WO2020013107A1 - 感光性樹脂組成物、エッチング方法及び樹脂構造体の製造方法 - Google Patents
感光性樹脂組成物、エッチング方法及び樹脂構造体の製造方法 Download PDFInfo
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- WO2020013107A1 WO2020013107A1 PCT/JP2019/026931 JP2019026931W WO2020013107A1 WO 2020013107 A1 WO2020013107 A1 WO 2020013107A1 JP 2019026931 W JP2019026931 W JP 2019026931W WO 2020013107 A1 WO2020013107 A1 WO 2020013107A1
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- Prior art keywords
- meth
- photosensitive resin
- acrylate
- mass
- etching
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- 150000003512 tertiary amines Chemical class 0.000 description 1
- 238000012719 thermal polymerization Methods 0.000 description 1
- YRHRIQCWCFGUEQ-UHFFFAOYSA-N thioxanthen-9-one Chemical compound C1=CC=C2C(=O)C3=CC=CC=C3SC2=C1 YRHRIQCWCFGUEQ-UHFFFAOYSA-N 0.000 description 1
- LLZRNZOLAXHGLL-UHFFFAOYSA-J titanic acid Chemical compound O[Ti](O)(O)O LLZRNZOLAXHGLL-UHFFFAOYSA-J 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- LDHQCZJRKDOVOX-UHFFFAOYSA-N trans-crotonic acid Natural products CC=CC(O)=O LDHQCZJRKDOVOX-UHFFFAOYSA-N 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/46—Polymerisation initiated by wave energy or particle radiation
- C08F2/48—Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F212/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
- C08F212/02—Monomers containing only one unsaturated aliphatic radical
- C08F212/04—Monomers containing only one unsaturated aliphatic radical containing one ring
- C08F212/06—Hydrocarbons
- C08F212/08—Styrene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof
- C08F222/10—Esters
- C08F222/12—Esters of phenols or saturated alcohols
- C08F222/20—Esters containing oxygen in addition to the carboxy oxygen
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F257/00—Macromolecular compounds obtained by polymerising monomers on to polymers of aromatic monomers as defined in group C08F12/00
- C08F257/02—Macromolecular compounds obtained by polymerising monomers on to polymers of aromatic monomers as defined in group C08F12/00 on to polymers of styrene or alkyl-substituted styrenes
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
- G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
- G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
- G03F7/028—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with photosensitivity-increasing substances, e.g. photoinitiators
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/004—Photosensitive materials
- G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
- G03F7/032—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with binders
- G03F7/033—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with binders the binders being polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. vinyl polymers
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/40—Treatment after imagewise removal, e.g. baking
Definitions
- the present invention relates to a photosensitive resin composition having excellent resistance to a strongly alkaline etching solution and excellent releasability after an etching step, an etching method using the photosensitive resin composition, and a method for producing a resin structure.
- Polyimide resins have excellent heat resistance, chemical resistance, electrical properties, mechanical properties, dimensional stability, etc., and are therefore used as electronic materials in various applications in the manufacture of ICs, LSIs, module substrates, and the like.
- the polyimide resin is used as a film or a coating film (hereinafter, a film-like polyimide resin or a polyimide resin coating film is referred to as a “polyimide film”).
- a film-like polyimide resin or a polyimide resin coating film is referred to as a “polyimide film”.
- it is necessary to form a large number of holes in the polyimide film such as through holes for securing conduction between metal layers and device holes for device mounting.
- an etching method of chemically processing using a strongly alkaline solution that dissolves polyimide as an etchant is known (for example, Patent Documents 1 and 2). Further, according to the etching method, not only a circular hole forming process but also various shapes can be formed.
- an etching solution containing hydrazine As a strong alkaline etching solution for dissolving polyimide, an etching solution containing hydrazine is known.
- the etching solution containing hydrazine not only has a problem in etching characteristics, but also has a problem that hydrazine is highly toxic and inflames mucous membrane by inhalation of steam. Therefore, as an alternative etching solution, a strongly alkaline etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound has been proposed (for example, Patent Documents 1 and 2). reference). According to the etching solution, the shape of the etching hole is hardly deformed.
- the polyimide film is etched using the metal layer or the resin layer patterned on the surface of the polyimide film as a resist.
- the metal layer is stable to the etching solution, does not penetrate the solution, and the metal layer and the polyimide film are hardly peeled off. Suitable for.
- a metal layer resist is expensive in many cases and cannot use a metal layer in a process in many cases, and the technique of etching using a resin layer as a resist is called for.
- Patent Documents 2 to 5 Techniques for etching the resin layer as a resist are disclosed in Patent Documents 2 to 5 and the like. Since the etching solution is strongly alkaline, for example, in Patent Document 4, an organic solvent developing type photosensitive resin layer represented by a combination of a rubber and a bis azide resin (for example, a negative photoresist OMR manufactured by Tokyo Ohka Kogyo Co., Ltd.) (Registered trademark) series), but an alkali-developable photosensitive resin layer is most preferable from the viewpoints of working environment, simplicity of development processing, and production cost.
- an organic solvent developing type photosensitive resin layer represented by a combination of a rubber and a bis azide resin (for example, a negative photoresist OMR manufactured by Tokyo Ohka Kogyo Co., Ltd.) (Registered trademark) series
- an alkali-developable photosensitive resin layer is most preferable from the viewpoints of working environment, simplicity of development processing, and production cost.
- Patent Documents 2, 3, and 5 disclose a technique in which an alkali-developable photosensitive resin layer is used as a resist, and a polyimide film is etched in a pattern with a strong alkaline etchant.
- the photosensitive resin layer may be dissolved, swelled or peeled off by the etchant, and since the photosensitive resin layer penetrates the etchant, the usable life of the resist is reduced. It is not suitable for processing of short and fine shapes, processing of thick polyimide films, and processing of polyimide films having a low dissolution rate.
- JP-A-10-097081 JP 2007-008969 A Japanese Patent No. 3401281 JP-A-6-234870 JP 2001-305750 A
- An object of the present invention is to provide a photosensitive resin composition having excellent resistance to a strongly alkaline etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound. It is an object of the present invention to provide an etching method using a conductive resin composition and a method for producing a resin structure using the etching method.
- a photosensitive resin composition used in an etching method for etching a substrate with an etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound, At least (A) an alkali-soluble resin, (B) a photopolymerization initiator and (C) a polymerizable monomer, As
- photosensitive resin composition (1) the photosensitive resin composition described in the above (1) may be abbreviated as “photosensitive resin composition (1)” in some cases.
- the alkali-soluble resin is a copolymer obtained by copolymerizing (I) methacrylic acid, (II) a styrene derivative, and (III) other monomers having an ethylenically unsaturated group, ) Methacrylic acid, (II) a styrene derivative, and (III) 20 to 40% by mass of methacrylic acid based on the total amount of monomers having an ethylenically unsaturated group, and (II) a styrene derivative.
- a photosensitive resin composition comprising:
- photosensitive resin composition (2) the photosensitive resin composition described in the above (2) may be abbreviated as “photosensitive resin composition (2)”.
- Step 1 of forming a photosensitive resin layer containing the photosensitive resin composition according to the above (1) or (2) on at least one surface of the substrate, and exposing and developing the photosensitive resin layer to form a resist At least a step 2 of forming a pattern and a step 3 of etching a substrate with an etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound. Characteristic etching method.
- the photosensitive resin composition (1) of the present invention comprises a compound represented by the aforementioned general formula (i), wherein m + n is 2 or more and 7 or less, is added to the (C) polymerizable monomer in an amount of 5 to 5%. 8080% by mass.
- the “compound represented by the general formula (i) and m + n is 2 or more and 7 or less” may be referred to as “compound (i) -S”.
- the compound (i) -S is a compound having extremely high alkali resistance, and the alkali resistance is further increased by crosslinking. And, by containing 5 to 80% by mass of the compound (i) -S with respect to the total amount of the polymerizable monomer (C), regardless of the monomer constituting the alkali soluble resin (A)
- the photosensitive resin composition (1) hardly swells or peels from “a strong alkaline etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound”. The effect can be achieved.
- etching solution ⁇ etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound
- etching solution ⁇ etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound
- the photosensitive resin composition (2) of the present invention comprises (I) methacrylic acid, (II) a styrene derivative and (III) other monomers having an ethylenically unsaturated group as copolymerizable components.
- the etching liquid ⁇ is used at a high temperature of, for example, 80 ° C.
- the effect that the photosensitive resin composition (2) is hard to swell or peel off can be achieved.
- the “compound represented by the general formula (i) and m + n is 2 or more and 20 or less” may be referred to as “compound (i) -P” in some cases.
- the etching solution ⁇ in the present invention is an etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound, and is preferably an aqueous solution.
- the alkali metal hydroxide at least one compound selected from the group consisting of potassium hydroxide, sodium hydroxide and lithium hydroxide is preferably used.
- potassium hydroxide can be suitably used.
- the content of the alkali metal hydroxide is more preferably from 20 to 45% by mass, even more preferably from 25 to 40% by mass, based on the entire etching solution.
- the ethanolamine compound examples include: primary amines such as ethanolamine; amines which are both primary and secondary amines such as N- ( ⁇ -aminoethyl) ethanolamine; N-methylethanolamine , A secondary amine such as N-ethylethanolamine and the like; and a tertiary amine such as N-ethyldiethanolamine and N-methyldiethanolamine; and at least one compound selected from the group consisting of Used.
- primary amines such as ethanolamine
- amines which are both primary and secondary amines such as N- ( ⁇ -aminoethyl) ethanolamine
- N-methylethanolamine N-methylethanolamine
- a secondary amine such as N-ethylethanolamine and the like
- a tertiary amine such as N-ethyldiethanolamine and N-methyldiethanolamine
- the content of the ethanolamine compound is more preferably from 20 to 40% by mass, and still more preferably from 25 to 3
- the etching method of the present invention includes a step 1 of forming a photosensitive resin layer containing the photosensitive resin composition of the present invention on at least one surface of a substrate, and exposing and developing the photosensitive resin layer to form a resist pattern.
- the method includes at least a step 2 of forming and a step 3 of etching the base material with the etching liquid ⁇ .
- Step 1 of forming a photosensitive resin layer on at least one surface of the substrate will be described.
- the substrate any substrate can be used as long as it can be etched by the etching solution ⁇ .
- a polyimide resin, a polyester resin, a resin containing an inorganic filler, a liquid crystal polymer, a resin containing a fluorine compound, glass, and the like can be given.
- polyimide resin examples include pyromellitic acid-based polyimide and biphenyltetracarboxylic acid-based polyimide.
- pyromellitic acid-based polyimide for example, "Kapton (registered trademark)” manufactured by DuPont of the United States and the like can be mentioned.
- biphenyltetracarboxylic acid-based polyimide examples include “UPILEX (registered trademark)” by Ube Industries, Ltd. It is known that the biphenyltetracarboxylic acid-based polyimide has a low dissolution rate in an alkaline etching solution among polyimide resins. Even a polyimide film having such a low dissolution rate can be processed into a pattern by using the photosensitive resin composition of the present invention.
- the polyester resin is not limited, and includes known resins.
- Examples of the inorganic filler of the resin containing an inorganic filler include silicates such as silica, glass, clay and mica; oxides such as alumina, magnesium oxide, titanium oxide and silica; and carbonates such as magnesium carbonate and calcium carbonate. Salts; hydroxides such as aluminum hydroxide, magnesium hydroxide and calcium hydroxide; sulfates such as barium sulfate and calcium sulfate; borates such as aluminum borate; nitrides such as aluminum nitride and boron nitride; titanic acid Titanates such as strontium and barium titanate; and the like.
- Specific examples of the resin component of the inorganic filler-containing resin include an alkali-insoluble resin.
- the alkali-insoluble resin refers to a resin having a very low content of an acid group such as a carboxyl group that exhibits alkali solubility.
- the acid value (JISJK2501: 2003), which is an index of the amount of free carboxyl groups and the like contained in the resin component of the resin containing an inorganic filler, is preferably less than 40 mgKOH / g. More specifically, a resin containing an epoxy resin and a thermosetting agent for curing the epoxy resin may be used.
- Examples of the epoxy resin include bisphenol type epoxy resins such as bisphenol A type epoxy resin, bisphenol F type epoxy resin and bisphenol S type epoxy resin; novolak type epoxy resins such as phenol novolak type epoxy resin and cresol novolak type epoxy resin; Is mentioned.
- Examples of the epoxy resin further include a biphenyl type epoxy resin, a naphthalene type epoxy resin, an anthracene type epoxy resin, a phenoxy type epoxy resin, and a fluorene type epoxy resin.
- Examples of the thermosetting agent include a phenol-based curing agent, a naphthol-based curing agent, an active ester-based curing agent, a benzoxazine-based curing agent, and a cyanate ester resin.
- the liquid crystal polymer, fluorine compound-containing resin, glass, and the like are not limited, and include known resins and glasses.
- a method of forming a photosensitive resin layer a method of applying a coating solution containing a photosensitive resin composition to a substrate, drying the coating solution, and forming a photosensitive resin layer is exemplified.
- a coating liquid containing the photosensitive resin composition of the present invention is applied to a carrier film to form a photosensitive resin layer containing the photosensitive resin composition, and then a dry film resist (hereinafter simply referred to as “DFR”) is formed. , which may be abbreviated as ”) and transferring the photosensitive resin layer to the substrate.
- DFR dry film resist
- Step 2 Step 2 of exposing and developing the photosensitive resin layer to form a resist pattern will be described.
- the photosensitive resin layer is exposed to light in a pattern, and the exposed portions are cured.
- Specific examples of the exposure include contact exposure using a photomask.
- a reflection image exposure, a proximity method, a projection method, a scanning exposure, and the like using a xenon lamp, a low-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a UV fluorescent lamp, or the like as a light source can be given.
- a laser light source such as a UV laser, a He-Ne laser, a He-Cd laser, an argon ion laser, a krypton ion laser, a ruby laser, a YAG laser, a nitrogen laser, a dye laser, and an excimer laser is used according to the emission wavelength. Scanning exposure using SHG wavelength conversion, or scanning exposure using a liquid crystal shutter or a micro mirror array shutter.
- the alkali developer used for the development for example, an aqueous solution of an inorganic alkaline compound can be used.
- the inorganic alkaline compound include carbonates and hydroxides such as lithium, sodium, and potassium.
- the alkali developer an aqueous solution of 0.1 to 3% by mass of sodium carbonate can be preferably used.
- a small amount of a surfactant, an antifoaming agent, a solvent, and the like can be appropriately mixed into the developer.
- the developing method includes a dip method, a battle method, a spray method, brushing, scraping and the like, and the spray method is most suitable for the removal speed.
- the processing temperature is preferably from 15 to 35 ° C.
- the spray pressure is preferably from 0.02 to 0.3 MPa.
- Step 3 of etching the base material with the etching liquid ⁇ will be described.
- etching method methods such as immersion treatment, paddle treatment, spray treatment, brushing, and scraping can be used.
- the immersion treatment is preferable.
- air bubbles are easily generated in the etching liquid ⁇ , and the air bubbles may adhere to the surface of the base material to cause poor etching.
- the temperature change of the etching liquid ⁇ is likely to be large, and the etching rate of the base material may vary.
- the processing temperature of the etching solution ⁇ is not particularly limited, but is preferably from 60 to 90 ° C., and the optimum processing temperature depends on the type and thickness of the substrate and the type, thickness and pattern shape of the photosensitive resin composition. Is different.
- the processing temperature is more preferably from 60 to 85 ° C, further preferably from 70 to 85 ° C.
- Step 4 of additionally exposing the resist pattern will be described.
- a step 4 of additionally exposing the resist pattern may be performed.
- the additional exposure is performed using a xenon lamp, a high-pressure mercury lamp, a low-pressure mercury lamp, an ultra-high-pressure mercury lamp, a UV fluorescent lamp, or the like as a light source, and irradiating the entire resist pattern including the ultraviolet-cured photosensitive resin layer, followed by crosslinking. Let it.
- the exposure amount of the additional exposure is not particularly limited, but is preferably 100 to 2000 mJ / cm 2 .
- the additional exposure of the resist pattern in step 4 further increases the alkali resistance of the photosensitive resin composition layer crosslinked in step 2.
- the additional exposure of the photosensitive resin composition of the present invention particularly exerts the effect that the resist pattern is less likely to swell or peel off in the subsequent etching treatment in step 3.
- the time from the end of Step 4 to the start of Step 3 is preferably 30 minutes or less, and more preferably 20 minutes or less. This allows the etching process to be performed in a state where the inside of the resist pattern formed by the photosensitive resin layer is sufficiently cured, and when the base material is etched by a strong alkaline etching solution ⁇ , the resist pattern is removed. Swelling or peeling can be further suppressed.
- a resist stripping step of stripping the resist pattern after step 3 will be described.
- the resist pattern may be left, but if unnecessary, the resist pattern is peeled off.
- an aqueous alkali solution is usefully used as the resist removing liquid.
- the basic compound used in the resist stripping solution include inorganic basic salts such as alkali metal silicate, alkali metal hydroxide, alkali metal phosphate, alkali metal carbonate, ammonium phosphate, and ammonium carbonate.
- Examples include organic basic compounds such as ethanolamine, ethylenediamine, propanediamine, triethylenetetramine, morpholine, and tetramethylammonium hydroxide.
- the resist pattern is less likely to be stripped in the resist stripping step.
- a resist stripping solution containing an inorganic basic compound such as sodium hydroxide is preferably used.
- an organic basic compound having higher permeability is used.
- organic amine-based release agents R-100 and R-100S are preferably used.
- the resist stripping step it is necessary to adjust the concentration, temperature, spray pressure, ultrasonic conditions and the like of the resist stripping solution in order to control the strippability of the cured photosensitive resin layer.
- the temperature of the resist stripping solution is higher, the speed at which the cured photosensitive resin layer is stripped becomes higher.
- a dip processing device, an ultrasonic device, a shower spray device, or the like can be used as a device.
- a polyimide film, a structure such as an inorganic filler-containing resin, through holes, holes such as device holes, or a pattern, can be suitably formed.
- the present invention is also a method for producing a resin structure having holes or patterns, characterized by using the above etching method.
- the photosensitive resin composition (1) of the present invention contains at least (A) an alkali-soluble resin, (B) a photopolymerization initiator, and (C) a polymerizable monomer, and (C) a polymerizable monomer.
- n and m in the general formula (i) are the number of repeating units in the general formula (i), and both are natural numbers.
- alkali-soluble resin in the alkali-soluble resin, the term “alkali-soluble” means that a target resin is formed into a film, and the film is dissolved in a 1% by mass aqueous solution of sodium carbonate at 25 ° C. for 10 minutes to have a thickness of 0.01 ⁇ m or more.
- the alkali-soluble resin is specifically a resin containing an acidic group, and includes a resin having an acid value of 40 mgKOH / g or more.
- Specific examples of the acidic group include a carboxyl group, a phenolic hydroxyl group, a sulfonic acid group, and a phosphoric acid group.
- the alkali-soluble resin examples include organic polymers such as (meth) acrylic resin, styrene resin, epoxy resin, amide resin, amide epoxy resin, alkyd resin, and phenol resin. . These may be used alone or in combination of two or more. Among them, it is preferable to use a (meth) acrylic resin.
- a (meth) acrylic resin a (meth) acrylic polymer obtained by copolymerizing an ethylenically unsaturated carboxylic acid with (meth) acrylate as a main component is preferable. Further, this may be obtained by copolymerizing another monomer having a copolymerizable ethylenically unsaturated group.
- Examples of the (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, n-hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, glycidyl (meth) Acrylate, lauryl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, 2- (dimethylamino) ethyl (meth) acrylate, 2- (diethylamino) ethyl (
- acrylic acid, methacrylic acid, monocarboxylic acids such as crotonic acid are preferably used, maleic acid, fumaric acid, dicarboxylic acids such as itaconic acid, and anhydrides and half esters thereof.
- acrylic acid and methacrylic acid are particularly preferred.
- Examples of the other copolymerizable monomers having an ethylenically unsaturated group include, for example, styrene, ⁇ -methylstyrene, p-methylstyrene, p-ethylstyrene, p-methoxystyrene, p-ethoxystyrene and p-methylstyrene.
- styrene ⁇ -methylstyrene
- p-methylstyrene p-methylstyrene
- p-ethylstyrene p-methoxystyrene
- p-ethoxystyrene p-ethoxystyrene
- -methylstyrene -Chlorostyrene, p-bromostyrene, (meth) acrylonitrile, (meth) acrylamide, diacetoneacrylamide, vinyltoluene, vinyl acetate,
- the acid value of the alkali-soluble resin affects the alkali developing speed, the resist peeling speed, the exposure sensitivity, the softness of the photosensitive resin layer, the adhesion between the photosensitive resin layer and the substrate, the resistance to the etching solution ⁇ , and the like. I do.
- the alkali-soluble resin preferably has an acid value of 40 to 500 mgKOH / g, more preferably 100 to 300 mgKOH / g. When the acid value is less than 40 mgKOH / g, the alkali developing time may be long.
- the acid value exceeds 500 mgKOH / g, the adhesion between the photosensitive resin layer and the base material may be poor, or the etching solution ⁇ Resistance may be reduced.
- the acid value is a value measured according to JIS K2501: 2003.
- the weight average molecular weight of the alkali-soluble resin (A) is preferably from 5,000 to 150,000, and particularly preferably from 10,000 to 100,000.
- the weight average molecular weight of the (A) alkali-soluble resin is less than 5,000, it may be difficult to form the photosensitive resin composition before curing into a film state.
- the weight average molecular weight of the alkali-soluble resin (A) exceeds 150,000, the solubility in an alkali developing solution may be deteriorated, or the rate of dissolution in a resist stripping solution may be reduced.
- the substituents of the aryl groups of the two 2,4,5-triarylimidazoles in the 2,4,5-triarylimidazole dimer may be identical or symmetric, or different. Asymmetric compounds may be provided. Further, a thioxanthone-based compound and a tertiary amine compound may be combined, such as a combination of diethylthioxanthone and dimethylaminobenzoic acid. These are used alone or in combination of two or more. Among these, imidazole dimer is highly sensitive and can be used preferably, and 2- (2'-chlorophenyl) -4,5-diphenylimidazole dimer can be particularly preferably used.
- the photosensitive resin composition (1) of the present invention contains, as the polymerizable monomer (C), compound (i) -S in an amount of 5 to 80% by mass based on the total amount of the polymerizable monomer (C). are doing.
- m + n in the compound (i) -S is 2 or more and 7 or less
- (A) the resistance to the etching solution ⁇ is excellent irrespective of the monomers constituting the alkali-soluble resin.
- M + n in the compound (i) -S is more preferably 3 or more and 5 or less.
- a resist stripping solution containing an organic basic compound is preferably used.
- a photosensitive resin composition which has resistance to a strongly alkaline etching solution ⁇ and also has a resist pattern stripping property in a resist stripping step is required.
- the compound (i) -S contains an ethoxy group (—CH 2 CH 2 O—), it is easily mixed with (A) an alkali-soluble resin having an acid value. (excellent compatible with each other), and the fact that the compound (i) -S is contained in the polymerizable monomer in an amount of 5 to 80% by mass with respect to the polymerizable monomer (C) also has an effect of being excellent in resist pattern removability. can get.
- the content of the compound (i) -S is 5 to 80% by mass, more preferably 6% by mass or more, still more preferably 8% by mass or more, based on the total amount of the polymerizable monomer (C). And particularly preferably at least 10% by mass. Further, it is more preferably at most 60% by mass, further preferably at most 40% by mass, particularly preferably at most 30% by mass.
- the content of the compound (i) -S is from 5 to 80% by mass (or within the above range)
- the compound has excellent resistance to the etching solution ⁇ , excellent peelability of the resist pattern, and excellent alkali developability. Is also excellent. If the content of the compound (i) -S is too low, the resistance to the etching solution ⁇ may be insufficient. On the other hand, if the content of the compound (i) -S is too high, the alkali developability is poor. In some cases, alkali development takes a long time. In addition, the peelability of the resist pattern may be deteriorate
- the photosensitive resin composition (1) of the present invention may contain a polymerizable monomer other than the compound (i) -S as the polymerizable monomer (C).
- a polymerizable monomer other than compound (i) -S a compound having one (meth) acryloyl group, a compound having two (meth) acryloyl groups, and having three or more (meth) acryloyl groups And the like.
- Compounds having one (meth) acryloyl group include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, Isobutyl (meth) acrylate, t-butyl (meth) acrylate, n-hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, isomyristyl (meth) acrylate, stearyl (Meth) acrylate, nonylphenoxy polyethylene glycol (meth) acrylate (at least one ethoxy group), 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, gly
- Examples of the (C) polymerizable monomer having two (meth) acryloyl groups include a compound obtained by reacting two (meth) acrylic acids with a polyhydric alcohol. .
- Examples of the compound (C) having a polymerizable monomer and having three or more (meth) acryloyl groups include a compound obtained by reacting (meth) acrylic acid with a polyhydric alcohol. .
- the photosensitive resin composition (2) of the present invention contains at least (A) an alkali-soluble resin, (B) a photopolymerization initiator, and (C) a polymerizable monomer, (A)
- the alkali-soluble resin is a copolymer obtained by copolymerizing (I) methacrylic acid, (II) a styrene derivative, and (III) other monomers having an ethylenically unsaturated group, ) Methacrylic acid, (II) a styrene derivative, and (III) 20 to 40% by mass of methacrylic acid based on the total amount of monomers having an ethylenically unsaturated group, and (II) a styrene derivative.
- n and m in the general formula (i) are the number of repeating units in the general formula (i), and both are natural numbers.
- alkali-soluble resin in the alkali-soluble resin, the term “alkali-soluble” means that a target resin is formed into a film, and the film is dissolved in a 1% by mass aqueous solution of sodium carbonate at 25 ° C. for 10 minutes to have a thickness of 0.01 ⁇ m or more.
- the alkali-soluble resin is specifically a resin containing an acidic group, and includes a resin having an acid value of 40 mgKOH / g or more.
- Specific examples of the acidic group include a carboxyl group, a phenolic hydroxyl group, a sulfonic acid group, and a phosphoric acid group.
- (I) methacrylic acid having a carboxyl group is used as a copolymerization component of (A) an alkali-soluble resin.
- (I) methacrylic acid is 20 to 40 to the total amount of (I) methacrylic acid, (II) styrene derivative and (III) other monomers having an ethylenically unsaturated group. %, More preferably 25 to 35% by mass, and (II) the styrene derivative is 25 to 50% by mass, more preferably 35 to 45% by mass.
- the styrene derivative (II) includes styrene, ⁇ -methylstyrene, p-methylstyrene, p-ethylstyrene, p-methoxystyrene, p-ethoxystyrene, p-chlorostyrene, p-bromostyrene and the like. No.
- the alkali resistance of the crosslinked photosensitive resin composition (2) of the present invention is improved.
- the crosslinked photosensitive resin composition (2) of the present invention is hardly swelled or peeled off by the strongly alkaline etching solution ⁇ . Further, even when the etching solution ⁇ is used at a high temperature of, for example, 80 ° C., the crosslinked photosensitive resin composition (2) of the present invention hardly swells or peels off.
- step 4 when the photosensitive resin layer is strongly crosslinked by performing additional exposure, the resist pattern is less likely to be stripped in the resist stripping step. Therefore, a resist stripping solution containing an organic basic compound is preferably used. However, it has been pointed out that as the photosensitive resin layer becomes thicker, the strippability of the resist pattern further deteriorates, and the resist pattern cannot be stripped even with a resist stripper containing an organic basic compound. Therefore, a photosensitive resin composition which has resistance to a strongly alkaline etching solution ⁇ and also has a resist pattern stripping property in a resist stripping step is required.
- the alkali-soluble resin needs an acidic group in order to impart alkali solubility.
- the alkali-soluble resin contains (I) methacrylic acid as a copolymer component having an acidic group. .
- the alkali developability becomes excellent.
- the resistance to the more strongly alkaline etching solution ⁇ can be improved.
- the resist pattern can be easily peeled without being damaged.
- Other monomers having an ethylenically unsaturated group include (meth) acrylates and monomers having a copolymerizable ethylenically unsaturated group other than (meth) acrylate.
- the seeds may be used alone, or two or more kinds may be used in combination.
- Examples of the (meth) acrylate include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, n-hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, glycidyl (meth) Acrylate, lauryl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, 2- (dimethylamino) ethyl (meth) acrylate, 2- (diethylamino) ethyl (
- Examples of the copolymerizable monomer having an ethylenically unsaturated group other than the (meth) acrylate include (meth) acrylonitrile, (meth) acrylamide, diacetone acrylamide, vinyltoluene, vinyl acetate, vinyl-n- Butyl ether and the like.
- the acid value of the alkali-soluble resin affects the alkali developing speed, the resist peeling speed, the exposure sensitivity, the softness of the photosensitive resin layer, the adhesion between the photosensitive resin layer and the substrate, the resistance to the etching solution ⁇ , and the like. I do.
- the alkali-soluble resin preferably has an acid value of 40 to 500 mgKOH / g, more preferably 100 to 300 mgKOH / g. When the acid value is less than 40 mgKOH / g, the alkali developing time may be long.
- the acid value exceeds 500 mgKOH / g, the adhesion between the photosensitive resin layer and the base material may be poor, or the etching solution ⁇ Resistance may be reduced.
- the acid value is a value measured according to JIS K2501: 2003.
- the weight average molecular weight of (A) the alkali-soluble resin is preferably from 5,000 to 150,000, more preferably from 10,000 to 100,000.
- the weight average molecular weight of the (A) alkali-soluble resin is less than 5,000, it may be difficult to form the photosensitive resin composition before curing into a film state.
- the weight average molecular weight of (A) the alkali-soluble resin exceeds 150,000, the solubility in an alkali developer may be deteriorated, or the rate of dissolution in a resist stripping solution may be slow.
- Examples of the photopolymerization initiator (B) include those similar to those described in the description of the photosensitive resin composition (1), and those suitable for the photosensitive resin composition (1) include the photosensitive resin.
- the composition (2) can also be suitably used.
- the photosensitive resin composition (2) of the present invention contains the compound (i) -P as a polymerizable monomer (C).
- the compound (i) -P By containing the compound (i) -P, it is possible to achieve an effect of being excellent in resistance to a strongly alkaline etching solution ⁇ and excellent in peelability after an etching step.
- compound (i) -P is contained, and then (A) the alkali-soluble resin is replaced with (I) methacrylic acid, (II) a styrene derivative and (III) other ethylenically unsaturated groups.
- methacrylic acid is 20 to 40% by mass
- (II) styrene derivative is 25 to 50% by mass
- the content of compound (i) -S is 80% in consideration of the peelability of the resist pattern.
- the alkali developability may be deteriorated and the alkali development may take a long time.
- the peelability of the resist pattern may be deteriorated.
- compound (i) -P in addition to “compound (i) -S”, a compound in which “m + n” is greater than 7 and 13 or less, and a compound in which “m + n” is greater than 13 and 20 or less Certain compounds are mentioned.
- the “compound represented by the general formula (i), wherein m + n is greater than 7 and 13 or less” may be abbreviated as “compound (i) -M”.
- compound represented by the general formula (i), wherein m + n is larger than 13 and 20 or less” may be abbreviated as “compound (i) -L”.
- the compound (i) is added to the total amount of the polymerizable monomer (C).
- the content of -P is preferably 60% by mass or more, more preferably 80% by mass or more, and still more preferably 90% by mass or more.
- the content of compound (i) -P may be 100% by mass.
- m + n” in the compound (i) -S is more preferably 3 to 5.
- M + n” in the compound (i) -M is more preferably 9 to 11.
- M + n” in the compound (i) -L is more preferably 16 to 18.
- the photosensitive resin composition (2) of the present invention may contain a polymerizable monomer other than the compound (i) -P as the polymerizable monomer (C).
- a polymerizable monomer other than compound (i) -P a compound having one (meth) acryloyl group, a compound having two (meth) acryloyl groups, and having three or more (meth) acryloyl groups And the like.
- Compounds having one (meth) acryloyl group include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, Isobutyl (meth) acrylate, t-butyl (meth) acrylate, n-hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, benzyl (meth) acrylate, isomyristyl (meth) acrylate, stearyl (Meth) acrylate, nonylphenoxy polyethylene glycol (meth) acrylate (at least one ethoxy group), 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, gly
- Examples of the (C) polymerizable monomer having two (meth) acryloyl groups include a compound obtained by reacting two (meth) acrylic acids with a polyhydric alcohol. . Further, for example, ethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate (with 2 to 30 ethoxy groups), propylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate (with 2 to 30 propoxy groups) ), Polytetramethylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, 3-methyl-1,5-pentanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, , 10-decanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, dimethylol tricyclode
- Examples of the compound (C) having a polymerizable monomer and having three or more (meth) acryloyl groups include a compound obtained by reacting (meth) acrylic acid with a polyhydric alcohol. .
- the content of (A) the alkali-soluble resin is as follows: (A) the alkali-soluble resin, (B) the photopolymerization initiator, and (C) the polymerizable monomer. It is preferably from 35 to 75% by mass, more preferably from 40 to 65% by mass, based on the total amount of the body.
- the content of (A) the alkali-soluble resin exceeds 75% by mass, the photopolymerizability may decrease.
- the content of (B) the photopolymerization initiator is 0.5 to 5.0% by mass based on the total amount of (A) the alkali-soluble resin, (B) the photopolymerization initiator, and (C) the polymerizable monomer. And more preferably 1.0 to 5.0% by mass. (B) If the content of the photopolymerization initiator is less than 0.5% by mass, the photopolymerizability may be insufficient, while if it exceeds 5.0% by mass, the resolution may be deteriorated. is there.
- the content of (C) the polymerizable monomer is 20 to 60% by mass based on the total amount of (A) the alkali-soluble resin, (B) the photopolymerization initiator, and (C) the polymerizable monomer. , And more preferably 30 to 55% by mass.
- the amount is less than 20% by mass, the photopolymerizability may be insufficient.
- the amount exceeds 60% by mass not only the tackiness of the photosensitive resin layer surface becomes remarkable but also the cured photosensitive resin layer. May become brittle.
- the photosensitive resin composition of the present invention may contain components other than the above components (A) to (C).
- Such components include sensitizers, solvents, thermal polymerization inhibitors, plasticizers, colorants (dyes and pigments), photochromic agents, photochromic materials, thermochromic inhibitors, fillers, defoamers, Examples include a flame retardant, an adhesion imparting agent, a leveling agent, a release accelerator, an antioxidant, a fragrance, a thermosetting agent, a water repellent, an oil repellent, and the like, each of which can be contained in an amount of about 0.01 to 20% by mass. .
- One of these components may be used alone, or two or more thereof may be used in combination.
- the photosensitive resin composition of the present invention may be applied to a carrier film to form a photosensitive resin layer to prepare a dry film resist (DFR), and the photosensitive resin layer may be transferred to a substrate.
- a transparent film that transmits ultraviolet light is preferable.
- the material of the transparent film for example, polypropylene, polyethylene, polyester, polyvinyl alcohol and the like can be used.
- polyethylene terephthalate film which is a kind of polyester, is advantageous for lamination suitability, release suitability, light transmittance, and refractive index, and is inexpensive, does not become brittle, and has excellent solvent resistance. It is very easy to use because of its advantages such as high tensile strength.
- the thickness of the carrier film is preferably from 1 to 100 ⁇ m.
- the method of forming the photosensitive resin layer on the base material or the carrier film can be performed by a coating method using an apparatus such as a roll coater, a comma coater, a gravure coater, an air knife, a die coater, and a bar coater.
- the thickness of the photosensitive resin layer is preferably from 3 to 120 ⁇ m, more preferably from 5 to 100 ⁇ m. If the thickness of the photosensitive resin layer is too large, problems such as reduced resolution and high cost may occur. Conversely, if the thickness is too small, adhesion may be reduced.
- the photosensitive resin layer formed on the carrier film may be covered with a protective film.
- the protective film is provided to prevent oxygen inhibition, blocking, and the like of the photosensitive resin layer, and is provided on the photosensitive resin layer opposite to the carrier film.
- the adhesive strength between the photosensitive resin layer and the protective film is preferably smaller than the adhesive strength between the photosensitive resin layer and the carrier film. Further, a protective film having a small fish eye is preferable. Examples of the protective film include a polyethylene film and a polypropylene film.
- Alkali-soluble resin The components shown in Table 1 were copolymerized to obtain (A) an alkali-soluble resin (A-1) to (A-10). The unit of the content of each component in Table 1 is [parts by mass]. Table 1 also shows (A) the acid value and the weight average molecular weight of the alkali-soluble resin.
- C Polymerizable monomer
- C-5 NK ester BPE-1300N (trade name, manufactured by Shin-Nakamura Chemical Co., Ltd., a compound represented by the general formula (i) and m + n is 30)
- Examples 1 to 6, Comparative Examples 1 to 5 The components shown in Table 3 were mixed to obtain a coating solution of the photosensitive resin composition. Using an applicator, the obtained coating liquid is applied onto a polyethylene terephthalate (PET) film (carrier film, trade name: R310, 16 ⁇ m thickness, manufactured by Mitsubishi Chemical Corporation), and dried at 80 ° C. for 5 minutes. The solvent component was removed to obtain a photosensitive resin layer (30 ⁇ m thick) containing the photosensitive resin composition on one surface of the PET film. A polyethylene film (protective film, trade name: GF1, 30 ⁇ m thick, manufactured by Tamapoly Co., Ltd.) was stuck on the photosensitive resin layer surface to produce a DFR.
- PET polyethylene terephthalate
- the polyimide film on which the resist pattern was formed was immersed in each of Liquids 1 to 4 kept at 80 ° C. for 12 minutes with stirring, and then washed with pure water.
- the resist pattern of space / line 300 ⁇ m / 300 ⁇ m swelled and peeled with any of the etching liquids of Liquids 1 to 4, and could not be etched well.
- the DFRs of Examples 1 to 6 withstand all liquids 1 to 4 at a liquid temperature of 80 ° C. for 12 minutes without desorbing, without desorbing.
- the resist was peeled off. It was immersed in a resist stripping solution (3% by mass sodium hydroxide aqueous solution, 50 ° C.). In Examples 1, 2 and 4, the resist stripping was completed in a short time of 1 minute or less. In Example 3, the resist peeling was completed in 5 minutes, and it took a little time. In Example 5, the resist stripping was completed in 15 minutes, and it took more time, but the resist pattern could be completely stripped. After the resist was peeled off, it was washed with water and dried, and the polyimide film after the completion of etching was observed under a microscope of 500 times. The space part of the resist pattern was penetrated, and the etching liquid entered the resist pattern line part. It was confirmed that there was no erosion. Therefore, in Examples 1 to 5, good etching could be achieved.
- a resist stripping solution 3% by mass sodium hydroxide aqueous solution, 50 ° C.
- Examples 11 to 14, Comparative Examples 11 to 15 The components shown in Table 4 were mixed to obtain a coating solution of the photosensitive resin composition. Using an applicator, apply the obtained coating liquid on a polyethylene terephthalate (PET) film (carrier film, trade name: R310, 16 ⁇ m thickness, manufactured by Mitsubishi Chemical Corporation), and dry at 80 ° C. for 5 minutes. The components were removed to obtain a photosensitive resin layer (30 ⁇ m thick) containing the photosensitive resin composition on one side of the PET film. A polyethylene film (protective film, trade name: GF1, 30 ⁇ m thick, manufactured by Tamapoly Co., Ltd.) was stuck on the photosensitive resin layer surface to produce a DFR.
- PET polyethylene terephthalate
- the polyimide film on which the resist pattern was formed was immersed in each of the liquids 1 to 4 kept at 80 ° C. for 12 minutes while stirring, and washed with pure water.
- the resist pattern of space / line 300 ⁇ m / 300 ⁇ m swelled and peeled with any of the etching liquids of liquids 1 to 4, and could not be etched well.
- the DFRs of Examples 11 to 14 were resistant to immersion at a liquid temperature of 80 ° C. for 12 minutes without swelling and peeling for all the etching liquids of Liquids 1 to 4.
- the resist was peeled off.
- an aqueous solution containing 15% by volume and 8% by volume of a stripping solution R-100S (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) and a stripping accelerator R-101 (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) It was immersed in 50 ° C.
- the resist was peeled off, it was washed with water and dried, and the polyimide film after completion of etching was observed under a microscope of 500 ⁇ .
- the space part of the resist pattern was penetrated, and the etching liquid was not penetrated in the line part of the resist pattern. No erosion was confirmed. Therefore, in Examples 11 to 14, good etching could be achieved.
- Examples 21 to 27, Comparative Examples 21 to 22 The components shown in Table 5 were mixed to obtain a coating solution of the photosensitive resin composition. Using an applicator, apply the obtained coating liquid on a polyethylene terephthalate (PET) film (carrier film, trade name: R310, 16 ⁇ m thickness, manufactured by Mitsubishi Chemical Corporation), and dry at 80 ° C. for 5 minutes. The components were removed to obtain a photosensitive resin layer (60 ⁇ m thick) containing the photosensitive resin composition on one surface of the PET film. A polyethylene film (protective film, trade name: GF1, 30 ⁇ m thick, manufactured by Tamapoly Co., Ltd.) was stuck on the photosensitive resin layer surface to produce a DFR.
- PET polyethylene terephthalate
- the polyimide film on which the resist pattern was formed was immersed in each of the liquids 1 to 4 kept at 80 ° C. for 12 minutes while stirring, and washed with pure water.
- the resist pattern of space / line 300 ⁇ m / 300 ⁇ m swelled and peeled with any of the etching liquids 1 to 4, and could not be etched well.
- the DFRs of Examples 21 to 27 were resistant to immersion at a liquid temperature of 80 ° C. for 12 minutes without desorbing all the etching liquids of Liquids 1 to 4.
- the resist was peeled off.
- an aqueous solution containing 15% by volume and 8% by volume of a stripping solution R-100S (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) and a stripping accelerator R-101 (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) It was immersed in 50 ° C.
- the resist peeling was completed in a short time of 1 minute or less.
- Example 23 the resist peeling was completed in 15 minutes, and a little time was required for the resist peeling.
- Comparative Examples 25 to 27 were immersed in the stripping solution for 60 minutes or longer, but could not be stripped.
- Examples 31 to 37, Comparative Examples 31 to 32 The components shown in Table 6 were mixed to obtain a coating solution of the photosensitive resin composition. Using an applicator, apply the obtained coating liquid on a polyethylene terephthalate (PET) film (carrier film, trade name: R310, 16 ⁇ m thickness, manufactured by Mitsubishi Chemical Corporation), and dry at 80 ° C. for 5 minutes. The components were removed to obtain a photosensitive resin layer (60 ⁇ m thick) containing the photosensitive resin composition on one surface of the PET film. A polyethylene film (protective film, trade name: GF1, 30 ⁇ m thick, manufactured by Tamapoly Co., Ltd.) was stuck on the photosensitive resin layer surface to produce a DFR.
- PET polyethylene terephthalate
- the polyimide film on which the resist pattern was formed was immersed in each of the liquids 1 to 4 kept at 80 ° C. for 12 minutes while stirring, and washed with pure water.
- the resist pattern of space / line 300 ⁇ m / 300 ⁇ m swelled and peeled in any of the etching liquids 1 to 4, and could not be etched well.
- the DFRs of Examples 31 to 37 were resistant to immersion at a liquid temperature of 80 ° C. for 12 minutes without desorbing from all the etching liquids of Liquids 1 to 4.
- the resist was peeled off.
- resist stripping an aqueous solution containing 15% by volume and 8% by volume of a stripping solution R-100S (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) and a stripping accelerator R-101 (trade name, manufactured by Mitsubishi Gas Chemical Co., Ltd.) It was immersed in 50 ° C.
- the resist peeling was completed in a short time of 1 minute or less.
- Example 33 the resist peeling was completed in 15 minutes, and a little time was required for the resist peeling.
- Examples 35 to 37 could not be peeled off when immersed in a peeling liquid for 60 minutes or more, but could be used without peeling.
- Examples 31 to 34 after the resist was peeled off, the polyimide film was washed with water and dried, and the etched polyimide film was observed under a microscope of 500 times. As a result, the space portion of the resist pattern was penetrated, and the line portion of the resist pattern was It was confirmed that no etching liquid entered and no erosion occurred. Therefore, in Examples 31 to 37, etching could be performed, and in Examples 31 to 34, the resist could be removed.
- Examples 41 to 48, Comparative Examples 41 to 42 The components shown in Table 7 were mixed to obtain a coating solution of the photosensitive resin composition. Using an applicator, apply the obtained coating liquid on a polyethylene terephthalate (PET) film (carrier film, trade name: R310, 16 ⁇ m thickness, manufactured by Mitsubishi Chemical Corporation), and dry at 80 ° C. for 5 minutes. The components were removed to obtain a photosensitive resin layer (60 ⁇ m thick) containing the photosensitive resin composition on one surface of the PET film. A polyethylene film (protective film, trade name: GF1, 30 ⁇ m thick, manufactured by Tamapoly Co., Ltd.) was stuck on the photosensitive resin layer surface to produce a DFR.
- PET polyethylene terephthalate
- the polyimide film on which the resist pattern was formed was immersed in each of the liquids 1 to 4 kept at 80 ° C. for 12 minutes while stirring, and washed with pure water.
- the resist pattern of space / line 300 ⁇ m / 300 ⁇ m swelled or peeled off in any of the etching liquids 1 to 4, and could not be etched well.
- the DFRs of Examples 41 to 48 endured immersion at a liquid temperature of 80 ° C. for 12 minutes without swelling or peeling even for all the etching liquids of Liquids 1 to 4.
- the resist was peeled off.
- the resist peeling was completed in a short time of 1 minute or less.
- Example 44 the resist peeling was completed in 15 minutes, and a little time was required for the resist peeling.
- Examples 47 and 48 could not be peeled off when immersed in a peeling solution for 60 minutes or more, but could be used without peeling.
- an etching treatment is performed using an etching solution containing 15 to 45% by mass of an alkali metal hydroxide and 5 to 40% by mass of an ethanolamine compound. Since there is no swelling or peeling at this time, it is widely used in the field of manufacturing and using resists and in the field of manufacturing electronic materials such as substrates.
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Abstract
Description
上記用途において、ポリイミドフィルムには、金属層間の導通を確保するためのスルーホールやデバイス実装用のデバイスホール等の孔を多数形成する必要がある。孔を形成するためには、ドリルやレーザで機械的に加工する方法以外に、ポリイミドを溶解せしめる強アルカリ性の溶液をエッチング液として用いて化学的に加工するエッチング方法が知られている(例えば、特許文献1及び2参照)。また、該エッチング方法によれば、円形の孔あけ加工だけでなく、様々な形状の加工を施すことも可能である。
そのため、代替のエッチング液として、15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有する強アルカリ性のエッチング液が提案されている(例えば、特許文献1及び2参照)。該エッチング液によれば、エッチング孔の形崩れが生じにくく、例えば、米国デュポン社製「カプトン(登録商標)」に代表されるピロメリット酸系ポリイミドだけでなく、他のエッチング液ではエッチングが困難であった、例えば、宇部興産株式会社製「ユーピレックス(登録商標)」に代表されるビフェニルテトラカルボン酸系ポリイミドでも、良好にエッチングされ、好適に使用できる。
金属層をレジストとする場合、金属層はエッチング液に対して安定で、液を浸透させず、かつ金属層とポリイミドフィルムとの剥離が起こりにくいため、微細な形状の加工や厚いフィルムの加工等に適している。しかし、金属層のレジストは、製造コストが高く、かつ工程上金属層を使えないケースも多くあり、樹脂層をレジストとしてエッチングする技術が求められている。
可使時間を長くするために、エッチングする前に感光性樹脂層を加熱(ポストキュア)する技術や、エッチングする前に感光性樹脂層に紫外線を照射する技術が知られているが、微細な形状の加工、厚いポリイミドフィルムの加工、溶解速度の遅いポリイミドフィルムの加工における対策は未だ不十分である。
15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液によって、基材をエッチング処理するエッチング方法において使用される感光性樹脂組成物であって、
少なくとも(A)アルカリ可溶性樹脂、(B)光重合開始剤及び(C)重合性単量体を含有し、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、7以下である化合物を、(C)重合性単量体の総量に対して5~80質量%含有することを特徴とする感光性樹脂組成物。
15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液によって、基材をエッチング処理するエッチング方法において使用される感光性樹脂組成物であって、
少なくとも(A)アルカリ可溶性樹脂、(B)光重合開始剤及び(C)重合性単量体を含有し、
(A)アルカリ可溶性樹脂が、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体を共重合して得られる共重合体であり、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体の総量に対して、(I)メタクリル酸が20~40質量%であり、(II)スチレン誘導体が25~50質量%であり、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、20以下である化合物を含有し、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、7以下である化合物の含有量が、(C)重合性単量体の総量に対して80質量%以下であることを特徴とする感光性樹脂組成物。
基材の少なくとも片面に、上記(1)又は(2)に記載の感光性樹脂組成物を含有してなる感光性樹脂層を形成する工程1、該感光性樹脂層を露光・現像してレジストパターンを形成する工程2、並びに、15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液によって基材をエッチング処理する工程3、を少なくとも含むことを特徴とするエッチング方法。
上記のエッチング方法を用いることを特徴とする孔又はパターンを有する樹脂構造体の製造方法。
以下、「一般式(i)で示され、m+nが2以上、7以下である化合物」を「化合物(i)-S」と記載する場合がある。
以下、「15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液」を「エッチング液α」と記載する場合がある。
また、エッチング液αを、例えば、80℃という高温で使用した場合であっても、感光性樹脂組成物(1)が膨潤又は剥離しにくいという効果を達成できる。
また、エッチング液αを、例えば80℃という高温で使用した場合であっても、感光性樹脂組成物(2)が膨潤又は剥離しにくいという効果を達成できる。
以下、「一般式(i)で示され、m+nが2以上、20以下である化合物」を「化合物(i)-P」と記載する場合がある。
本発明におけるエッチング液αは、15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液であり、水溶液であることが好ましい。
上記アルカリ金属水酸化物としては、水酸化カリウム、水酸化ナトリウム及び水酸化リチウムよりなる群から選ばれる少なくとも1種の化合物が好適に用いられる。アルカリ金属水酸化物は、これらの中の1種類を単独で使用してもよいし、2種類以上を組み合わせて使用してもよい。なかでも水酸化カリウムが好適に使用できる。アルカリ金属水酸化物の含有率は、エッチング液全体に対して、20~45質量%がより好ましく、25~40質量%がさらに好ましい。
該エタノールアミン化合物は、1種類を単独で使用してもよいし、2種類以上を組み合わせて使用してもよい。エタノールアミン化合物の含有率は、エッチング液全体に対して、20~40質量%がより好ましく、25~35質量%がさらに好ましい。
次に、本発明のエッチング方法を説明する。本発明のエッチング方法は、基材の少なくとも片面に、本発明の感光性樹脂組成物を含有してなる感光性樹脂層を形成する工程1、感光性樹脂層を露光・現像してレジストパターンを形成する工程2、エッチング液αによって基材をエッチング処理する工程3を少なくとも含む。
基材の少なくとも片面に感光性樹脂層を形成する工程1を説明する。
基材としては、エッチング液αによってエッチングできる基材であれば何れであってもよい。例えば、ポリイミド樹脂、ポリエステル樹脂、無機充填材含有樹脂、液晶ポリマー、フッ素化合物含有樹脂、ガラス等が挙げられる。
該ピロメリット酸系ポリイミドとしては、例えば、米国デュポン社製「カプトン(登録商標)」等が挙げられる。また、ビフェニルテトラカルボン酸系ポリイミドとしては、例えば、宇部興産株式会社「ユーピレックス(登録商標)」等が挙げられる。
該ビフェニルテトラカルボン酸系ポリイミドは、ポリイミド樹脂の中でもアルカリ性のエッチング液への溶解速度が遅いことが知られている。このような溶解速度の遅いポリイミドのフィルムでも、本発明の感光性樹脂組成物を用いることによって、パターン状に加工することができる。
該無機充填材含有樹脂の樹脂成分としては、具体的にはアルカリ不溶性樹脂が挙げられる。アルカリ不溶性樹脂とは、アルカリ可溶性を発現するカルボキシル基等の酸基の含有量が非常に少ない樹脂を言う。
熱硬化剤としては、例えば、フェノール系硬化剤、ナフトール系硬化剤、活性エステル系硬化剤、ベンゾオキサジン系硬化剤、シアネートエステル樹脂等が挙げられる。
また、本発明の感光性樹脂組成物を含む塗工液を、キャリアーフィルムに塗工して、感光性樹脂組成物を含む感光性樹脂層を形成して、ドライフィルムレジスト(以下、単に「DFR」と略記することがある)を作製し、基材に感光性樹脂層を転写する方法が挙げられる。
感光性樹脂層を露光・現像してレジストパターンを形成する工程2を説明する。
工程2では、まず、感光性樹脂層に対してパターン状の露光を実施し、露光部を硬化させる。露光としては、具体的には、フォトマスクを用いた密着露光が挙げられる。また、キセノンランプ、低圧水銀灯、高圧水銀灯、超高圧水銀灯、UV蛍光灯等を光源とした、反射画像露光、プロキシミティ方式、プロジェクション方式、走査露光等が挙げられる。
走査露光としては、UVレーザ、He-Neレーザ、He-Cdレーザ、アルゴンイオンレーザ、クリプトンイオンレーザ、ルビーレーザ、YAGレーザ、窒素レーザ、色素レーザ、エキシマレーザ等のレーザ光源を、発光波長に応じてSHG波長変換した走査露光、あるいは、液晶シャッター、マイクロミラーアレイシャッターを利用した走査露光等が挙げられる。
現像に使用するアルカリ現像液としては、例えば、無機アルカリ性化合物の水溶液を用いることができる。無機アルカリ性化合物としては、リチウム、ナトリウム、カリウム等の炭酸塩や水酸化物が挙げられる。アルカリ現像液としては、0.1~3質量%の炭酸ナトリウム水溶液が好ましく使用できる。現像液には、界面活性剤、消泡剤、溶剤等を適宜少量混入することもできる。
現像処理方法としては、ディップ方式、バトル方式、スプレー方式、ブラッシング、スクレーピング等があり、スプレー方式が除去速度のためには最も適している。処理温度は15~35℃が好ましく、また、スプレー圧は、0.02~0.3MPaが好ましい。
エッチング液αによって基材をエッチング処理する工程3を説明する。エッチング方法としては、浸漬処理、パドル処理、スプレー処理、ブラッシング、スクレーピング等の方法を用いることができる。この中でも、浸漬処理が好ましい。
浸漬処理以外の方法では、エッチング液α中に気泡が発生しやすく、その気泡が基材の表面に付着してエッチング不良が発生する場合がある。また、浸漬処理以外の方法では、エッチング液αの温度変化が大きくなりやすく、基材のエッチング速度にばらつきが発生する場合がある。
レジストパターンに追加露光する工程4を説明する。
本発明の感光性樹脂組成物を使用したエッチング方法において、工程2と工程3の間で、レジストパターンに追加露光をする工程4を実施してもよい。
該追加露光は、具体的には、キセノンランプ、高圧水銀灯、低圧水銀灯、超高圧水銀灯、UV蛍光灯等を光源として、紫外線を硬化した感光性樹脂層を含むレジストパターン全面に照射し、さらに架橋させる。追加露光の露光量は、特に限定はないが、100~2000mJ/cm2が好ましい。
本発明の感光性樹脂組成物は、工程4の追加露光をすることによって、その後の工程3のエッチング処理において、レジストパターンが膨潤又は剥離しにくいという効果が特に奏されるようになる。
工程4を行う場合には、工程4終了から工程3開始までの時間は、30分以下であることが好ましく、20分以下であることがより好ましい。これによって、感光性樹脂層で形成されたレジストパターンの内部まで充分に硬化された状態で、エッチング処理が可能であり、強アルカリ性のエッチング液αによって、基材をエッチング処理した場合に、レジストパターンが膨潤又は剥離することをより抑制することができる。
次いで、工程3後にレジストパターンを剥離するレジスト剥離工程を説明する。工程3後に、レジストパターンを残しておいてもよいが、不要であれば、レジストパターンを剥離する。
レジスト剥離工程において、レジスト剥離液としては、アルカリ水溶液が有用に使用される。レジスト剥離液に使用される塩基性化合物としては、例えば、ケイ酸アルカリ金属塩、アルカリ金属水酸化物、リン酸アルカリ金属塩、炭酸アルカリ金属塩、リン酸アンモニウム、炭酸アンモニウム塩等の無機塩基性化合物;エタノールアミン、エチレンジアミン、プロパンジアミン、トリエチレンテトラミン、モルホリン、水酸化テトラメチルアンモニウム等の有機塩基性化合物を挙げることができる。
本発明は、上記エッチング方法を用いることを特徴とする孔又はパターンを有する樹脂構造体の製造方法でもある。
本発明の感光性樹脂組成物(1)は、少なくとも(A)アルカリ可溶性樹脂、(B)光重合開始剤及び(C)重合性単量体を含有し、(C)重合性単量体として、一般式(i)で示され、m+nが2以上、7以下である化合物(化合物(i)-S)を、(C)重合性単量体の総量に対して5~80質量%含有することを特徴とする。
アルカリ可溶性樹脂とは、具体的には、酸性基を含む樹脂であり、酸価が40mgKOH/g以上である樹脂が挙げられる。該酸性基としては、具体的にはカルボキシル基、フェノール性水酸基、スルホン酸基、リン酸基等が挙げられる。
その中でも、(メタ)アクリル系樹脂を用いることが好ましい。該(メタ)アクリル系樹脂としては、(メタ)アクリレートを主成分とし、これにエチレン性不飽和カルボン酸を共重合させてなる(メタ)アクリル系重合体が好ましい。また、これには、その他の共重合可能なエチレン性不飽和基を有する単量体を共重合させたものでもよい。
酸価が40mgKOH/g未満では、アルカリ現像時間が長くなる場合があり、一方、500mgKOH/gを超えると、感光性樹脂層と基材との密着性が悪くなる場合や、エッチング液αへの耐性が悪くなる場合がある。上記酸価は、JIS K2501:2003に準拠して測定した値である。
(A)アルカリ可溶性樹脂の質量平均分子量が5,000未満では、硬化前の感光性樹脂組成物をフィルム状態に形成することが困難になる場合がある。一方、(A)アルカリ可溶性樹脂の質量平均分子量が150,000を超えると、アルカリ現像液に対する溶解性が悪化する場合や、レジスト剥離液に溶解する速度が遅くなる場合がある。
これらは単独で又は2種類以上を組み合わせて使用される。なかでも、イミダゾール二量体が、高感度であり好適に使用でき、さらに、2-(2’-クロロフェニル)-4,5-ジフェニルイミダゾール二量体が特に好適に使用できる。
化合物(i)-Sの含有率が、5~80質量%であること(又は上記範囲であること)によって、エッチング液αへの耐性に優れ、レジストパターンの剥離性にも優れ、アルカリ現像性にも優れている。
化合物(i)-Sの含有率が少なすぎると、エッチング液αへの耐性が不十分になる場合があり、一方、化合物(i)-Sの含有率が多すぎると、アルカリ現像性が悪くなり、アルカリ現像に多くの時間を有する場合がある。また、レジストパターンの剥離性が悪くなる場合がある。
(A)アルカリ可溶性樹脂が、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体を共重合して得られる共重合体であり、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体の総量に対して、(I)メタクリル酸が20~40質量%であり、(II)スチレン誘導体が25~50質量%であり、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、20以下である化合物(化合物(i)-P)を含有し、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、7以下である化合物(化合物(i)-S)の含有量が、(C)重合性単量体の総量に対して80質量%以下であることを特徴とする。
アルカリ可溶性樹脂とは、具体的には、酸性基を含む樹脂であり、酸価が40mgKOH/g以上である樹脂が挙げられる。該酸性基としては、具体的にはカルボキシル基、フェノール性水酸基、スルホン酸基、リン酸基等が挙げられる。
本発明の感光性樹脂組成物(2)では、カルボキシル基を有する(I)メタクリル酸を(A)アルカリ可溶性樹脂の共重合成分として使用する。
一方、(II)スチレン誘導体を、上記上限を超えて含むと、アルカリ現像性が悪くなり、アルカリ現像に多くの時間を有する場合やアルカリ現像ができなくなる場合がある。また、レジストパターンの剥離性が悪くなる場合がある。
酸価が40mgKOH/g未満では、アルカリ現像時間が長くなる場合があり、一方、500mgKOH/gを超えると、感光性樹脂層と基材との密着性が悪くなる場合や、エッチング液αへの耐性が悪くなる場合がある。上記酸価は、JIS K2501:2003に準拠して測定した値である。
(A)アルカリ可溶性樹脂の質量平均分子量が5,000未満では、硬化前の感光性樹脂組成物をフィルム状態に形成することが困難になる場合がある。一方、(A)アルカリ可溶性樹脂の質量平均分子量が150,000を超えると、アルカリ現像液に対する溶解性が悪化する場合や、レジスト剥離液への溶解する速度が遅くなる場合がある。
化合物(i)-Sの含有率が多すぎると、アルカリ現像性が悪くなり、アルカリ現像に多くの時間を有する場合がある。また、レジストパターンの剥離性が悪くなる場合がある。
以下、「一般式(i)で示され、m+nが7より大きく、13以下である化合物」を「化合物(i)-M」と略記する場合がある。また、「一般式(i)で示され、m+nが13より大きく、20以下である化合物」を「化合物(i)-L」と略記する場合がある。
本発明の感光性樹脂組成物(1)及び(2)において、(A)アルカリ可溶性樹脂の含有率は、(A)アルカリ可溶性樹脂、(B)光重合開始剤及び(C)重合性単量体の総量に対して、35~75質量%であることが好ましく、40~65質量%であることがより好ましい。
(A)アルカリ可溶性樹脂の含有率が35質量%未満では、感光性樹脂層のタック性が高く、キャリアーフィルムに感光性樹脂層を形成したDFRとしたとき、エッジフュージョンが発生しやすくなる場合や、フィルムにしわが入りやすくなる場合がある。一方、(A)アルカリ可溶性樹脂の含有率が75質量%を超えると、光重合性が低下する場合がある。
このような成分としては、増感剤、溶剤、熱重合禁止剤、可塑剤、着色剤(染料、顔料)、光発色剤、光減色材、熱発色防止剤、充填剤、消泡剤、難燃剤、密着性付与剤、レベリング剤、剥離促進剤、酸化防止剤、香料、熱硬化剤、撥水剤、撥油剤等が挙げられ、それぞれ、0.01~20質量%程度含有することができる。これらの成分は1種を単独で用いてもよいし、2種類以上を組み合わせて用いることもできる。
該透明フィルムの材質としては、例えば、ポリプロピレン、ポリエチレン、ポリエステル、ポリビニルアルコール等が使用できる。その中でも特に、ポリエステルの一種であるポリエチレンテレフタレートフィルムを使用すると、ラミネート適性、剥離適性、光透過性、屈折率に対して有利であり、また、安価で、脆化せず、耐溶剤性に優れ、高い引っ張り強度を持つ等の利点から、非常に利用しやすい。
キャリアーフィルムの厚みは、1~100μmであることが好ましい。
感光性樹脂層の厚みは、3~120μmであることが好ましく、5~100μmであることがより好ましい。この感光性樹脂層の厚みが大きすぎると、解像性の低下、コスト高、等の問題が発生する場合があり、逆に薄すぎると、密着性が低下する場合がある。
表1に示す各成分を共重合させて(A-1)~(A~10)の(A)アルカリ可溶性樹脂を得た。なお、表1における各成分の含有量の単位は[質量部]である。また、表1には、(A)アルカリ可溶性樹脂の酸価及び質量平均分子量も記載した。
(B-1):2-(2’-クロロフェニル)-4,5-ジフェニルイミダゾール二量体
(B-2):4,4’-ビス(ジエチルアミノ)ベンゾフェノン
(C-1):NKエステルBPE-100(商品名、新中村化学工業社製、化合物(i)-S、m+n=2.6)
(C-2):NKエステルBPE-200(商品名、新中村化学工業社製、化合物(i)-S、m+n=4)
(C-3):NKエステルBPE-500(商品名、新中村化学工業社製、化合物(i)-M、m+n=10)
(C-4):NKエステルBPE-900(商品名、新中村化学工業社製、化合物(i)-L、m+n=17)
(C-5):NKエステルBPE-1300N(商品名、新中村化学工業社製、一般式(i)で示され、m+nが30である化合物)
(C-6):ポリエチレングリコール♯200ジメタクリレート(エトキシ基数が4)
(C-7):ポリエチレングリコール♯400ジメタクリレート(エトキシ基数が9)
(C-8):ライトアクリレート4EG-A(商品名、共栄社化学株式会社製、ポリエチレングリコールジアクリレート(エトキシ基数が4))
表3に示す各成分を混合し、感光性樹脂組成物の塗工液を得た。
アプリケーターを用いて、ポリエチレンテレフタレート(PET)フィルム(キャリアーフィルム、商品名:R310、16μm厚、三菱ケミカル社製)上に、得られた塗工液を塗工し、80℃で5分間乾燥して溶剤成分を除去し、PETフィルムの片面上に、感光性樹脂組成物を含む感光性樹脂層(30μm厚)を得た。
ポリエチレンフィルム(保護フィルム、商品名:GF1、30μm厚、タマポリ社製)を感光性樹脂層面に貼り付け、DFRを作製した。
続いて、5kWの超高圧水銀灯光源を搭載した両面露光機を用い、ライン/スペース=300μm/300μmのテスト用パターンを有するフォトマスクを通して上記のポリイミドフィルムの両面に形成されたDFRに対して密着露光を行い、コンベアー式現像機を用いて、液温30℃の1質量%炭酸ナトリウム水溶液で、スプレー圧力0.2MPaの条件で、90秒間現像処理し、テスト用パターン部に、ボトム部でスペース/ライン=300μm/300μmのレジストパターンを得た。
次に、上記両面露光機を使用し、露光量1000mJ/cm2にて紫外線を全面に追加露光した。一連の工程後、レジストパターンを確認したが、比較例5のDFRに関しては、現像が進まず、現像できなかった。
その際、比較例1~4のDFRに関しては、液1~4の何れのエッチング液においても、スペース/ライン=300μm/300μmのレジストパターンが膨潤剥離してしまい、良好にエッチングができなかった。一方、実施例1~6のDFRについては、液1~4の全てのエッチング液に対しても、脱離することなく、液温度80℃、12分間の浸漬に耐えた。
実施例1、2及び4では、1分以内と短時間にレジスト剥離が完了した。実施例3では、5分でレジスト剥離が完了し、少し時間を要した。実施例5では、15分でレジスト剥離が完了し、さらに時間を要したが、完全にレジストパターンを剥離することができた。
レジスト剥離後に、水洗後乾燥し、エッチングが完了したポリイミドフィルムを500倍の顕微鏡で観察したところ、レジストパターンのスペース部分は貫通しており、また、レジストパターンのライン部分においては、エッチング液の入り込みがなく、侵食されていないことが確認できた。
よって、実施例1~5においては、良好なエッチングが達成できた。
表4に示す各成分を混合し、感光性樹脂組成物の塗工液を得た。アプリケーターを用いて、ポリエチレンテレフタレート(PET)フィルム(キャリアーフィルム、商品名:R310、16μm厚、三菱ケミカル社製)上に得られた塗工液を塗工し、80℃で5分間乾燥し、溶剤成分を除去し、PETフィルムの片面上に、感光性樹脂組成物を含む感光性樹脂層(30μm厚)を得た。
ポリエチレンフィルム(保護フィルム、商品名:GF1、30μm厚、タマポリ社製)を感光性樹脂層面に貼り付け、DFRを作製した。
続いて、5kWの超高圧水銀灯光源を搭載した両面露光機を用い、ライン/スペース=300μm/300μmのテスト用パターンを有するフォトマスクを通して上記のポリイミドフィルムの両面に形成されたDFRに対して密着露光を行い、コンベアー式現像機を用いて、液温30℃の1質量%炭酸ナトリウム水溶液で、スプレー圧力0.2MPaの条件で、90秒間現像処理し、テスト用パターン部に、ボトム部でスペース/ライン=300μm/300μmのレジストパターンを得た。次に、上記両面露光機を使用し、露光量1000mJ/cm2にて紫外線を全面追加露光して、レジストパターンをさらに架橋させた。一連の工程後、レジストパターンを確認したが、比較例12及び比較例13のDFRに関しては、現像が進まず、現像できなかった。
一方、実施例11~14のDFRについては、液1~4の全てのエッチング液に対しても、膨潤剥離することなく、液温度80℃、12分間の浸漬に耐えた。
レジスト剥離後に、水洗後乾燥し、エッチングが完了したポリイミドフィルムを500倍の顕微鏡で観察したところ、レジストパターンのスペース部分は貫通しており、またレジストパターンのライン部分においては、エッチング液の入り込みがなく、侵食されていないことが確認できた。
よって、実施例11~14においては、良好なエッチングが達成できた。
表5に示す各成分を混合し、感光性樹脂組成物の塗工液を得た。アプリケーターを用いて、ポリエチレンテレフタレート(PET)フィルム(キャリアーフィルム、商品名:R310、16μm厚、三菱ケミカル社製)上に得られた塗工液を塗工し、80℃で5分間乾燥し、溶剤成分を除去し、PETフィルムの片面上に、感光性樹脂組成物を含む感光性樹脂層(60μm厚)を得た。ポリエチレンフィルム(保護フィルム、商品名:GF1、30μm厚、タマポリ社製)を感光性樹脂層面に貼り付け、DFRを作製した。
続いて、5kWの超高圧水銀灯光源を搭載した両面露光機を用い、ライン/スペース=300μm/300μmのテスト用パターンを有するフォトマスクを通して上記のポリイミドフィルムの両面に形成されたDFRに対して密着露光を行い、コンベアー式現像機を用いて、液温30℃の1質量%炭酸ナトリウム水溶液で、スプレー圧力0.2MPaの条件で、90秒間現像処理し、テスト用パターン部に、ボトム部でスペース/ライン=300μm/300μmのレジストパターンを得た。
次に、上記両面露光機を使用し、露光量1000mJ/cm2にて紫外線を全面に追加露光した。一連の工程後、レジストパターンを確認したが、比較例22のDFRに関しては、現像が進まず、現像できなかった。
その際、比較例21のDFRに関しては、液1~4の何れのエッチング液においても、スペース/ライン=300μm/300μmのレジストパターンが膨潤剥離してしまい、良好にエッチングができなかった。
一方、実施例21~27のDFRについては、液1~4の全てのエッチング液に対しても、脱離することなく、液温度80℃、12分間の浸漬に耐えた。
実施例21、22及び24に関しては1分以内と短時間にレジスト剥離が完了した。実施例23は15分でレジスト剥離が完了し、少しレジスト剥離に時間を要した。比較例25~27は、60分以上剥離液に浸漬したが、剥離できなかった。
レジスト剥離後に、水洗後乾燥し、エッチングが完了したポリイミドフィルムを500倍の顕微鏡で観察したところ、レジストパターンのスペース部分は貫通しており、またレジストパターンのライン部分においては、エッチング液の入り込みがなく、侵食されていないことが確認できた。
よって、実施例21~27では、エッチングができ、実施例21~24では、レジスト剥離もできた。
表6に示す各成分を混合し、感光性樹脂組成物の塗工液を得た。アプリケーターを用いて、ポリエチレンテレフタレート(PET)フィルム(キャリアーフィルム、商品名:R310、16μm厚、三菱ケミカル社製)上に得られた塗工液を塗工し、80℃で5分間乾燥し、溶剤成分を除去し、PETフィルムの片面上に、感光性樹脂組成物を含む感光性樹脂層(60μm厚)を得た。
ポリエチレンフィルム(保護フィルム、商品名:GF1、30μm厚、タマポリ社製)を感光性樹脂層面に貼り付け、DFRを作製した。
続いて、5kWの超高圧水銀灯光源を搭載した両面露光機を用い、ライン/スペース=300μm/300μmのテスト用パターンを有するフォトマスクを通して上記のポリイミドフィルムの両面に形成されたDFRに対して密着露光を行い、コンベアー式現像機を用いて、液温30℃の1質量%炭酸ナトリウム水溶液で、スプレー圧力0.2MPaの条件で、90秒間現像処理し、テスト用パターン部に、ボトム部でスペース/ライン=300μm/300μmのレジストパターンを得た。
次に、上記両面露光機を使用し、露光量1000mJ/cm2にて紫外線を全面追加露光した。一連の工程後、レジストパターンを確認したが、比較例32のDFRに関しては、現像が進まず、現像できなかった。
一方、実施例31~37のDFRについては、液1~4の全てのエッチング液に対しても、脱離することなく、液温度80℃、12分間の浸漬に耐えた。
実施例31、32、34に関しては、1分以内と短時間にレジスト剥離が完了した。実施例33は、15分でレジスト剥離が完了し、少しレジスト剥離に時間を要した。実施例35~37は、60分以上剥離液に浸漬したところ剥離できなかったが、剥離しないで使用することはできた。
よって、実施例31~37では、エッチングができ、実施例31~34では、レジスト剥離もできた。
表7に示す各成分を混合し、感光性樹脂組成物の塗工液を得た。アプリケーターを用いて、ポリエチレンテレフタレート(PET)フィルム(キャリアーフィルム、商品名:R310、16μm厚、三菱ケミカル社製)上に得られた塗工液を塗工し、80℃で5分間乾燥し、溶剤成分を除去し、PETフィルムの片面上に、感光性樹脂組成物を含む感光性樹脂層(60μm厚)を得た。
ポリエチレンフィルム(保護フィルム、商品名:GF1、30μm厚、タマポリ社製)を感光性樹脂層面に貼り付け、DFRを作製した。
続いて、5kWの超高圧水銀灯光源を搭載した両面露光機を用い、ライン/スペース=300μm/300μmのテスト用パターンを有するフォトマスクを通して上記のポリイミドフィルムの両面に形成されたDFRに対して密着露光を行い、コンベアー式現像機を用いて、液温30℃の1質量%炭酸ナトリウム水溶液で、スプレー圧力0.2MPaの条件で、90秒間現像処理し、テスト用パターン部に、ボトム部でスペース/ライン=300μm/300μmのレジストパターンを得た。
次に、上記両面露光機を使用し、露光量1000mJ/cm2にて紫外線を全面に追加露光した。一連の工程後、レジストパターンを確認したが、比較例42のDFRに関しては、現像が進まず、現像できなかった。
一方、実施例41~48のDFRについては、液1~4の全てのエッチング液に対しても、膨潤又は剥離することなく、液温度80℃、12分間の浸漬に耐えた。
実施例41~43、45及び46に関しては1分以内と短時間にレジスト剥離が完了した。実施例44は15分でレジスト剥離が完了し、少しレジスト剥離に時間を要した。実施例47及び48は、60分以上剥離液に浸漬したところ剥離できなかったが、剥離しないで使用することはできた。
Claims (4)
- 15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液によって、基材をエッチング処理するエッチング方法において使用される感光性樹脂組成物であって、
少なくとも(A)アルカリ可溶性樹脂、(B)光重合開始剤及び(C)重合性単量体を含有し、
(A)アルカリ可溶性樹脂が、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体を共重合して得られる共重合体であり、(I)メタクリル酸、(II)スチレン誘導体及び(III)その他のエチレン性不飽和基を有する単量体の総量に対して、(I)メタクリル酸が20~40質量%であり、(II)スチレン誘導体が25~50質量%であり、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、20以下である化合物を含有し、
(C)重合性単量体として、一般式(i)で示され、m+nが2以上、7以下である化合物の含有量が、(C)重合性単量体の総量に対して80質量%以下であることを特徴とする感光性樹脂組成物。
- 基材の少なくとも片面に、請求項1又は請求項2に記載の感光性樹脂組成物を含有してなる感光性樹脂層を形成する工程1、該感光性樹脂層を露光・現像してレジストパターンを形成する工程2、並びに、15~45質量%のアルカリ金属水酸化物及び5~40質量%のエタノールアミン化合物を含有するエッチング液によって基材をエッチング処理する工程3、を少なくとも含むことを特徴とするエッチング方法。
- 請求項3に記載のエッチング方法を用いることを特徴とする孔又はパターンを有する樹脂構造体の製造方法。
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JP2000075484A (ja) * | 1998-08-28 | 2000-03-14 | Hitachi Chem Co Ltd | 感光性樹脂組成物、感光性エレメント、感光性積層体及びフレキシブルプリント板の製造法 |
JP2001305750A (ja) | 2000-04-18 | 2001-11-02 | Toray Eng Co Ltd | ポリイミドフィルムのエッチング方法 |
CN1940723B (zh) * | 2005-09-28 | 2011-11-09 | 旭化成电子材料株式会社 | 感光性树脂组合物及其层合体 |
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2019
- 2019-07-08 KR KR1020217001814A patent/KR20210030368A/ko not_active Application Discontinuation
- 2019-07-08 CN CN201980044443.1A patent/CN112384857A/zh active Pending
- 2019-07-08 JP JP2020530160A patent/JP7457649B2/ja active Active
- 2019-07-08 WO PCT/JP2019/026931 patent/WO2020013107A1/ja active Application Filing
- 2019-07-12 TW TW108124705A patent/TW202006470A/zh unknown
Patent Citations (4)
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JP2007008969A (ja) * | 2004-06-17 | 2007-01-18 | Mitsubishi Paper Mills Ltd | 樹脂エッチング液、樹脂エッチング方法、樹脂剥離方法、およびフレキシブルプリント配線板の製造方法 |
JP2006053352A (ja) * | 2004-08-12 | 2006-02-23 | Asahi Kasei Electronics Co Ltd | 感光性樹脂積層体 |
US9982108B2 (en) * | 2012-07-18 | 2018-05-29 | Industrial Technology Research Institute | Polyimide-containing layer and method for etching polyimide-containing layer |
WO2017159873A1 (ja) * | 2016-03-17 | 2017-09-21 | 日立化成株式会社 | 感光性樹脂組成物、感光性エレメント、レジストパターン付き基板の製造方法、及びプリント配線板の製造方法 |
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JP7457649B2 (ja) | 2024-03-28 |
CN112384857A (zh) | 2021-02-19 |
TW202006470A (zh) | 2020-02-01 |
JPWO2020013107A1 (ja) | 2021-08-26 |
KR20210030368A (ko) | 2021-03-17 |
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