an amino group, or benzoic acid ester compounds having an amino group are preferable.
- Examples of the ⁇ -aminoalkylphenone compound include 2-methyl- [4- (methylthio) phenyl] -2-morpholinopropan-1-one, 2-dimethylamino-2- (4-methylbenzyl) -1- (4-morpholin-4-yl-phenyl) -butan-1-one or 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone-1.
- acylphosphine oxide compound examples include 2,4,6-trimethylbenzoylphenylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, or bis (2,6-dimethoxybenzoyl)-(2 , 4,4-trimethylpentyl) -phosphine oxide.
- oxime ester compounds include 1-phenyl-1,2-propanedione-2- (o-ethoxycarbonyl) oxime, 1,2-octanedione, 1- [4- (phenylthio) -2- (O— Benzoyloxime)], 1-phenyl-1,2-butadion-2- (o-methoxycarbonyl) oxime, 1,3-diphenylpropanetrione-2- (o-ethoxycarbonyl) oxime or ethanone, 1- [9- And ethyl-6- (2-methylbenzoyl) -9H-carbazol-3-yl]-, 1- (0-acetyloxime).
- benzophenone compound having an amino group examples include 4,4-bis (dimethylamino) benzophenone and 4,4-bis (diethylamino) benzophenone.
- benzoic acid ester compound having an amino group examples include ethyl p-dimethylaminobenzoate, 2-ethylhexyl-p-dimethylaminobenzoate, and ethyl p-diethylaminobenzoate.
- polyfunctional monomer that is a component imparting photosensitivity examples include diethylene glycol diacrylate, triethylene glycol diacrylate, tetraethylene glycol diacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, and trimethylol.
- Dimethylol-tricyclodecane diacrylate, dimethylol-tricyclodecane dimethacrylate, ethoxylated bisphenol A diacrylate or 9,9-bis [4- (2-acryloyloxyethoxy) Phenyl] fluorene are preferred.
- polyfunctional monomers include, for example, epoxy (meth) acrylates obtained by reacting polyfunctional epoxy compounds with (meth) acrylic acid.
- examples of the polyfunctional epoxy compound include the following compounds.
- the 3% weight loss temperature (Td3) of the film B used in the present invention is preferably 300 ° C. or higher. As a result, degassing is suppressed. For example, when a gas barrier film is formed on the resin laminate of the present invention, generation of cracks in the gas barrier film due to degassing is suppressed, and the display performance of the display is improved.
- the 3% weight loss temperature (Td3) mentioned here means that in the first stage, the temperature of the sample is raised to 150 ° C. at a rate of temperature rise of 3.5 ° C./min to remove adsorbed water from the sample, and in the second stage, When cooled to 40 ° C. at a rate of 10 ° C./min, the weight when cooled to 40 ° C. is measured, and when this measurement is performed at a temperature rising rate of 10 ° C./min in the third stage, the weight is 3 It means the temperature when it decreases by%.
- the transmission chromaticity coordinates of the resin layer of the membrane B are preferably in the ranges of 0.300 ⁇ x ⁇ 0.325 and 0.305 ⁇ y ⁇ 0.325. Thereby, the transmitted light visually recognized through the resin laminate can have a color tone close to white.
- the transmission chromaticity coordinates are more preferably in the ranges of 0.300 ⁇ x ⁇ 0.310 and 0.305 ⁇ y ⁇ 0.315.
- “transmission chromaticity coordinates” refers to the coordinates of transmission chromaticity in the CIE 1931 color system measured with a C light source and a two-degree field of view.
- the resin layer of the film B preferably contains a colorant so that the transmission chromaticity coordinates are in the above range.
- the colorant include organic pigments, inorganic pigments, and dyes. Blue pigments, blue dyes, purple pigments, or purple dyes are preferable for adjusting the color tone of transmitted light.
- blue pigments examples include C.I. I. Pigment Blue 1, 1: 2, 9, 14, 15, 15: 1, 15: 2, 15: 3, 15: 4, 15: 6, 16, 17, 19, 25, 27, 28, 29, 33, 35, 36, 56, 56: 1, 60, 61, 61: 1, 62, 63, 66, 67, 68, 71, 72, 73, 74, 75, 76, 78 or 79.
- I. Pigment Blue 15, 15: 1, 15: 2, 15: 3, 15: 4, 15: 6 or 60 is preferable.
- I. Pigment Blue 15: 6 is more preferable.
- Examples of purple pigments include C.I. I. Pigment Violet 1, 1: 1, 2, 2: 2, 3, 3: 1, 3: 3, 5, 5: 1, 14, 15, 16, 19, 23, 25, 27, 29, 31, 32, 37, 39, 42, 44, 47, 49 or 50.
- I. Pigment Violet 19 or 23 is preferred, and C.I. I. Pigment Violet 23 is more preferable.
- pigments may be subjected to surface treatment such as rosin treatment, acidic group treatment or basic treatment, if necessary, and pigment derivatives may be added as a dispersant.
- the form of the dye examples include those having any form of various dyes such as oil-soluble dyes, acid dyes, direct dyes, basic dyes, mordant dyes, and acid mordant dyes.
- the dye may be used in the form of a lake, or may be in the form of a salt-forming compound of a dye and a nitrogen-containing compound.
- the dye is not particularly limited as long as it is generally referred to as a dye.
- a dye triphenylmethane dye, diphenylmethane dye, quinoline dye, thiazine dye, thiazole dye, xanthene dye, flavin A dye, an auramine dye, a safranin dye, a phloxine dye, a methylene blue dye, a rhodamine dye or the like can be preferably used.
- Solvent Blue 2 3, 4, 5, 718, 25, 26, 35, 36, 37, 38, 43, 44, 45, 48, 51, 58, 59, 59: 1, 63, 64, 67, 68, 69, 70, 78, 79, 83, 94, 97, 98, 100, 101, 102, 104, 105, 111, 112, 122, 124, 128, 129, 132, 136, 137, 138, 139, 143, C. I. Acid Blue 22, 25, 40, 78, 78, 92, 113, 129, 167, 230, C.I. I. Basic Blue 3, 7, 9, 17, 41, 66, C.I. I.
- Solvent violet 2 8, 9, 11, 13, 14, 21, 21: 1, 26, 31, 36, 37, 38, 45, 46, 47, 48, 49, 50, 51, 55, 56, 57, 58, 59, 60, 61, C.I. I. Acid Red 52, 87, 91, 92, 94, 289 and the like.
- a basic dye it is preferably a salt-forming compound salted with an organic acid or perchloric acid.
- the organic acid is preferably an organic sulfonic acid or an organic carboxylic acid.
- naphthalene sulfonic acid such as tobias acid and perchloric acid are preferable in terms of resistance.
- chlorination was performed using a quaternary ammonium salt compound, a tertiary amine compound, a secondary amine compound, a primary amine compound, etc., and a resin component having these functional groups.
- a salt-forming compound or a salt-forming compound obtained by sulfonamidation to form a sulfonic acid amide compound is preferably a salt-forming compound or a salt-forming compound obtained by sulfonamidation to form a sulfonic acid amide compound.
- colorants may be used alone, but it is preferable to use two or more types in combination because it is easy to make transmitted light close to white.
- combinations of colorants include C.I. I. Pigment blue 15: 6, C.I. I. Pigment violet 23, C.I. A combination of colorants selected from the group consisting of I Acid Red 289 is preferred.
- the film B may contain other pigments or dyes in addition to these blue pigments, blue dyes, purple pigments or purple dyes in order to adjust the transmission color tone more accurately.
- examples of other pigments include red pigments, green pigments, yellow pigments, and orange pigments.
- the ratio of the colorant in the film B is preferably 0.0001 to 10% by weight, more preferably 0.001 to 1% by weight, based on the solid content, because the color tone can be easily adjusted.
- the film B contains a pigment derivative or a polymer dispersant as a dispersant.
- the method for producing the resin laminate of the present invention is not particularly limited, but preferably includes the following steps. (1) A step of obtaining a film A ′ by applying a resin solution containing a polyimide precursor resin on a support substrate. (2) A step of obtaining a film B ′ by applying a polysiloxane resin composition onto the film A ′. (3) A step of heating the film A ′ and the film B ′ to obtain a resin laminate.
- Application methods include, for example, a slit coating method, a spin coating method, a spray coating method, a roll coating method, a bar coating method, and the like, and these methods may be applied in combination.
- the solvent in the resin varnish is removed by drying.
- a hot plate an oven, an infrared ray, a vacuum chamber or the like is used.
- the object to be heated is heated by holding it directly on the plate or on a jig such as a proxy pin installed on the plate.
- a material of the proxy pin there are a metal material such as aluminum or sterylene, or a synthetic resin such as polyimide resin or “Teflon (registered trademark)”, and any proxy pin may be used.
- the height of the proxy pin varies depending on the size of the substrate, the type of the resin layer to be heated, the purpose of heating, etc. In this case, the height of the proxy pin is preferably about 2 to 12 mm.
- the heating temperature for drying varies depending on the type and purpose of the object to be heated, and it is preferably performed in the range of room temperature to 170 ° C. for 1 minute to several hours.
- the room temperature is usually 20-30 ° C., preferably 25 ° C.
- the polysiloxane resin composition is applied onto the film A ′ by the same method as that for the film A ′, and a drying process is performed to form the film B ′ on the film A ′.
- the resin coating film is heated in the range of 180 ° C. or more and 500 ° C. or less to obtain a resin laminate composed of the film A and the film B.
- a heating process may be performed after passing through a certain process after the said drying process.
- the atmosphere of the heating process is not particularly limited, and may be air or an inert gas such as nitrogen or argon.
- the atmosphere of the heating process is not particularly limited, and may be air or an inert gas such as nitrogen or argon.
- the mechanical properties are deteriorated such that the film A and the film B become brittle due to oxidative degradation.
- oxygen concentration management in the ppm order is often difficult at the manufacturing site.
- the resin film of the present invention is preferable if the oxygen concentration during heating is 5% or less because higher mechanical properties can be maintained.
- the film B ′ is exposed and exposed after the step of obtaining the film B ′.
- a developing step can be added.
- an exposure machine such as a stepper, mirror projection mask aligner (MPA), parallel light mask aligner (PLA), etc., light of 10 mJ / m 2 or more and 1000 mJ or less / m 2 or less (wavelength 365 nm exposure dose conversion) of the desired mask Irradiate through or without.
- the light source is not limited, and ultraviolet rays such as i-line, g-line, and h-line, KrF (wavelength 248 nm) laser, ArF (wavelength 193 nm) laser, and the like can be used.
- the unexposed part or the exposed part can be dissolved by development to form a pattern.
- a developing method it is preferable to immerse in a developing solution for 5 seconds or more and 10 minutes or less by a method such as showering, dipping, or paddle.
- a known alkali developer can be used as the developer.
- specific examples include inorganic alkalis such as alkali metal hydroxides, carbonates, phosphates, silicates and borates, amines such as 2-dimethylaminoethanol, monoethanolamine and diethanolamine, and tetramethylammonium.
- examples thereof include an aqueous solution containing one or more quaternary ammonium salts such as hydroxide and choline. After development, it is preferable to rinse with water, followed by drying and baking in the range of 50 ° C. or higher and 150 ° C. or lower.
- the laminate composed of the above-described film A containing polyimide resin and film B containing polysiloxane resin may be manufactured through the following two-stage film forming process. First, after applying a resin solution containing a polyimide precursor resin on the support substrate in the step (1), heating is performed in the step (3) to form the film A. Then, the polysiloxane resin composition is applied on the film A as the step (2), and heating is performed as the step (3) as in the first layer.
- the above resin laminate is used as a display support substrate applicable to color filters, organic EL elements, on-chip substrates, sealing resins, touch panels, circuit boards, liquid crystal panels, PDP panels, electronic paper, see-through displays, etc. Used.
- the resin laminate of the present invention preferably has a coefficient of linear thermal expansion (CTE) of 40 ppm / ° C. or less.
- CTE coefficient of linear thermal expansion
- the coefficient of linear expansion (CTE) is 35 ppm / ° C. or less.
- the linear expansion coefficient mentioned here means that the temperature of the sample is raised to 150 ° C. at a temperature rising rate of 5 ° C./min in the first stage to remove the adsorbed water of the sample, and the air is cooled to room temperature at a temperature lowering rate of 5 ° C./min in the second stage. In the third stage, this measurement is performed at a temperature rising rate of 5 ° C./min, and the value is obtained from the average of the linear expansion coefficients of 50 to 200 ° C.
- the resin laminate When the resin laminate is used for a color filter, it is a color filter having at least a black matrix and colored pixels on the film B.
- the organic EL element When the resin laminate is used for an organic EL element, the organic EL element includes at least a TFT, an electrode, and an organic layer on the film B. Each of these may have a support substrate on the membrane A side.
- the color filter using the display support substrate of the present invention can be manufactured through the following steps in addition to the steps (1) to (3). (4) A step of forming a black matrix on the resin laminate. (5) A step of forming colored pixels on the resin laminate. (6) The process of peeling the said resin laminated body from a support substrate.
- the black matrix is preferably a resin black matrix in which a black pigment is dispersed in a resin.
- the black pigment include carbon black, titanium black, titanium oxide, titanium oxynitride, titanium nitride, or iron tetroxide.
- carbon black and titanium black are suitable.
- a red pigment, a green pigment, and a blue pigment can be mixed and used as a black pigment.
- the resin used for the resin black matrix is preferably a polyimide resin because a thin pattern can be easily formed.
- the polyimide resin is preferably a polyimide resin obtained by thermosetting a polyamic acid synthesized from an acid anhydride and a diamine after patterning.
- the acid anhydride, diamine and solvent those mentioned above for the polyimide resin can be used.
- the resin used for the resin black matrix a photosensitive acrylic resin is also preferable.
- the resin black matrix using this contains a black pigment-dispersed alkali-soluble acrylic resin, a photopolymerizable monomer, a polymer dispersant and an additive.
- alkali-soluble resin examples include a copolymer of an unsaturated carboxylic acid and an ethylenically unsaturated compound.
- unsaturated carboxylic acids include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid, vinyl acetic acid or acid anhydrides.
- photopolymerizable monomers examples include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, triacryl formal, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate or dipentaerythritol. Examples include penta (meth) acrylate.
- photopolymerization initiators examples include benzophenone, N, N′-tetraethyl-4,4′-diaminobenzophenone, 4-methoxy-4′-dimethylaminobenzophenone, 2,2-diethoxyacetophenone, ⁇ -hydroxyisobutylphenone , Thioxanthone or 2-chlorothioxanthone.
- Examples of the solvent for dissolving the photosensitive acrylic resin include propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl acetoacetate, methyl-3-methoxypropionate, ethyl-3-ethoxypropionate, Mention may be made of methoxybutyl acetate or 3-methyl-3-methoxybutyl acetate.
- a black resin composition for a resin black matrix made of polyamic acid in which a black pigment is dispersed is applied by a method such as a spin coater or a die coater so that the film thickness after curing is 1 ⁇ m, and is 60 Pa or less. After drying under reduced pressure, semi-cure is performed in a hot air oven or hot plate at 110 to 140 ° C.
- a positive resist is applied by a spin coater or die coater so that the film thickness after pre-baking is 1.2 ⁇ m, and then dried under reduced pressure up to 80 Pa. And a resist film is formed. Then, after selectively exposing with ultraviolet rays through a photomask by a proximity exposure machine or a projection exposure machine, 1.5 to 3.0% by weight of potassium hydroxide, tetramethylammonium hydroxide, etc. The exposed area is removed by immersing in an alkaline developer for 20 to 300 seconds. After stripping the positive resist using a stripper, the polyamic acid is converted to polyimide by heating in a hot air oven or hot plate at 200 to 300 ° C. for 10 to 60 minutes to disperse the black pigment in the resin film. A resin black matrix is formed. In the case of forming with a photosensitive resin, exposure and development can be performed without applying a positive resist.
- the colored pixels are formed.
- the colored pixels are generally composed of colored pixels of three colors of red, green, and blue.
- the brightness of the white color of the display device can be improved by forming the pixels of the fourth color which are colorless and transparent or very thinly attached.
- the colored pixel of the color filter uses a resin containing a pigment or a dye as a colorant.
- pigments used for red colored pixels include PR254, PR149, PR166, PR177, PR209, PY138, PY150 or PYP139
- examples of pigments used for green colored pixels are PG7, PG36, PG58. , PG37, PB16, PY129, PY138, PY139, PY150 or PY185
- examples of pigments used for blue colored pixels include PB15: 6 or PV23.
- blue dyes include C.I. I. Basic blue (BB) 5, BB7, BB9 or BB26 may be mentioned.
- red dyes include C.I. I. Acid Red (AR) 51, AR87 or AR289.
- resins used for red, green and blue colored pixels include acrylic resins, epoxy resins, and polyimide resins, but photosensitive acrylic resins are preferred because the manufacturing cost of the color filter can be reduced.
- the photosensitive acrylic resin generally contains an alkali-soluble resin, a photopolymerizable monomer, and a photopolymerization initiator.
- alkali-soluble resin examples include a copolymer of an unsaturated carboxylic acid and an ethylenically unsaturated compound.
- unsaturated carboxylic acids include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid, vinyl acetic acid or acid anhydrides.
- photopolymerizable monomers examples include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, triacryl formal, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate or dipentaerythritol. Examples include penta (meth) acrylate.
- photopolymerization initiators examples include benzophenone, N, N′-tetraethyl-4,4′-diaminobenzophenone, 4-methoxy-4′-dimethylaminobenzophenone, 2,2-diethoxyacetophenone, ⁇ -hydroxyisobutylphenone , Thioxanthone or 2-chlorothioxanthone.
- Examples of the solvent for dissolving the photosensitive acrylic resin include propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl acetoacetate, methyl-3-methoxypropionate, ethyl-3-ethoxypropionate , Methoxybutyl acetate or 3-methyl-3-methoxybutyl acetate.
- the colored pixels of the color filter are made using a colorant and a resin.
- a pigment is used as the colorant
- the pigment is mixed with a polymer dispersant and a solvent and subjected to a dispersion treatment, and then added with an alkali-soluble resin, a monomer, a photopolymerization initiator, and the like.
- the dye is prepared by adding a solvent, an alkali-soluble resin, a monomer, a photopolymerization initiator, and the like.
- the total solid content in this case is the total of the polymer component, the alkali-soluble resin and monomer, which are resin components, and the colorant.
- the obtained colorant composition is applied to a target film thickness of 0.8 to 3.0 ⁇ m after heat treatment on a transparent substrate on which a resin black matrix is formed by a method such as a spin coater or a die coater. After coating, the film is dried under reduced pressure to 80 Pa, and prebaked in a hot air oven or hot plate at 80 to 110 ° C. to form a colorant coating film.
- the gas barrier film described above may be formed between the resin film and the black matrix / colored pixel layer.
- a flattening layer may be provided on the color filter.
- the resin used for forming the planarization layer include an epoxy resin, an acrylic epoxy resin, an acrylic resin, a siloxane resin, or a polyimide resin.
- the film thickness of the planarizing layer is preferably a film thickness that makes the surface flat, more preferably 0.5 to 5.0 ⁇ m, and even more preferably 1.0 to 3.0 ⁇ m.
- the color filter is peeled off by cutting around the resin laminate.
- a color filter using the display support substrate can be manufactured.
- the order of patterning the colored pixels is not particularly limited.
- Organic EL device using the display support substrate of the present invention can be produced through the following steps in addition to the steps (1) to (3). (4) A step of forming an organic EL element on the resin laminate. (5) The process of peeling the said resin laminated body from a support substrate.
- a gas barrier film for suppressing permeation of a gas such as water vapor or oxygen is formed on the above-described resin laminate film B.
- Preferred gas barrier films include, for example, metal oxides composed mainly of one or more metals selected from the group consisting of silicon, aluminum, magnesium, zinc, zirconium, titanium, yttrium, and tantalum, silicon, aluminum , Boron metal nitrides or mixtures thereof.
- silicon oxide, nitride, or oxynitride is the main component from the viewpoint of gas barrier properties, transparency, surface smoothness, flexibility, film stress, cost, and the like.
- These gas barrier films can be produced by a vapor deposition method in which a film is formed by depositing a material in a vapor phase such as sputtering, vacuum deposition, ion plating, plasma CVD or the like.
- a vapor deposition method in which a film is formed by depositing a material in a vapor phase such as sputtering, vacuum deposition, ion plating, plasma CVD or the like.
- the sputtering method is preferable from the viewpoint that particularly excellent gas barrier properties can be obtained.
- the thickness of the gas barrier film is preferably 10 to 300 nm, and more preferably 30 to 200 nm.
- the film-forming temperature of the gas barrier film is preferably high, preferably 300 ° C. or higher, more preferably 400 ° C. or higher, and further preferably 500 ° C. or higher.
- TFT is formed on the gas barrier film.
- the semiconductor layer for forming the TFT include an amorphous silicon semiconductor, a polycrystalline silicon semiconductor, an oxide semiconductor typified by InGaZnO, and an organic semiconductor typified by pentacene and polythiophene.
- a gas barrier film, a gate electrode, a gate insulating film, a polycrystalline silicon semiconductor layer, an etching stopper film, and a source / drain electrode are sequentially formed by a known method to form a bottom gate TFT. Make it.
- a planarization layer is provided on the TFT.
- the resin used for forming the planarization layer include an epoxy resin, an acrylic epoxy resin, an acrylic resin, a polysiloxane resin, or a polyimide resin.
- an electrode and an organic layer are formed thereon. Specifically, a first electrode made of Al / ITO or the like, an insulating film covering the end of the first electrode, a hole injection layer, a hole transport layer, a light emitting layer, an electron transport layer, an electron injection layer A white organic EL light-emitting layer made of is formed, a second electrode made of ITO or the like is formed, and a sealing film is formed. After manufacturing through the above steps, the organic EL element can be obtained by peeling the resin film from the support substrate.
- an on-chip type substrate can be manufactured by directly forming a color filter on the organic EL element thus obtained by the above-described method.
- the display support substrate of the present invention can be used for display devices such as liquid crystal displays, organic EL displays, electronic paper, PDP displays, LED displays, and see-through displays, light receiving devices such as color filters, touch panels, solar cells, and CMOS. it can. In particular, when utilizing these display devices and light receiving devices as flexible devices that can be bent, the display support substrate of the present invention is preferably used.
- the circuit required for the display device and the light receiving device is formed on the resin film formed on the substrate, and the resin laminate is formed by cutting and physically peeling as described above. Is peeled off from the substrate.
- the color filter and the organic EL element produced in the present invention have a flexible resin laminate as a base material, they can be a flexible color filter and a flexible organic EL element. And a flexible organic EL display can be produced using these flexible color filters and flexible organic EL elements.
- a flexible display device for full color display can be obtained by bonding a light emitting device to a color filter using the flexible substrate of the present invention.
- a flexible organic EL display in which an organic EL element using the flexible substrate of the present invention and a color filter are combined is preferable.
- the polysiloxane resin composition was spin-coated so that the thickness after pre-baking at 100 ° C. ⁇ 2 minutes would be the thickness shown in Table 1. did.
- the coating film after the pre-baking treatment was heated to 300 ° C. at 3.5 ° C./min under nitrogen flow (oxygen concentration 20 ppm or less) using an inert oven (INH-21CD manufactured by Koyo Thermo System Co., Ltd.) for 30 minutes. This was held and cooled to 50 ° C. at 5 ° C./min to produce a resin laminate (on a glass substrate).
- the polyimide precursor is such that the thickness after pre-baking at 140 ° C. ⁇ 4 minutes is the thickness shown in Table 1.
- the resin solution was spin coated. Thereafter, a pre-bake treatment at 140 ° C. for 4 minutes was similarly performed using a Mark-7 hot plate. Subsequently, a polysiloxane resin composition was spin-coated using a spin coater MS-A200 manufactured by Mikasa Co., Ltd. so that the thickness after pre-baking at 100 ° C. ⁇ 2 minutes would be the thickness shown in Table 1.
- the coating film after the pre-baking treatment was heated to 300 ° C. at 3.5 ° C./min under nitrogen flow (oxygen concentration 20 ppm or less) using an inert oven (INH-21CD manufactured by Koyo Thermo System Co., Ltd.) for 30 minutes. This was held and cooled to 50 ° C. at 5 ° C./min to produce a resin laminate. Subsequently, a cut was made around the obtained resin laminate, immersed in hot water of 65 ° C. for 1 to 4 minutes, and then physically pulled to peel the resin laminate from the substrate and air-dried.
- T Measurement of light transmittance
- the light transmittance at a wavelength of 400 nm was measured using an ultraviolet-visible spectrophotometer (MultiSpec 1500, manufactured by Shimadzu Corporation).
- MultiSpec 1500 manufactured by Shimadzu Corporation
- the resin laminated body on a glass substrate produced by (1) was used for the measurement.
- CTE linear thermal expansion coefficient
- the resin laminated body produced by (3) was used for the measurement, and it determined with the following evaluation methods. Excellent (A): 35 ppm / ° C or less Good (B): More than 35 ppm / ° C and 40 ppm / ° C or less Defective (C): More than 40 ppm / ° C.
- TE refractive index (n (TE)) and TM refractive index (n (TM)) at a wavelength of 632.8 nm were measured using a prism coupler (PC2010, manufactured by METRICON).
- n (TE) and n (TM) are refractive indexes in parallel and perpendicular directions to the film surface, respectively.
- Birefringence is calculated as the n difference (TE) and n (TM) (n (TE ) -n (TM)), the birefringence of the film A was .DELTA.N A, .DELTA.N B birefringence film B.
- the resin film prepared in (2) was used.
- Td3 3% weight loss temperature
- the polysiloxane resin film prepared in (2) is scraped off, and about 15 mg is put into an aluminum cell, and nitrogen is measured using a thermogravimetric measuring device (TGA-50 manufactured by Shimadzu Corporation). Measurements were performed under air flow.
- the temperature raising method was performed under the following conditions. In the first stage, the temperature of the sample is raised to 150 ° C. at a rate of temperature rise of 3.5 ° C./min to remove the adsorbed water of the sample. This measurement was carried out at a heating rate of 10 ° C./min, and the temperature (Td3) when the weight was reduced by 3% was determined.
- membrane A containing a polyimide resin was produced.
- the C light source (L * a * b * ) color space of the resin laminate substrate was measured using a microspectrophotometer “MCPD-2000” manufactured by Otsuka Electronics Co., Ltd., and the transmission color tone was determined as follows. .
- the presence or absence of cracks in the film B before and after the bending operation was used as an index, and 100 sheets were visually observed using an optical microscope (Nikon (manufactured by OPTIPHOT 300)) after the test.
- the average of the absolute values of the deviation amounts obtained by the measurement was obtained by calculation, and the obtained value was taken as the deviation amount from the ideal lattice of BM at that level. While evaluating the value of the amount of deviation in each Example and Comparative Example, and evaluating how much difference there is in the amount of deviation between the case where the BM pattern was produced on the glass substrate and the case where it was produced on the resin laminate, The determination was made by the following evaluation method. Excellent (A): BM displacement amount is 1.8 ⁇ m or less. Good (B): BM displacement amount is more than 1.8 ⁇ m and less than 2.4 ⁇ m. (C): BM displacement amount is more than 2.4 ⁇ m.
- the high temperature and high humidity test was conducted by placing the organic EL element peeled from the glass substrate in a high temperature and high humidity tank having an internal temperature of 85 ° C. and a humidity of 85% for 24 hours.
- Synthesis Example 3 Synthesis of Transparent Polyimide Precursor Resin Solution (III) 7.90 g (26) of 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride (BPDA) in a 200 mL four-necked flask under a dry nitrogen stream .4 mmol), 2,2-bis (4- (3,4-dicarboxyphenoxy) phenyl) propane dianhydride (BSAA) 14.01 g (26.4 mmol), trans-1,4-diaminocyclohexane ( (CHDA) 6.1375 g (53.7 mmol) and N-methyl-2-pyrrolidone 100 g were added and heated and stirred at 65 ° C. After 6 hours, it was cooled to obtain a transparent polyimide precursor resin solution (III).
- BPDA 4,4′-biphenyltetracarboxylic dianhydride
- BSAA 2,2-bis (4- (3,4-dicarboxyphenoxy) phen
- Synthesis Example 4 Synthesis of Transparent Polyimide Precursor Resin Solution (IV) 13.72 g (46) of 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride (BPDA) in a 200 mL four-necked flask under a dry nitrogen stream .6 mmol), trans-1,4-diaminocyclohexane (CHDA) 5.33 g (46.6 mmol), and N-methyl-2-pyrrolidone 100 g were added and heated and stirred at 65 ° C. After 6 hours, it was cooled to obtain a transparent polyimide precursor resin solution (IV).
- BPDA 4,4′-biphenyltetracarboxylic dianhydride
- CHDA trans-1,4-diaminocyclohexane
- N-methyl-2-pyrrolidone 100 g were added and heated and stirred at 65 ° C. After 6 hours, it was cooled to obtain a transparent polyimide precursor
- Synthesis Example 5 Synthesis of Transparent Polyimide Precursor Resin Solution (V) 7.23 g (36.9 mmol) of 1,2,3,4-cyclobutanetetracarboxylic dianhydride (CBDA) in a 200 mL four-necked flask under a dry nitrogen stream ), 2,2′-bis (trifluoromethyl) benzidine (TFMB) 11.81 g (36.9 mmol) and N-methyl-2-pyrrolidone 100 g were added and stirred at 65 ° C. with heating. After 6 hours, it was cooled to obtain a transparent polyimide precursor resin solution (V).
- CBDA 1,2,3,4-cyclobutanetetracarboxylic dianhydride
- TFMB 2,2′-bis (trifluoromethyl) benzidine
- N-methyl-2-pyrrolidone 100 g were added and stirred at 65 ° C. with heating. After 6 hours, it was cooled to obtain a transparent polyimide precursor
- Synthesis Example 7 Synthesis of Polyimide Precursor Resin Solution (VII) 7.03 g (32.2 mmol) of pyromellitic anhydride (PMDA), 4,4′-biphthalic anhydride in a 200 mL four-necked flask under a dry nitrogen stream (BPDA) 6.32 g (21.5 mmol), 1,4-phenylenediamine (PDA) 5.81 g (53.7 mmol), and N-methyl-2-pyrrolidone 100 g were added, and the mixture was heated and stirred at 65 ° C. After 6 hours, it was cooled to obtain a polyimide precursor resin solution (VII).
- PMDA pyromellitic anhydride
- PDA 1,4-phenylenediamine
- N-methyl-2-pyrrolidone 100 g were added, and the mixture was heated and stirred at 65 ° C. After 6 hours, it was cooled to obtain a polyimide precursor resin solution (VII).
- Synthesis Example 8 Synthesis of Polyimide Precursor Resin Solution (VIII) 10.21 g (34.7 mmol) of 4,4′-biphthalic anhydride (BPDA), trans-1,4- Diaminocyclohexane (CHDA) 1.59 g (13.9 mmol), 9,9-bis (4-aminophenyl) fluorene (FDA) 7.26 g (20.8 mmol), N-methyl-2-pyrrolidone 100 g The mixture was heated and stirred at ° C. After 6 hours, it was cooled to obtain a polyimide precursor resin solution (VIII).
- BPDA 4,4′-biphthalic anhydride
- CHDA trans-1,4- Diaminocyclohexane
- FDA 9,9-bis (4-aminophenyl) fluorene
- N-methyl-2-pyrrolidone 100 g
- the mixture was heated and stirred at ° C. After 6 hours, it was cooled to obtain a polyimide precursor resin solution
- Synthesis Example 9 Synthesis of polyimide precursor resin solution (VIIII) 4,4′-diaminophenyl ether (ODA) 60.07 g (300.0 mmol), 1,4-phenylenediamine (PDA) 70. 33 g (650.4 mmol) and 1,3-bis (3-aminopropyl) tetramethyldisiloxane 12.43 g (50.0 mmol) were charged with 850 g ⁇ -butyrolactone and 850 g N-methyl-2-pyrrolidone, 309.43 g (997.5 mmol) of 3,3 ′, 4,4′-oxydiphthalcarboxylic dianhydride (ODPA) was added and reacted at 80 ° C. for 3 hours. 1.96 g (20.0 mmol) of maleic anhydride was added and further reacted at 80 ° C. for 1 hour to obtain a polyimide precursor resin solution (VIIII).
- ODA 4,4′-diaminophenyl
- Synthesis Example 10 Synthesis of Polysiloxane Resin Solution (I) 46.05 g (0.34 mo) of methyltrimethoxysilane was added to a 500 ml three-necked flask. l), 83.79 g (0.42 mol) of phenyltrimethoxysilane, (2- (3, 20.82 g (0.08 mo) of 4-epoxycyclohexyl) ethyltrimethoxysilane l), 151.6836.55 g of propylene glycol monomethyl ether acetate (PGMEA) and 15.17 g of methanol were charged, and 0.45 g of phosphoric acid (charged) was added to 47.21 g of water (theoretical amount required for hydrolysis) while stirring at room temperature.
- PGMEA propylene glycol monomethyl ether acetate
- a phosphoric acid aqueous solution in which 0.3% by weight of the monomer was dissolved was added with a dropping funnel over 10 minutes. Thereafter, the flask was immersed in a 40 ° C. oil bath and stirred for 30 minutes, and then the oil bath was heated to 115 ° C. over 30 minutes. One hour after the start of temperature increase, the internal temperature of the solution reached 100 ° C., from which it was heated and stirred for 2 hours (internal temperature was 100 to 110 ° C.) to obtain a polysiloxane solution (I). During heating and stirring, nitrogen was flowed at 0.05 l (liter) / min.
- Synthesis Example 11 Synthesis of Polysiloxane Resin Solution (II) 47.67 g (0.35 mol) methyltrimethoxysilyl, 39.66 g (0.20 mol) phenyltrimethoxysilane, 82.04 g (0 .35 mol) of ⁇ -acryloylpropyltrimethoxysilane, 26.23 (0.1 mol) of 3-trimethoxysilylpropyl succinic anhydride and 195.6 g of diacetone alcohol (DAA), and an oil bath at 40 ° C.
- DAA diacetone alcohol
- aqueous solution of phosphoric acid in which 0.39 g of phosphoric acid (0.2 parts by weight with respect to the charged monomer) is dissolved in 55.8 g of water (theoretical amount necessary for hydrolysis) with stirring. Added over minutes. After stirring at 40 ° C. for 1 hour, the oil bath temperature was set to 70 ° C. and stirred for 1 hour, and the oil bath was further heated to 115 ° C. over 30 minutes. One hour after the start of temperature increase, the internal temperature of the solution reached 100 ° C., and was then heated and stirred for 2 hours (the internal temperature was 100 to 110 ° C.).
- Polysiloxane Resin Composition 1 7.42 g of Polysiloxane Solution (I) obtained
- PMA-ST manufactured by Nissan Chemical Industries, Ltd .
- 0.0898 g of Irgacure OXE-02 and 0.0299 g of hydroquinone methyl ether (HQME) were added and dissolved in 6.00 g of DAA and 1.44 g of PGMEA and stirred.
- Preparation Example 4 Preparation of black resin composition for forming a black matrix 50 g of carbon black (MA100; manufactured by Mitsubishi Chemical Corporation) and 200 g of N were added to 250 g of the polyimide precursor resin solution (VIIII) of Synthesis Example 9. -Methyl-2-pyrrolidone was mixed, and dispersion treatment was performed at 3200 rpm for 3 hours using zirconia beads having a diameter of 0.3 mm using DYNOMILL KDL-A to obtain a black resin dispersion.
- Non-photosensitive black resin composition by adding 49.9 g of N-methyl-2-pyrrolidone and 0.1 g of a surfactant (LC951; manufactured by Enomoto Chemical Co., Ltd.) to 50 g of this black dispersion.
- a surfactant LC951; manufactured by Enomoto Chemical Co., Ltd.
- Preparation Example 6 Preparation of Resin Composition for Forming Transparent Protective Film 280 g of GBL and 74.95 g of ⁇ -aminopropyltriethoxysilane were added to 65.05 g of trimellitic acid, and 120 ° C. for 2 hours. Heated. To 20 g of the obtained solution, 7.00 g of bisphenoxyethanol fluorenediglycidyl ether and 15.00 g of diethylene glycol dimethyl ether were added to obtain a resin composition.
- Preparation Example 7 Preparation of pigment dispersion (d1) PB15: 65 g, PV23 35 g, bic chemie “BYK2001” 40 g and propylene glycol monomethyl acetate 860 g as a dispersing agent together with 1000 g of zirconia beads having a diameter of 0.3 mm using a homogenizer After the dispersion treatment at 7000 rpm for 30 minutes, the zirconia beads were removed by filtration to obtain a pigment dispersion liquid (d1).
- Example 1 Production of a color filter and an organic EL element using a display support substrate (FIGS. 3 and 4)
- a transparent polyimide precursor resin solution (I) obtained in Synthesis Example 1 is applied to a glass substrate 1 (AN100 (manufactured by Asahi Glass Co., Ltd.)) of 300 mm ⁇ 400 mm ⁇ 0.7 mm thickness. Spin coating was performed so that the thickness after pre-baking at 140 ° C. for 10 minutes was 15 ⁇ 0.5 ⁇ m. Then, the prebaking process was performed for 10 minutes at 140 degreeC using the ventilation dryer.
- AN100 manufactured by Asahi Glass Co., Ltd.
- the polysiloxane resin composition 1 obtained in Preparation Example 1 was spin-coated on the polyimide resin film so that the thickness after prebaking at 100 ° C. for 2 minutes was 1.2 ⁇ m. Then, the prebaking process was performed for 2 minutes at 100 degreeC using the ventilation dryer. Thereafter, heating was performed for 30 minutes in an inert oven (INH-21CD manufactured by Koyo Thermo System Co., Ltd.) heated to 300 ° C. under a nitrogen stream (oxygen concentration of 20 ppm or less), a film A containing polyimide resin A 10 ⁇ m, and a film B 1 ⁇ m containing polysiloxane resin The resin laminated body which consists of was produced.
- an inert oven IH-21CD manufactured by Koyo Thermo System Co., Ltd.
- 2.38% tetramethylammonium hydroxide aqueous solution is used to simultaneously develop the photoresist and etch the black resin coating to form a pattern, strip the resist with methyl cellosolve acetate,
- the resin was imidized by heating at 280 ° C. for 10 minutes to form a resin black matrix in which carbon black was dispersed in a polyimide resin.
- the thickness of the black matrix was measured, it was 1.4 ⁇ m.
- the position accuracy of the black matrix was evaluated by the above-described method, the amount of BM positional deviation was 1.7 ⁇ m.
- the film was dipped in a developer composed of a 0.2% tetramethylammonium hydroxide aqueous solution, developed, washed with pure water, and then heat-treated in an oven at 230 ° C. for 30 minutes to produce a red pixel 7R.
- a green pixel 7G made of a photosensitive green resist and a blue pixel 7B made of a photosensitive blue resist prepared in Preparation Example 4 were produced, and a color filter (FIG. 3) was obtained.
- the rotation speed of the spinner was adjusted so that the thickness of the colored layer portion after the heat treatment was 2.5 ⁇ m, and the resin composition produced in Adjustment Example 6 was applied. Then, it heat-processed for 30 minutes in 230 degreeC oven, and produced the overcoat layer.
- a flattening layer was formed on the insulating film with the unevenness due to the wiring embedded.
- the planarization layer is formed by spin-coating a photosensitive polyimide varnish on a substrate, pre-baking on a hot plate (120 ° C., 3 minutes), exposing and developing through a mask having a desired pattern, and under an air flow The heat treatment was performed at 230 ° C. for 60 minutes. The applicability when applying the varnish was good, and no wrinkles or cracks were observed in the flattened layer obtained after exposure, development and heat treatment. Furthermore, the average level difference of the wiring was 500 nm, a 5 ⁇ m square contact hole was formed in the prepared planarization layer, and the thickness was about 2 ⁇ m.
- FIG. 4 Production of white light emitting organic EL element (FIG. 4) A top emission type organic EL element was formed on the flattening layer of the TFT obtained by the above method.
- a first electrode made of Al / ITO Al: reflective electrode
- a resist was applied, prebaked, exposed through a mask having a desired pattern, and developed.
- patterning of the first electrode was performed by wet etching using an ITO etchant.
- the resist pattern was stripped using a resist stripping solution (mixed solution of monoethanolamine and diethylene glycol monobutyl ether).
- the substrate after peeling was washed with water and dehydrated by heating at 200 ° C. for 30 minutes to obtain an electrode substrate with a planarizing layer.
- the change in the thickness of the flattening layer was less than 1% after heat dehydration with respect to that before the stripping solution treatment.
- the first electrode thus obtained corresponds to the anode of the organic EL element.
- an insulating layer having a shape covering the end of the first electrode was formed.
- the photosensitive polyimide varnish was also used for the insulating layer.
- a hole transport layer, an organic light emitting layer, and an electron transport layer were sequentially deposited through a desired pattern mask in a vacuum deposition apparatus to provide a white organic EL light emitting layer.
- a second electrode made of Mg / ITO was formed on the entire surface above the substrate.
- a SiON sealing film was formed by CVD film formation to obtain an organic EL element (FIG. 4).
- the obtained organic EL device was measured for luminous efficiency by the method described above. As a result, the luminous efficiency was 5 cd / A immediately after fabrication and after the high-temperature and high-humidity test.
- Example 2 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (II) obtained in Synthesis Example 2 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 85.5% and 20 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 3 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (III) obtained in Synthesis Example 3 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 91.0% and 32 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 4 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (IV) obtained in Synthesis Example 4 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 86.8% and 9.0 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 5 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (V) obtained in Synthesis Example 5 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 95.3% and 19 ppm, respectively. Further, birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 6 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (VI) obtained in Synthesis Example 6 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 96.1% and 29 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 7 A resin laminate, a color filter, and an organic EL device are produced in the same manner as in Example 1 except that the polyimide precursor resin solution (VII) obtained in Synthesis Example 7 is used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 2.4% and 6.0 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 8 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that the polyimide precursor resin solution (VIII) obtained in Synthesis Example 8 was used instead of the polyimide precursor resin solution (I). did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 65.2% and 23 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 9 instead of the polysiloxane resin composition 1, the polysiloxane resin composition 2 obtained in Preparation Example 2 was used, and the polysiloxane resin composition 2 was applied and prebaked, followed by Canon Inc., UV exposure machine “PLA” ⁇ 5011 ′′, the entire surface of the coating film was exposed at 150 mJ / cm 2 (i-line conversion), and after the film B ′ was photocured, a developer composed of 0.2% tetramethylammonium hydroxide aqueous solution was used. A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film was immersed for 1 minute, developed, and then washed with pure water.
- Canon Inc. UV exposure machine “PLA” ⁇ 5011 ′′
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 87.4% and 30 ppm, respectively. Further, birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 10 A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that 0.1 g of the pigment dispersion (d1) was added in Preparation Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 87.7% and 30 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 1.
- Example 11 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film A was changed to 20 ⁇ m and the film B was changed to 3 ⁇ m.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 76.3% and 29 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 12 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1, except that the film thickness of the film A was changed to 5 ⁇ m and the film thickness of the film B was changed to 3 ⁇ m.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 91.1% and 25 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 13 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1, except that the film thickness of the film A was changed to 10 ⁇ m and the film thickness of the film B was changed to 2.5 ⁇ m.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 85.6% and 28 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 14 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1, except that the film thickness of the film A was changed to 15 ⁇ m and the film thickness of the film B was changed to 1.5 ⁇ m.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 82.2% and 31 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 15 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film thickness of the film A was changed to 19 ⁇ m in Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 77.1% and 36 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 16 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film thickness of the film A was changed to 24 ⁇ m in Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 75.8% and 38 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 17 The polysiloxane resin composition 2 obtained in Preparation Example 3 was used in place of the polysiloxane resin composition 1, and the polysiloxane resin composition 2 was applied and pre-baked, followed by Canon Inc., UV exposure. Using a machine “PLA-5011”, the entire surface of the coating film was exposed at 150 mJ / cm 2 (i-line conversion), and after film B ′ was photocured, it was composed of a 0.2% tetramethylammonium hydroxide aqueous solution. A resin laminate, a color filter, and an organic EL device were produced in the same manner as in Example 1 except that it was immersed in a developer for 1 minute, developed, and then washed with pure water.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 87.6% and 30 ppm, respectively. Further, birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 18 A resin laminate, a color filter, and an organic EL element were prepared in the same manner as in Example 1 except that the content of silica particles in the varnish solid content was 65 wt% in Preparation Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 88.0% and 29 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 19 A resin laminate, a color filter, and an organic EL device were prepared in the same manner as in Example 1, except that the content of silica particles in the varnish solid content was 80 wt%.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 88.1% and 27 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- a laminate, a color filter, and an organic EL element were produced.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 83.5% and 36 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 21 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film thickness of the film B was changed to 0.4 ⁇ m in Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 88.5% and 39 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 22 A resin laminate, a color filter, and an organic EL device were prepared in the same manner as in Example 1 except that the content of silica particles in the varnish solid content was 90 wt% in Preparation Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 86.2% and 25 ppm / ° C., respectively. It was 88.5% and 25 ppm.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 1 a resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1, except that the film B was not formed.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 88.0% and 48 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Comparative Example 2 A resin laminate, a color filter, and an organic EL device were prepared in the same manner as in Example 1 except that PMA-ST was not added in Preparation Example 1.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 87.7% and 53 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Comparative Example 3 A resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1, except that the film thickness of the film A was changed to 25 ⁇ m and the film thickness of the film B was changed to 0.5 ⁇ m.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 73.4% and 42 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 4 a resin laminate, a color filter, and an organic EL element were produced in the same manner as in Example 1 except that the film A was changed to 4.0 ⁇ m and the film B was changed to 3.0 ⁇ m. did.
- the visible light transmittance and CTE at a wavelength of 400 nm of the resin laminate were 92.1% and 23 ppm, respectively.
- birefringence measurement, flexural resistance evaluation, 3% weight loss temperature measurement, chromaticity measurement, black matrix positional accuracy evaluation, and luminous efficiency measurement were performed by the above-described methods. The results are shown in Table 2.
- Example 23 Production of organic EL display (FIG. 5) [1] Production of Color Filter with Glass Substrate and White Light-Emitting Organic EL Element A color filter and a white light-emitting organic EL element were produced on a glass substrate by the method described in Example 1.
- Example 24 An organic EL display was produced in the same manner as in Example 23 except that the color filter produced in Example 10 was used.
- Example 25 An organic EL display was produced in the same manner as in Example 23 except that the color filter produced in Example 4 was used.
- Example 26 An organic EL display was produced in the same manner as in Example 23 except that the color filter produced in Example 8 was used.
- Reference Example 1 Production of polyimide resin film A glass substrate 1 (AN100 (Asahi Glass Co., Ltd.)) having a thickness of 300 mm ⁇ 400 mm ⁇ 0.7 mm was applied to the polyimide precursor resin solution (VII) obtained in Synthesis Example 7 at 140 ° C. Was applied by spin coating so that the thickness after pre-baking for 10 minutes was 15 ⁇ 0.5 ⁇ m. Then, the prebaking process was performed for 10 minutes at 140 degreeC using the ventilation dryer. After the temperature of the substrate dropped to room temperature, it was heated for 30 minutes in an inert oven (INH-21CD manufactured by Koyo Thermo System Co., Ltd.) heated to 300 ° C.
- an inert oven IH-21CD manufactured by Koyo Thermo System Co., Ltd.
- Example 27 Production of Organic EL Display [1] Production of Color Filter with Glass Substrate A color filter was produced on a glass substrate by the method described in Example 1.
- TFT support substrate was produced on the polyimide resin film produced in (1) above in the same manner as in [4] of Example 1.
- Example 28 An organic EL display was produced in the same manner as in Example 23, except that the color filter produced in Example 16 was used.
- Example 29 An organic EL display was produced in the same manner as in Example 23, except that the color filter produced in Example 20 was used.
- Comparative Example 5 An organic EL display was produced in the same manner as in Example 23 except that the color filter produced in Comparative Example 1 was used.
- Comparative Example 6 An organic EL display was produced in the same manner as in Example 23 except that the white light emitting organic EL element produced in Comparative Example 1 was used.
- the organic EL displays of Examples 23, 24, and 27 were capable of producing a clear and high-contrast display with little displacement of the color filter and no deterioration of the organic EL element.
- Example 24 by adjusting the transmission chromaticity of the resin film used for the film B, it was possible to reduce the coloring of the display support substrate and to create a display with good visibility.
- Example 25 Although the effect of reducing external light reflection was slightly inferior, it was possible to create a display with good visibility and display performance.
- Example 26 Although the transparency of the support substrate for the color filter was slightly low, the display was good as a whole although the clarity was inferior.
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Abstract
Description
本発明において膜Aに含まれるポリイミド樹脂は、特に制限はなく、一般的に、下記一般式(11)で表されるポリイミド樹脂を用いることができる。これは例えば下記一般式(12)で表されるポリイミド前駆体樹脂をイミド閉環(イミド化反応)させることで得られる。イミド化反応の方法としては特に限定されず、熱イミド化や化学イミド化が挙げられる。中でも、ポリイミド樹脂膜の耐熱性、可視光領域での透明性の観点から、熱イミド化が好ましい。
膜Aは、熱架橋剤を含有していてもよい。熱架橋剤としては、エポキシ化合物やアルコキシメチル基またはメチロール基を少なくとも2つ有する化合物が好ましい。これらの基を少なくとも2つ有することで、樹脂および同種分子と縮合反応して架橋構造体が形成され、加熱処理後の硬化膜の機械強度や耐薬品性を向上させることができる。
膜Aは基材との接着性向上のため、シランカップリング剤、チタンカップリング剤等のカップリング剤を添加することができる。カップリング剤は、樹脂100重量部に対し、0.1~10重量部含有することが好ましい。
膜Aは、無機フィラーを含有していてもよい。無機フィラーとしては、シリカ微粒子、アルミナ微粒子、チタニア微粒子、ジルコニア微粒子などが挙げられる。無機フィラーの形状は特に限定されず、球状、楕円形状、偏平状、ロッド状、繊維状などが挙げられる。含有させた無機フィラーは光の散乱を防ぐため粒径が小さいことが好ましい。平均粒径は0.5~100nmであり、0.5~30nmの範囲が好ましく、無機フィラーは、樹脂100重量部に対し、1~100重量部含有することが好ましい。前記粒径範囲の無機フィラーを樹脂100重量部に対し、1~100重量部添加することによって、可撓性を損なわず、ポリイミド樹脂のCTEや複屈折を低下させることが可能である。
本発明において膜Bに含まれるポリシロキサン樹脂としては特に制限はない。膜Bの形成に用いるポリシロキサン樹脂組成物が非感光性またはポジ型感光性である場合は塗液の保存安定性の観点からフェニル基又はナフチル基を有するものが好ましく、耐薬品性の観点から、エポキシ基又はアミノ基を有するものが好ましい。また、膜Bの形成に用いるポリシロキサン樹脂組成物がネガ型感光性である場合は塗液の保存安定性の観点から、フェニル基又はナフチル基を有するものが好ましく、硬化性の観点から、(メタ)アクリル基又はビニル基を有するものが好ましく、パターン加工性の観点から、カルボキシル基又はフェノール性水酸基を有するものが好ましい。
ポリシロキサン樹脂を含む膜Bは無機酸化物粒子を含有する。無機酸化物粒子を含有することで、膜BのCTEを低下させることができ、膜Bを膜Aの少なくとも一方に形成することによって樹脂積層体のCTEを低下させることが可能である。
ここでdi は粒子の等価円直径(粒子の断面積と同じ面積を持つ円の直径)、Nは個数
である。
膜Bの形成に用いるポリシロキサン樹脂組成物の固形分濃度は、膜厚が制御し易いことから、5~35wt%が好ましい。
膜Bの樹脂層の透過色度座標は0.300≦x≦0.325および0.305≦y≦0.325の範囲にあることが好ましい。これにより、樹脂積層体を通して視認される透過光を白色に近い色調とすることができる。この透過色度座標は0.300≦x≦0.310および0.305≦y≦0.315の範囲にあることがより好ましい。ここで、「透過色度座標」とは、C光源、2度視野で測定したCIE1931表色系における透過色度の座標のことをいう。
膜Bの樹脂層は、その透過色度座標を上記範囲とするため、着色剤を含有することが好ましい。着色剤としては、例えば、有機顔料、無機顔料、又は染料が挙げられるが、透過光の色調調整のためには、青色顔料、青色染料、紫色顔料又は紫色染料が好ましい。
本発明の樹脂積層体の作製方法は、特に限定は無いが、以下の工程を含むことが好ましい。
(1)支持基板上にポリイミド前駆体樹脂を含む樹脂溶液を塗布して膜A’を得る工程。
(2)前記膜A’上にポリシロキサン樹脂組成物を塗布して膜B’を得る工程。
(3)前記膜A’と前記膜B’とをそれぞれ加熱して樹脂積層体を得る工程。
樹脂積層体がカラーフィルター用に利用される場合は、膜B上に少なくともブラックマトリックスおよび着色画素を備えてカラーフィルターとされる。樹脂積層体が有機EL素子に利用される場合は、膜B上に少なくともTFT、電極および有機層を備えて有機EL素子とされる。これらは、それぞれ膜A側に支持基板を備えていてもよい。
(4)前記樹脂積層体上にブラックマトリックスを形成する工程。
(5)前記樹脂積層体上に着色画素を形成する工程。
(6)支持基板から前記樹脂積層体を剥離する工程。
酸無水物、ジアミンおよび溶剤の例としては、前述のポリイミド樹脂で挙げたものを用いることができる。
本発明のディスプレイ用支持基板を利用した有機EL素子は、前記(1)~(3)の工程に加え、更に下記の工程を経て製造することができる。
(4)前記樹脂積層体上に有機EL素子を形成する工程。
(5)支持基板から前記樹脂積層体を剥離する工程。
<デバイス>
本発明のディスプレイ用支持基板は、液晶ディスプレイ、有機ELディスプレイ、電子ペーパー、PDPディスプレイ、LEDディスプレイ、シースルーディスプレイといった表示デバイス、カラーフィルター、タッチパネル、太陽電池、CMOSなどの受光デバイス等に使用することができる。特に、これらの表示デバイスや受光デバイスを折り曲げ可能なフレキシブルデバイスとして活用する上で、本発明のディスプレイ用支持基板が好ましく用いられる。
50mm×50mm×1.1mm厚のガラス基板(テンパックス)に、ミカサ(株)製のスピンコーターMS-A200を用いて140℃×4分のプリベーク後の厚さが表1記載の厚さになるようにポリイミド前駆体樹脂溶液をスピン塗布した。その後、大日本スクリーン(株)製ホットプレートD-SPINを用いて140℃×4分のプリベーク処理を行った。続いて、同様にミカサ(株)製のスピンコーターMS-A200を用いて100℃×2分のプリベーク後の厚さが表1に記載の厚さになるようにポリシロキサン樹脂組成物をスピン塗布した。プリベーク処理後の塗膜をイナートオーブン(光洋サーモシステム(株)製INH-21CD)を用いて窒素気流下(酸素濃度20ppm以下)、3.5℃/minで300℃まで昇温し、30分間保持し、5℃/minで50℃まで冷却し、樹脂積層体(ガラス基板上)を作製した。
1/4に切断した4インチシリコン基板に、ミカサ(株)製のスピンコーターMS-A200を用いてプリベーク後の膜厚が5±0.5μmになるようにポリイミド前駆体樹脂またはポリシロキサン樹脂組成物をスピン塗布した。その後、大日本スクリーン(株)製ホットプレートD-SPINを用いてプリベーク処理を行った。(ポリイミド前駆体樹脂は140℃×4分、ポリシロキサン樹脂組成物は100℃×2分の条件でプリベークを行った。)プリベーク膜をイナートオーブン(光洋サーモシステム株式会社製 INH-21CD)を用いて窒素気流下(酸素濃度20ppm以下)、3.5℃/minで300℃又は350℃まで昇温し、30分間保持し、5℃/minで50℃まで冷却し耐熱性樹脂膜(シリコン基板上)を作製した。
6インチシリコン基板上に、東京エレクトロン(株)製の塗布現像装置Mark-7を用いて、140℃×4分のプリベーク後の厚さが表1に記載の厚さになるようにポリイミド前駆体樹脂溶液をスピン塗布した。その後、同じくMark-7のホットプレートを用いて140℃×4分のプリベーク処理を行った。続いて、ミカサ(株)製のスピンコーターMS-A200を用いて100℃×2分のプリベーク後の厚さが表1に記載の厚さになるようにポリシロキサン樹脂組成物をスピン塗布した。プリベーク処理後の塗膜をイナートオーブン(光洋サーモシステム(株)製INH-21CD)を用いて窒素気流下(酸素濃度20ppm以下)、3.5℃/minで300℃まで昇温し、30分間保持し、5℃/minで50℃まで冷却し樹脂積層体を作製した。続いて、得られた樹脂積層体の周囲に切り込みを入れ、65℃のお湯に1~4分間浸漬した後に物理的に引っ張って樹脂積層体を基板から剥離し、風乾した。
紫外可視分光光度計((株)島津製作所製 MultiSpec1500)を用い、波長400nmにおける光透過率を測定した。なお、測定には(1)で作製したガラス基板上樹脂積層体を用いた。
熱機械分析装置(エスアイアイ・ナノテクノロジー株式会社製 EXSTAR6000 TMA/SS6000)を用いて、窒素気流下で測定を行った。昇温方法は、以下の条件にて行った。第1段階で昇温レート5℃/minで150℃まで昇温して試料の吸着水を除去し、第2段階で降温レート5℃/minで室温まで空冷した。第3段階で、昇温レート5℃/minで本測定を行い、50~200℃の線膨張係数の平均から線膨張係数(CTE)を求めた。なお、測定には(3)で作製した樹脂積層体を用い、以下の評価方法にて判定した。
優良(A):35ppm/℃以下
良(B):35ppm/℃超40ppm/℃以下
不良(C):40ppm/℃超。
プリズムカプラー(METRICON社製、PC2010)を用い、波長632.8nmのTE屈折率(n(TE))およびTM屈折率(n(TM))を測定した。n(TE)、n(TM)は、それぞれ膜面に対して、平行、垂直方向の屈折率である。複屈折はn(TE)とn(TM)の差(n(TE)-n(TM))として計算し、膜Aの複屈折をΔNA、膜Bの複屈折をΔNBとした。なお、測定には(2)で作製した樹脂膜を用いた。
(2)で作成したポリシロキサン樹脂膜を削り取り、アルミセルに約15mg入れ、熱重量測定装置(株式会社島津製作所製 TGA-50)を用いて窒素気流下で測定を行った。昇温方法は、以下の条件にて行った。第1段階で、昇温レート3.5℃/minで150℃まで昇温して試料の吸着水を除去し、第2段階で、降温レート10℃/minで40℃まで冷却し第3段階で昇温レート10℃/minで本測定を実施し、重量が3%減少した時の温度(Td3)を求めた。
無アルカリガラス(ガラス厚み0.7mm)上に形成された膜Bの、XYZ表色系色度図における透過色度座標を大塚電子(株)製、顕微分光光度計“MCPD-2000”を用いて測定した。
A(非常に良好:◎):a*、b*の値が、0≦|a*|≦0.5かつ0≦|b*|≦1.0
B(良好:○):a*、b*の値が、0≦|a*|≦1.0かつ1.0<|b*|≦1.8
C(可:△):a*、b*の値が、0≦|a*|≦1.5かつ1.8<|b*|≦2.5
D(不良:×):a*、b*の値が、|a*|>1.5又は|b*|>2.5。
(9)フレキシブルカラーフィルターの耐屈曲性評価
フレキシブルカラーフィルターの耐屈曲性を以下の手法で測定した。まず、ガラス基板から剥離したカラーフィルターを100mm×140mmにサンプリングし、面上の中央部に直径30mmの金属円柱を固定し、この円柱に沿って、円柱の抱き角0°(サンプルが平面の状態)の状態に置き(図1参照)、円柱への抱き角が180°(円柱で折り返した状態)となる範囲(図2参照)で、100回折り曲げ動作を行った。耐屈曲性は、曲げ動作前後の膜Bにおけるクラック発生の有無を指標とし、試験後に光学顕微鏡(Nikon(製)、OPTIPHOT300)を用いて目視で100枚観察を行った。
ガラス基板付きカラーフィルターにおけるBMの理想格子からのズレ量を、SMIC-800(ソキア・トプコン社製)を用い、以下のように測定した。まず、形成箇所をガラス基板上とすること以外は実施例1[2]に記載されたのと同様にして、ガラス基板上にBMパターンを作成した。そのBMパターンの24箇所について、理想格子からのズレ量を測定した。次に、各実施例および比較例で得られたカラーフィルターにおけるBMパターンの24箇所について、理想格子からのズレ量を測定した。いずれも、測定により得られたズレ量の絶対値の平均を計算により求め、得られた値をその水準におけるBMの理想格子からのズレ量とした。各実施例および比較例におけるズレ量の値を評価するとともに、BMパターンをガラス基板上に作製した場合と樹脂積層体上に作製した場合でズレ量にどの程度の違いがあるかを評価し、以下の評価方法にて判定した。
優良(A):BM位置ずれ量が1.8μm以下
良(B):BM位置ずれ量が1.8μm超2.4μm以下
不良(C):BM位置ずれ量が2.4μm超。
作製直後の有機EL素子、高温高湿試験後の有機EL素子、および屈曲試験に続く高温高湿試験後の有機EL素子における輝度1000cd/m2での電流効率(cd/A)を測定した。前記、屈曲試験はガラス基板から剥離した有機EL素子を100mm×140mmにサンプリングし、面上の中央部に直径30mmの金属円柱を固定し、この円柱に沿って、円柱の抱き角0°(サンプルが平面の状態)の状態に置き(図1参照)、円柱への抱き角が180°(円柱で折り返した状態)となる範囲(図2参照)で、100回折り曲げることにより行った。また、前記、高温高湿試験はガラス基板から剥離した有機EL素子を内温85℃、湿度85%の高温高湿槽に24時間入れて行った。
乾燥窒素気流下、200mL4つ口フラスコに4,4’-オキシジフタル酸無水物(ODPA)16.66g(53.7mmol)、2,2-ビス[3-(3-アミノベンズアミド)-4-ヒドロキシフェニル]ヘキサフルオロプロパン(HFHA)32.46g(53.7mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(I)とした。
乾燥窒素気流下、200mL4つ口フラスコに3,3’,4,4’-ビフェニルテトラカルボン酸二無水物(BPDA)11.53g(39.2mmol)、1,2,3,4-シクロブタンテトラカルボン酸二無水物(CBDA)1.92g(9.79mmol)、trans-1,4-ジアミノシクロへキサン(CHDA)5.59g(49.0mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(II)とした。
乾燥窒素気流下、200mL4つ口フラスコに3,3’,4,4’-ビフェニルテトラカルボン酸二無水物(BPDA)7.90g(26.4mmol)、2,2-ビス(4-(3,4-ジカルボキシフェノキシ)フェニル)プロパン二無水物(BSAA)14.01g(26.4mmol)、trans-1,4-ジアミノシクロへキサン(CHDA)6.1375g(53.7mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(III)とした。
乾燥窒素気流下、200mL4つ口フラスコに3,3’,4,4’-ビフェニルテトラカルボン酸二無水物(BPDA)13.72g(46.6mmol)、trans-1,4-ジアミノシクロへキサン(CHDA)5.33g(46.6mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(IV)とした。
乾燥窒素気流下、200mL4つ口フラスコに1,2,3,4-シクロブタンテトラカルボン酸二無水物(CBDA)7.23g(36.9mmol)、2,2’-ビス(トリフルオロメチル)ベンジジン(TFMB)11.81g(36.9mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(V)とした。
乾燥窒素気流下、200mL4つ口フラスコに1,2,4,5‐シクロヘキサンテトラカルボン酸二無水物(PMDA-HS)12.04g(53.7mmol)、2,2-ビス[3-(3-アミノベンズアミド)-4-ヒドロキシフェニル]ヘキサフルオロプロパン(HFHA)32.46g(53.7mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却して透明ポリイミド前駆体樹脂溶液(VI)とした。
乾燥窒素気流下、200mL4つ口フラスコにピロメリット酸無水物(PMDA)7.03g(32.2mmol)、4,4’-ビフタル酸無水物(BPDA)6.32g(21.5mmol)、1、4-フェニレンジアミン(PDA)5.81g(53.7mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却してポリイミド前駆体樹脂溶液(VII)とした。
乾燥窒素気流下、200mL4つ口フラスコに4,4’-ビフタル酸無水物(BPDA)10.21g(34.7mmol)、trans-1,4-ジアミノシクロヘキサン(CHDA)1.59g(13.9mmol)、9,9-ビス(4-アミノフェニル)フルオレン(FDA)7.26g(20.8mmol)、N-メチル-2-ピロリドン100gを入れて65℃で加熱撹拌した。6時間後、冷却してポリイミド前駆体樹脂溶液(VIII)とした。
乾燥窒素気流下、4,4’-ジアミノフェニルエーテル(ODA)60.07g(300.0mmol)、1、4-フェニレンジアミン(PDA)70.33g(650.4mmol)および1,3-ビス(3-アミノプロピル)テトラメチルジシロキサン12.43g(50.0mmol)を、850gのγ-ブチロラクトンおよび850gのN-メチル-2-ピロリドンと共に仕込み、3,3’,4,4’-オキシジフタルカルボン酸二無水物(ODPA)309.43g(997.5mmol)を添加し、80℃で3時間反応させた。無水マレイン酸1.96g(20.0mmol)を添加し、更に80℃で1時間反応させ、ポリイミド前駆体樹脂溶液(VIIII)を得た。
500mlの三口フラスコにメチルトリメトキシシランを46.05g(0.34mo
l)、フェニルトリメトキシシランを83.79g(0.42mol)、(2-(3,
4-エポキシシクロヘキシル)エチルトリメトキシシランを20.82g(0.08mo
l)、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)を151.68136.51g、メタノール15.17g仕込み、室温で攪拌しながら水47.21g(加水分解に必要な理論量)にリン酸0.45g(仕込みモノマーに対して0.3重量%)を溶かしたリン酸水溶液を滴下ロートで10分かけて添加した。その後、フラスコを40℃のオイルバスに浸けて30分攪拌した後、オイルバスを30分かけて115℃まで昇温した。昇温開始1時間後に溶液の内温が100℃に到達し、そこから2時間加熱攪拌し(内温は100~110℃)、ポリシロキサン溶液(I)を得た。なお、加熱攪拌中、窒素を0.05l(リットル)/min流した。反応中に副生成物であるメタノール、水、および溶媒が合計105g留出した。得られたポリシロキサンのPGMEA溶液に、ポリマー濃度が40wt%となるようにPGMEAを加え、ポリシロキサン溶液(I)を得た(Mw=5500(ポリスチレン換算))。固形分濃度はアルミカップにポリシロキサン樹脂溶液を1g秤取し、ホットプレートを用いて250℃で30分間加熱して液分を蒸発させ、加熱後のアルミカップに残った固形分を秤量して求めた。また、重量平均分子量はGPC(Waters社製410型RI検出器、流動層:テトラヒドロフラン)にてポリスチレン換算により求めた。
500mLのフラスコに47.67g(0.35mol)のメチルトリメトキシシリル、39.66g(0.20mol)のフェニルトリメトキシシラン、82.04g(0.35mol)のγ-アクリロイルプロピルトリメトキシシラン、26.23(0.1mol)の3-トリメトキシシリルプロピルコハク酸無水物及び195.6gのダイアセトンアルコール(DAA)を仕込み、40℃のオイルバスに漬けて撹拌しながら55.8gの水(加水分解に必要な理論量)に0.39gのリン酸(仕込みモノマーに対して0.2重量部)を溶かしたリン酸水溶液を滴下ロートで10分かけて添加した。40℃で1時間撹拌した後、オイルバス温度を70℃に設定して1時間撹拌し、さらにオイルバスを30分かけて115℃まで昇温した。昇温開始1時間後に溶液の内温が100℃に到達し、そこから2時間加熱撹拌した(内温は100~110℃)。反応中に副生成物であるメタノール、水が合計127g留出した。得られたポリシロキサン樹脂のDAA溶液に、ポリマー濃度が40wt%となるようにDAAを加え、ポリシロキサン樹脂溶液(II)を得た(Mw=4500(ポリスチレン換算))。
合成例10で得られたポリシロキサン溶液(I)7.42g、無機酸化物粒子としてPMA-ST(日産化学工業(株)製;二酸化ケイ素プロピレングリコールモニメチルエーテルアセテート分散液;固形分濃度=30wt%)2.66g、レベリング剤としてメガファックF-477(DIC製)0.01g、溶剤としてPGMEA4.94g、ジエチレングリコールエチルメチルエーテル(EDM)4.80gを混合、攪拌して均一溶液とした後、0.45μmのフィルターで濾過してシリカ粒子のワニス固形分中の含有率が20wt%であるポリシロキサン樹脂組成物1を調製した。
黄色灯下にて、1.995gのPMA-ST(日産化学工業(株)製;二酸化珪素プロピレングリコールモノメチルエーテルアセテート分散液;固形分濃度=30wt%)、0.0898gのイルガキュアOXE-02及び0.0299gのハイドロキノンメチルエーテル(HQME)を加え、6.00gのDAA及び1.44gのPGMEAに溶解させ撹拌した。そこへ、ジペンタエリスリトールヘキサアクリレート(DPHA)の50wt%PGMEA溶液を1.257g、ポリシロキサン溶液(II)を4.115g、BYK-333のPGMEA1wt%溶液を0.075g、それぞれ加えて、撹拌した。次いで0.45μmのフィルターで濾過を行い、シリカ粒子のワニス固形分中の含有率が20wt%であるネガ型感光性のポリシロキサン樹脂組成物2を得た。
合成例9のポリイミド前駆体樹脂溶液(VIIII)250gに、50gのカーボンブラック(MA100;三菱化学(株)製)および200gのN-メチル-2-ピロリドンを混合し、ダイノーミルKDL-Aを用いて、直径0.3mmのジルコニアビーズを使用して、3200rpmで3時間の分散処理を行い、黒色樹脂分散液を得た。
ピグメントレッドPR177、8.05gを3-メチル-3-メトキシブタノール50gとともに仕込み、ホモジナイザーを用い、7000rpmで5時間分散後、ガラスビーズを濾過し、除去した。アクリル共重合体溶液(ダイセル化学工業(株)製“サイクロマー”P、ACA-250、43wt%溶液)70.00g、多官能モノマーとしてペンタエリスリトールテトラメタクリレート30.00g、光重合開始剤として“イルガキュア”369、15.00gにシクロペンタノン260.00gを加えた濃度20重量%の感光性アクリル樹脂溶液(AC)134.75gを加え、感光性赤レジストを得た。同様にして、ピグメントグリーンPG38とピグメントイエローPY138からなる感光性緑レジスト、ピグメントブルーPB15:6からなる感光性青レジストを得た。
65.05gのトリメリット酸に、280gのGBLおよび74.95gのγ-アミノプロピルトリエトキシシランを添加し、120℃で2時間加熱した。得られた溶液20gに、7.00gのビスフェノキシエタノールフルオレンジグリシジルエーテルおよび15.00gのジエチレングリコールジメチルエーテルを添加し、樹脂組成物を得た。
PB15:6 65g、PV23 35g、分散剤としてbic chemie社“BYK2001”40g及びプロピレングリコールモノメチルアセテート860gを、直径0.3mmのジルコニアビーズ1000gとともにホモジナイザーを用いて、7000rpmで30分間分散処理後、ジルコニアビーズを濾過により除去し、顔料分散液(d1)を得た。
[1]樹脂積層体の作製
300mm×400mm×0.7mm厚のガラス基板1(AN100(旭硝子(株)製))に、合成例1で得られた透明ポリイミド前駆体樹脂溶液(I)を、140℃で10分間プリベーク後の厚さが15±0.5μmになるようにスピン塗布した。その後、送風乾燥器を用いて140℃で10分間プリベーク処理を行った。続いて、ポリイミド樹脂膜上に調製例1で得られたポリシロキサン樹脂組成物1を、100℃で2分間プリベーク後の厚さが1.2μmになるようにスピン塗布した。その後、送風乾燥器を用いて100℃で2分間プリベーク処理を行った。その後、窒素気流下(酸素濃度20ppm以下)300℃に加熱したイナートオーブン(光洋サーモシステム(株)製 INH-21CD)で30分間加熱し、ポリイミド樹脂を含む膜A10μm、ポリシロキサン樹脂を含む膜B1μmよりなる樹脂積層体を作製した。得られた樹脂積層体の波長400nmにおける可視光透過率、CTEを測定したところ、透過率は87.8%、CTEは30ppm/℃であった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定を行った。結果を表1に示す。
[1]で作製した積層体のポリシロキサン樹脂を含む膜Bの上に調整例4で作製した黒色樹脂組成物をスピン塗布し、ホットプレートで130℃、10分間乾燥し、黒色の樹脂塗膜を形成した。ポジ型フォトレジスト(シプレー社製、“SRC-100”)をスピン塗布、ホットプレートで120℃、5分間プリベークし、超高圧水銀灯を用いて100mJ/cm2(i線換算)紫外線照射してマスク露光した後、2.38%のテトラメチルアンモニウムヒドロキシド水溶液を用いて、フォトレジストの現像と黒色の樹脂塗膜のエッチングを同時に行い、パターンを形成、メチルセロソルブアセテートでレジスト剥離し、ホットプレートで280℃、10分間加熱させることでイミド化させ、ポリイミド樹脂にカーボンブラックを分散した樹脂ブラックマトリクスを形成した。ブラックマトリクスの厚さを測定したところ、1.4μmであった。また、前述の方法でブラックマトリックスの位置精度の評価を行ったところ、BM位置ずれ量が1.7μmであった。
[1]、[2]で作製した、ブラックマトリクスがパターン加工された樹脂積層体に、調製例5で調整した感光性赤レジストを、熱処理後のブラックマトリクス開口部での膜厚が2.0μmになるようにスピン塗布し、ホットプレートで100℃、10分間プリベークすることにより、赤色着色層を得た。次に、キャノン(株)製、紫外線露光機“PLA-5011”を用い、ブラックマトリクス開口部とブラックマトリクス上の一部の領域についてアイランド状に光が透過するクロム製フォトマスクを介して、100mJ/cm2(i線換算)で露光した。露光後に0.2%のテトラメチルアンモニウムヒドロキシド水溶液からなる現像液に浸漬を行い現像し、続いて純水洗浄後、230℃のオーブンで30分間加熱処理し、赤画素7Rを作製した。同様にして、調製例4で調整した感光性緑レジストからなる緑画素7G、感光性青レジストからなる青画素7Bを作製し、カラーフィルター(図3)を得た。続いて、熱処理後の着色層部での厚さが2.5μmになるようにスピナーの回転数を調整し、調整例6で作製した樹脂組成物を塗布した。その後、230℃のオーブンで30分間加熱処理し、オーバーコート層を作製した。
[1]の方法で作製した樹脂積層体(ガラス基板上)のポリシロキサン樹脂を含む膜B上に、プラズマCVD法を用いてSiOから成る無機ガスバリア膜を製膜した。その後、ボトムゲート型のTFTを形成し、このTFTを覆う状態でSi3N4から成る絶縁膜を形成した。次に、この絶縁膜に、コンタクトホールを形成した後、このコンタクトホールを介してTFTに接続される配線(高さ1.0μm)を絶縁膜上に形成した。この配線は、TFT間または、後の工程で形成される有機EL素子とTFTとを接続するためのものである。
上記の方法で得られたTFTの平坦化層上に、トップエミッション型の有機EL素子を形成した。まず、平坦化層上に、Al/ITO(Al:反射電極)からなる第一電極を、コンタクトホールを介して配線に接続させて形成した。その後、レジストを塗布、プリベークし、所望のパターンのマスクを介して露光し、現像した。このレジストパターンをマスクとして、ITOエッチャント用いたウエットエッチングにより第一電極のパターン加工を行った。その後、レジスト剥離液(モノエタノールアミンとジエチレングリコールモノブチルエーテルの混合液)を用いて該レジストパターンを剥離した。剥離後の基板を水洗し、200℃で30分間加熱脱水して平坦化層付き電極基板を得た。平坦化層の厚さの変化は、剥離液処理前に対して加熱脱水後で1%未満であった。こうして得られた第一電極は、有機EL素子の陽極に相当する。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例2で得られたポリイミド前駆体樹脂溶液(II)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ85.5%、20ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例3で得られたポリイミド前駆体樹脂溶液(III)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ91.0%、32ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例4で得られたポリイミド前駆体樹脂溶液(IV)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ86.8%、9.0ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例5で得られたポリイミド前駆体樹脂溶液(V)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ95.3%、19ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例6で得られたポリイミド前駆体樹脂溶液(VI)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ96.1%、29ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例7で得られたポリイミド前駆体樹脂溶液(VII)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ2.4%、6.0ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリイミド前駆体樹脂溶液(I)の代わりに合成例8で得られたポリイミド前駆体樹脂溶液(VIII)を使用した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ65.2%、23ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
ポリシロキサン樹脂組成物1の代わりに調製例2で得られたポリシロキサン樹脂組成物2を使用し、ポリシロキサン樹脂組成物2の塗布、プリベークに続いてキャノン(株)製、紫外線露光機“PLA-5011”を用い、塗布膜全面に150mJ/cm2(i線換算)で露光し、膜B’の光硬化を行った後に、0.2%のテトラメチルアンモニウムヒドロキシド水溶液からなる現像液に1分間浸漬を行い現像し、続いて純水洗浄したこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ87.4%、30ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
調製例1において、顔料分散液(d1)を0.1g添加した以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ87.7%、30ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表1に示す。
実施例1において、膜Aの膜厚を20μmに、膜Bの膜厚を3μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ76.3%、29ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を5μmに、膜Bの膜厚を3μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ91.1%、25ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を10μmに、膜Bの膜厚を2.5μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ85.6%、28ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を15μmに、膜Bの膜厚を1.5μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ82.2%、31ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を19μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ77.1%、36ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を24μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ75.8%、38ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
調製例1において、シリカ粒子のワニス固形分中の含有率を65wt%にした以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ88.0%、29ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
調製例1において、シリカ粒子のワニス固形分中の含有率を80wt%にした以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ88.1%、27ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Bの膜厚を0.4μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ88.5%、39ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
調製例1において、シリカ粒子のワニス固形分中の含有率を90wt%にした以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ86.2%、25ppm/℃であった。88.5%、25ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Bを形成しなかったこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ88.0%、48ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
調製例1において、PMA-STを添加しなかったこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ87.7%、53ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を25μmに、膜Bの膜厚を0.5μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ73.4%、42ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
実施例1において、膜Aの膜厚を4.0μmに、膜Bの膜厚を3.0μmに変えたこと以外、実施例1と同様にして樹脂積層体、カラーフィルターおよび有機EL素子を作製した。樹脂積層体の波長400nmにおける可視光透過率、CTEはそれぞれ92.1%、23ppmであった。また、前述の方法で複屈折の測定、耐屈曲性評価、3%重量減少温度の測定、色度の測定、ブラックマトリックスの位置精度の評価および発光効率の測定を行った。結果を表2に示す。
[1]ガラス基板付きカラーフィルターおよび白色発光型有機EL素子の作製
実施例1に記載の方法で、ガラス基板上にカラーフィルターおよび白色発光型有機EL素子を作製した。
上記[1]で得られたガラス基板付きカラーフィルターとガラス基板付き白色発光型有機EL素子を、粘着層を介して貼り合わせた。続いて、エキシマレーザー(波長308nm)をガラス基板側から照射することにより、ガラス基板からカラーフィルターと白色発光型有機EL素子を剥離した。続いて、カラーフィルター側の膜Aに円偏光フィルムを貼り付け、有機ELディスプレイ(図5)を作製した。
実施例10で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
実施例4で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
実施例8で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
300mm×400mm×0.7mm厚のガラス基板1(AN100(旭硝子(株)))に、合成例7で得たポリイミド前駆体樹脂溶液(VII)を、140℃で10分間プリベーク後の厚さが15±0.5μmになるようにスピン塗布した。その後、送風乾燥器を用いて140℃で10分間プリベーク処理を行った。基板の温度が室温に下がった後、窒素気流下(酸素濃度20ppm以下)300℃に加熱したイナートオーブン(光洋サーモシステム(株)製 INH-21CD)で30分間加熱し、ポリイミド樹脂膜を作製した。得られた樹脂膜の波長400nmの可視光透過率、CTEを測定したところ、透過率は2.5%、CTEは6ppm/℃であった。
[1]ガラス基板付きカラーフィルターの作製
実施例1に記載の方法で、ガラス基板上にカラーフィルターを作製した。
(1)ポリイミド樹脂膜の作製
参考例1に記載の方法で、ガラス基板上に樹脂膜を作製した。
上記(1)で作製したポリイミド樹脂膜上に実施例1の[4]と同様にしてTFT用支持基板を作製した。
上記(2)で作製したTFT基板上に実施例1の[5]と同様にして白色発光型有機EL素子を作製した。
上記[1]で得られたガラス基板付きカラーフィルターと[2]で得られたガラス基板付き白色発光型有機EL素子を、粘着層を介して貼り合わせた。続いて、エキシマレーザー(波長308nm)をガラス基板側から照射することにより、ガラス基板からカラーフィルターと白色発光型有機EL素子を剥離し、有機ELディスプレイを作製した。
実施例16で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
実施例20で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
比較例1で作製したカラーフィターを用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
比較例1で作製した白色発光型有機EL素子を用いた以外は実施例23と同様にして有機ELディスプレイを作製した。
有機ELディスプレイを白色表示したときの色目を目視で観察し、視認性を以下のように判定した。
優良(A):白色に見える
良(B):やや着色しているように見えるが、気にならない程度の白色に見える
不良(C):明らかに着色しており、白色とは言えない。
各実施例、比較例のディスプレイについて駆動回路を介して電圧を印加し、晴天の日の屋外におけるディスプレイの視認性について確認した。
優良(A):外光反射が十分に抑制され、視認性に優れている。
良(B):外光反射低減効果がやや劣るものの、視認性良好である。
不良(C):外光反射が低減されず、視認性に劣る。
各実施例、比較例のディスプレイについて駆動回路を介して電圧を印加し、ディスプレイの鮮明さ、コントラストについて確認した。
優良(A):鮮明でコントラストに優れたディスプレイである。
良(B):鮮明さに劣るものの全体として表示良好なディスプレイである。
不良(C):欠陥が多数見られ、表示性能に劣るディスプレイである。
2 フレキシブルカラーフィルター
3 ガラス基板
4 膜A
5 膜B
6 ブラックマトリックス
7R 赤色画素
7G 緑色画素
7B 青色画素
8 オーバーコート層
9 平坦化層
10 第一電極
11 絶縁層
12 白色EL素子
13 第二電極
14 封止層
15 TFT層
16 ガスバリア層
17 粘着層
18 円偏光フィルム
19 フレキシブルカラーフィルター
20 フレキシブル有機EL素子
Claims (23)
- ポリイミド樹脂を含む膜Aの少なくとも片面にポリシロキサン樹脂を含む膜Bを有するディスプレイ用支持基板であって、前記膜Bに無機酸化物粒子を含むことを特徴とするディスプレイ用支持基板。
- 前記膜Aと前記膜Bの膜厚比率が膜A/膜B=25/1~1.5/1であることを特徴とする請求項1に記載のディスプレイ用支持基板。
- 前記ディスプレイ用支持基板の線膨張係数が40ppm/℃以下である請求項1または2に記載のディスプレイ用支持基板。
- 前記膜Aの複屈折をΔNA、前記膜Bの複屈折をΔNBとした時に(ΔNA-ΔNB)≦0.065である請求項1~3のいずれかに記載のディスプレイ用支持基板。
- 前記膜B中の前記無機酸化物粒子の含有量が20~80重量%である請求項1~4のいずれかに記載のディスプレイ用支持基板。
- 前記無機酸化物粒子が二酸化ケイ素である請求項1~5のいずれかに記載のディスプレイ用支持基板。
- 透明であることを特徴とする請求項1~6のいずれかに記載のディスプレイ用支持基板。
- 前記膜Aの膜厚が5.0μm以上20μm以下であり、前記膜Bの膜厚が0.2μm以上3.0μm以下である請求項1~7のいずれかに記載のディスプレイ用支持基板。
- 前記ポリイミド樹脂が、トリフルオロメチル基および脂環式炭化水素基から選ばれる少なくとも1種の基を有する、請求項1~8のいずれかに記載のディスプレイ用支持基板。
- 前記ポリイミド樹脂に含まれるジアミン残基の全量に対して、トリフルオロメチル基および脂環式炭化水素基から選ばれる少なくとも1種の基を有するジアミン残基が50モル%以上含まれることを特徴とする、請求項1~9のいずれかに記載のディスプレイ用支持基板。
- 前記膜Bの3%重量減少温度が300℃以上である請求項1~12のいずれかに記載のディスプレイ用支持基板。
- 前記膜BのXYZ表色系色度図における透過色度座標が0.300≦x≦0.325および0.305≦y≦0.325の範囲にある請求項1~13のいずれかに記載のディスプレイ用支持基板。
- 請求項1~14のいずれかに記載のディスプレイ用支持基板の前記膜B上にブラックマトリックスおよび着色画素を備えたカラーフィルター。
- 前記カラーフィルターの前記膜A側に支持基板を備えた請求項15記載のカラーフィルター。
- 少なくとも下記(1)~(6)の工程を含むカラーフィルターの製造方法。
(1)支持基板上にポリイミド前駆体樹脂を含む樹脂溶液を塗布して塗布膜A’を得る工程。
(2)前記膜A’上にポリシロキサン樹脂組成物を塗布して膜B’を得る工程。
(3)前記膜A’と前記膜B’とをそれぞれ加熱して樹脂積層体を得る工程。
(4)前記樹脂積層体上にブラックマトリックスを形成する工程。
(5)前記樹脂積層体上に着色画素を形成する工程。
(6)支持基板から前記樹脂積層体を剥離する工程。 - 前記膜B’を得るための樹脂組成物が感光性樹脂組成物であって、前記膜B’を得る工程の後、膜B’を露光及び現像する工程を含む、請求15記載のカラーフィルターの製造方法。
- 請求項1~14のいずれかに記載のディスプレイ用支持基板の膜B上に有機EL素子を備えた有機EL素子。
- 前有機EL素子の膜A側に支持基板を備えた請求項19に記載の有機EL素子。
- 少なくとも下記(1)~(5)の工程を含む有機EL素子の製造方法。
(1)支持基板上にポリイミド前駆体樹脂を含む樹脂溶液を塗布して塗布膜A’を得る工程。
(2)前記膜A’上にポリシロキサン樹脂組成物を塗布して膜B’を得る工程。
(3)前記膜A’と前記膜B’とをそれぞれ加熱して樹脂積層体を得る工程。
(4)前記樹脂積層体上に有機EL素子を形成する工程。
(5)支持基板から前記樹脂積層体を剥離する工程。 - 前記膜B’を得るための樹脂組成物が感光性樹脂組成物であって、前記膜B‘を得る工程の後、膜B’を露光及び現像する工程を含む、請求項19記載の有機EL素子の製造方法。
- 請求項15に記載のカラーフィルターおよび/または請求項19に記載の有機EL素子を備えたフレキシブル有機ELディスプレイ。
Priority Applications (4)
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KR1020177007256A KR20170066340A (ko) | 2014-09-30 | 2015-09-25 | 디스플레이용 지지 기판, 그것을 이용한 컬러 필터 및 그 제조 방법, 유기 el 소자 및 그 제조 방법, 및 플렉시블 유기 el 디스플레이 |
SG11201702467QA SG11201702467QA (en) | 2014-09-30 | 2015-09-25 | Support substrate for display, color filter employing same and method for manufacturing same, organic led element and method for manufacturing same, and flexible organic el display |
US15/515,729 US10431753B2 (en) | 2014-09-30 | 2015-09-25 | Substrate for display, color filter using the same and method for the production thereof, organic EL element and method for the production thereof, and flexible organic EL display |
CN201580052928.7A CN107073914A (zh) | 2014-09-30 | 2015-09-25 | 显示器用支承基板、使用其的滤色片及其制造方法、有机el元件及其制造方法以及柔性有机el显示器 |
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JP2014-200267 | 2014-09-30 | ||
JP2014200266A JP6503674B2 (ja) | 2014-09-30 | 2014-09-30 | 樹脂積層体、それを用いた有機el素子基板、カラーフィルター基板及びそれらの製造方法ならびにフレキシブル有機elディスプレイ |
JP2014200267 | 2014-09-30 | ||
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KR (1) | KR20170066340A (ja) |
CN (1) | CN107073914A (ja) |
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Also Published As
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TW201612012A (en) | 2016-04-01 |
US20170309844A1 (en) | 2017-10-26 |
SG11201702467QA (en) | 2017-04-27 |
KR20170066340A (ko) | 2017-06-14 |
US10431753B2 (en) | 2019-10-01 |
CN107073914A (zh) | 2017-08-18 |
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