WO2020136965A1 - 透明導電層の支持用の積層フィルム - Google Patents
透明導電層の支持用の積層フィルム Download PDFInfo
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- WO2020136965A1 WO2020136965A1 PCT/JP2019/029286 JP2019029286W WO2020136965A1 WO 2020136965 A1 WO2020136965 A1 WO 2020136965A1 JP 2019029286 W JP2019029286 W JP 2019029286W WO 2020136965 A1 WO2020136965 A1 WO 2020136965A1
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- film
- transparent conductive
- conductive layer
- protective film
- base film
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/027—Thermal properties
- B32B7/028—Heat-shrinkability
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/03—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features
- B32B7/035—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features using arrangements of stretched films, e.g. of mono-axially stretched films arranged alternately
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F3/00—Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
- G06F3/01—Input arrangements or combined input and output arrangements for interaction between user and computer
- G06F3/03—Arrangements for converting the position or the displacement of a member into a coded form
- G06F3/041—Digitisers, e.g. for touch screens or touch pads, characterised by the transducing means
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0026—Apparatus for manufacturing conducting or semi-conducting layers, e.g. deposition of metal
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/14—Non-insulated conductors or conductive bodies characterised by their form comprising conductive layers or films on insulating-supports
Definitions
- the present invention relates to a laminated film for supporting a transparent conductive layer used for manufacturing a touch sensor panel, for example.
- a transparent conductive film in which a transparent conductive layer is supported by a base film is often used for this touch panel.
- This transparent conductive film is obtained by peeling the protective film together with the pressure-sensitive adhesive layer from a laminate with a transparent conductive layer in which a base film supporting a transparent conductive layer and a protective film are laminated via a pressure-sensitive adhesive layer.
- Patent Document 1 an example of the laminated body with the transparent conductive layer is disclosed in Patent Document 1.
- PET polyethylene terephthalate
- Patent Document 1 PET (polyethylene terephthalate) resin is used for the base film and the protective film, and the curl is suppressed by reducing the absolute value of the difference in heat shrinkage between the base film and the protective film. ing.
- JP-A-2016-107503 see claim 1, paragraphs [0095], [0105], [0106], FIG. 1 and the like
- the protective film and the base film are laminated via an adhesive layer to form a base film.
- peeling the protective film together with the pressure-sensitive adhesive layer from the base film to produce a thin transparent conductive film peeling the protective film from the base film It was found that the transparent conductive film was deformed during the process. It is considered that this is because when the base film is thin, the base film is pulled to the side of the protective film through the adhesive layer when the protective film is peeled off, and wrinkles are formed in the base film.
- the transparent conductive layer may be damaged (for example, broken) when the transparent conductive film is wound into a roll.
- Patent Document 2 since the heat shrinkage rate of the protective film is small, the shrinkage stress generated during heating is small, and since the glass transition temperature Tg of the protective film is low, the stress generated during heating is relaxed. I will end up. Therefore, sufficient residual stress cannot be obtained, and it is necessary to peel the protective film with a high peeling force. Therefore, it is considered that when the base film is thinned, the base film is easily pulled toward the protective film in the peeling step, and the transparent conductive film is more easily deformed.
- the present invention has been made to solve the above problems, and the object thereof is to provide a transparent conductive film at the time of peeling a protective film after forming a transparent conductive layer, even if the base film is thin. It is an object of the present invention to provide a laminated film for supporting a transparent conductive layer, which can suppress deformation and thereby enables a thin transparent conductive film to be manufactured with high productivity.
- the laminated film of one aspect of the present invention is a laminated film for supporting a transparent conductive layer of a transparent conductive film, A base film for supporting the transparent conductive layer, It has a protective film that supports the base film via an adhesive layer,
- the base film and the protective film each include a cycloolefin resin,
- the thickness of the base film is 5 ⁇ m or more and 40 ⁇ m or less
- the heat shrinkage A (%) in the width direction of the base film when heated at 140° C. for 90 minutes is 0.01% or more and 0.20% or less
- B (%) 0.02 ⁇ A/B ⁇ 0.50 Is.
- the base film and the transparent conductive layer are formed when the protective film is peeled off after the transparent conductive layer is formed on the base film.
- the deformation of the film can be suppressed. This makes it possible to manufacture a thin transparent conductive film roll-to-roll with high productivity.
- FIG. 3 is a flowchart showing a flow of a method of manufacturing a transparent conductive film used for the touch sensor panel of the touch panel display device of FIG. 1 or 2. It is sectional drawing which shows the manufacturing process of the said transparent conductive film. It is explanatory drawing which shows the schematic structure of the manufacturing apparatus which manufactures the optical film contained in the laminated film used for manufacture of the said transparent conductive film. It is a flowchart which shows the flow of the manufacturing method of the said optical film.
- FIG. 1 is a sectional view showing a schematic configuration of a touch panel display device 1 of this embodiment.
- the touch panel display device 1 is configured to include a touch sensor panel 3 on the display unit 2.
- the display unit 2 is configured by, for example, a liquid crystal display device, but may be configured by another display device such as an organic EL (Electro-Luminescence) display device also called an OLED (Organic light-Emitting Diode).
- OLED Organic light-Emitting Diode
- the touch sensor panel 3 is configured by laminating an adhesive layer 13, a transparent conductive film 12, an adhesive layer 13, a transparent conductive film 12, and an adhesive layer 13 in this order on a glass substrate 11 as a transparent substrate. ..
- Each transparent conductive film 12 is configured by laminating a base film 16 and a transparent conductive layer 17 in this order.
- the transparent conductive film 12 closer to the glass substrate 11 is positioned so that the base film 16 is closer to the glass substrate 11 than the transparent conductive layer 17.
- the other transparent conductive film 12 (the transparent conductive film 12 closer to the display unit 2) is positioned such that the base film 16 is closer to the display unit 2 than the transparent electrode layer 17.
- FIG. 2 is a cross-sectional view showing another configuration of the touch panel display device 1.
- the touch sensor panel 3 of the touch panel display device 1 may be configured by laminating an adhesive layer 13, a transparent conductive film 12, and an adhesive layer 13 in this order on a glass substrate 11. ..
- the transparent conductive film 12 is positioned so that the base film 16 is closer to the display unit 2 side than the transparent conductive layer 17.
- the transparent conductive layer 17 can be made of, for example, indium oxide (ITO) containing tin oxide or a conductive film containing metal nanowires.
- ITO indium oxide
- the transparent conductive layer 17 does not break even when repeated bending, and from the viewpoint of exhibiting good bending durability, the transparent conductive layer 17 is made of a conductive film containing metal nanowires. Is desirable.
- the adhesive layer 13 is composed of, for example, an optical adhesive film.
- the transparent conductive film 12 can be manufactured as follows, for example.
- FIG. 3 is a flowchart showing the flow of the method for manufacturing the transparent conductive film 12.
- FIG. 4 is a cross-sectional view showing a manufacturing process of the transparent conductive film 12.
- the transparent conductive film 12 includes a laminated film preparing step (S1), a transparent conductive layer forming step (S2), and a protective film peeling step (S3).
- the laminated film 20 is prepared.
- the laminated film 20 is configured by laminating the protective film 14 and the base film 16 with the adhesive layer 15 interposed therebetween.
- the base film 16 is composed of a thin film having a thickness of 5 ⁇ m or more and 40 ⁇ m or less as described later.
- the laminated film 20 is previously wound into a roll.
- a cured resin layer (hard coat layer) may be formed on at least one surface of the base film 16. Details of such a laminated film 20 will be described later.
- the laminated film 20 wound into a roll is unwound, and the transparent conductive layer 17 is formed on the base film 16 of the unwound laminated film 20 to obtain the laminated body 10 with a transparent conductive layer.
- the laminated film 20 with a transparent conductive layer is obtained by transporting the laminated film 20 in a vacuum device and forming the transparent conductive layer 17 on the base material film 16 by a vacuum process such as sputtering or vapor deposition.
- the transparent conductive layer 17 may be patterned into a desired shape by etching.
- the composition forming the transparent conductive layer 17 may be applied to the surface of the base film 16 and dried to form the transparent conductive layer 17 and obtain the laminate 10 with the transparent conductive layer.
- the obtained laminated body 10 with a transparent conductive layer is wound into a roll.
- the thin transparent conductive film 12 is manufactured by roll-to-roll by using the laminated film 20 having the thin base film 16. be able to. This makes it possible to manufacture the thin transparent conductive film 12 with high productivity.
- the laminated film 20 is a laminated film for supporting the transparent conductive layer 17 included in the transparent conductive film 12.
- the laminated film 20 has a base film 16 for supporting the transparent conductive layer 17 and a protective film 14 for supporting the base film 16 via the adhesive layer 15.
- the base film 16 and the protective film 14 each contain a cycloolefin resin (COP resin).
- COP resin cycloolefin resin
- the thickness of the base film 16 is 5 ⁇ m or more and 40 ⁇ m or less.
- the thickness of the base film 16 is within the above range, it is possible to reduce damage (for example, breakage) of the transparent conductive layer 17 due to cracking of the base film 16 when the transparent conductive film 12 is bent and conveyed. Therefore, the thin transparent conductive film 12 can be manufactured with high productivity by roll-to-roll. That is, it is possible to realize the laminated film 20 suitable for manufacturing the thin transparent conductive film 12 with high productivity.
- the base film 16 when the film thickness of the base film 16 is less than 5 ⁇ m, the base film 16 is too thin. Therefore, when the transparent conductive film 12 is conveyed while being bent by a conveyance roll, the base film 16 is broken. As a result, the transparent conductive layer 17 on the base material film 16 is likely to be broken, resulting in defective conduction. On the contrary, when the film thickness of the base film 16 exceeds 40 ⁇ m, the transparent conductive layer 17 on the base film 16 is stretched in the circumferential direction of the roll when the transparent conductive film 12 is bent by the roll during conveyance. Is likely to be broken, which also tends to cause defective conduction.
- the heat shrinkage ratio A (%) in the width direction of the base film 16 when heated at 140° C. for 90 minutes is 0.01% or more and 0.20% or less. This makes it possible to suppress damage to the transparent conductive layer 17 when the transparent conductive layer 17 is heat-processed (including when dried) and when the protective film 14 is peeled off, and a laminated film suitable for manufacturing the transparent conductive film 12. 20 can be realized.
- the heat shrinkage A exceeds 0.20%, the amount of heat shrinkage of the base film 16 at the time of heat processing of the transparent conductive layer 17 is too large, so that the transparent conductive layer 17 on the base film 16 is a base material. It is considered that the shrinkage of the film 16 cannot be followed, the film 16 is easily broken, and the defective conduction is likely to occur.
- the thermal shrinkage A is less than 0.01%, the shrinkage stress generated in the base film 16 during the heat processing of the transparent conductive layer 17 is small, and a sufficient residual stress cannot be obtained. For this reason, it becomes difficult to uniformly peel off the protective film 14 from the base film 16, and the base film 16 is partially pulled toward the protective film 14 side. It is considered that at such a location, the transparent conductive layer 17 on the base film 16 is partially broken, and a poor current flow is likely to occur.
- Predicting the mechanism of action and effect development is as follows. That is, when the laminated film 20 is heated in the process of forming the transparent conductive layer 17, the protective film 14 and the base material film 16 have different shrinking forces at the time of heating, and when they are subsequently cooled (at room temperature). When returning), residual stress is generated in the pressure-sensitive adhesive layer 15 and the protective film 14. When peeling the protective film 14 from the roll-shaped laminated film 20, not only the tension in the longitudinal direction due to the peeling roll but also the shrinkage in the width direction due to the residual stress occurs. It is possible to peel with less force.
- the base film 16 is less likely to be pulled toward the protective film 14 when the protective film 14 is peeled off, and the transparent conductive layer 17 supported by the base film 16 is less likely to be pulled. Is less likely to be pulled toward the protective film 14 side. As a result, it is possible to reduce the deformation (occurrence of wrinkles and folds) of the transparent conductive film 12 when the protective film 14 is peeled off.
- the protective film 14 when the transparent conductive layer 17 is heat-processed, the protective film 14 largely undergoes heat shrinkage, and the end portion of the protective film 14 is easily peeled off. Becomes difficult. As a result, when the protective film 14 is peeled off, the base film 16 is likely to have wrinkles, and the transparent conductive film 12 is easily deformed.
- the protective film 14 can be easily peeled off without weakening the adhesive force of the pressure-sensitive adhesive layer 15, the protective film 14 is peeled off from the base film 16 during transportation before peeling due to the adhesive force of the pressure-sensitive adhesive layer 15. It is possible to avoid such a situation. Therefore, the peeled protective film 14 is not rolled up by the roll for transportation, and the laminated body 10 with the transparent conductive layer is not broken.
- the film thickness of the protective film 14 is preferably 40 ⁇ m or more and 100 ⁇ m or less and is thicker than the film thickness of the base film 16. With this configuration, the shrinkage force of the protective film 14 due to heat can be appropriately generated with respect to the thickness of the base film 16. Accordingly, it is possible to reduce the occurrence of wrinkles in the base film 16 under the influence of heat shrinkage of the protective film 14 during the transportation of the transparent conductive layer 17 during the heating process. Therefore, it is possible to reduce damage to the transparent conductive layer 17 on the base film 17 when the laminate 10 with the transparent conductive layer is wound up. Further, the mechanical strength of the protective film 14 is sufficiently secured, and damage (for example, cracking) of the protective film 14 during transportation is also sufficiently reduced.
- the transparent conductive layer 17 is preferably composed of a conductive film containing metal nanowires. From this, it can be said that it is desirable that the base film 16 constitutes the laminated film 20 for supporting the conductive film including the metal nanowire as the transparent conductive layer 17.
- the base film preferably contains a cycloolefin resin in terms of easy control of optical properties.
- the cycloolefin resin is not particularly limited as long as it is a resin having a monomer unit composed of a cyclic olefin (cycloolefin).
- the cycloolefin resin used for the substrate film may be either a cycloolefin polymer (COP) or a cycloolefin copolymer (COC).
- the cycloolefin copolymer refers to a non-crystalline cyclic olefin resin which is a copolymer of a cyclic olefin and an olefin such as ethylene.
- cyclic olefin there are polycyclic cyclic olefin and monocyclic cyclic olefin.
- polycyclic cyclic olefins include norbornene, methylnorbornene, dimethylnorbornene, ethylnorbornene, ethylidenenorbornene, butylnorbornene, dicyclopentadiene, dihydrodicyclopentadiene, methyldicyclopentadiene, dimethyldicyclopentadiene, tetracyclododecene.
- Methyltetracyclododecene dimethylcyclotetradodecene, tricyclopentadiene, tetracyclopentadiene and the like.
- examples of the monocyclic olefin include cyclobutene, cyclopentene, cyclooctene, cyclooctadiene, cyclooctatriene, cyclododecatriene and the like.
- the cycloolefin resin is also available as a commercial product, and examples thereof include “ZEONOR” manufactured by Zeon Corporation, “ARTON” manufactured by JSR, “TOPAS” manufactured by Polyplastics, and “APEL” manufactured by Mitsui Chemicals, Inc. ..
- the base film is subjected to an etching treatment or undercoating treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, chemical conversion, or oxidation on the surface in advance, and a transparent conductive layer formed on the base film. You may make it improve adhesiveness. Further, before forming the transparent conductive layer, the surface of the base material film may be removed and cleaned by solvent cleaning or ultrasonic cleaning, if necessary.
- an etching treatment or undercoating treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, chemical conversion, or oxidation on the surface in advance, and a transparent conductive layer formed on the base film. You may make it improve adhesiveness. Further, before forming the transparent conductive layer, the surface of the base material film may be removed and cleaned by solvent cleaning or ultrasonic cleaning, if necessary.
- the glass transition temperature of the cycloolefin resin forming the base film is preferably 130°C or higher, more preferably 140°C or higher. As a result, it is possible to suppress the occurrence of curl after the heat treatment process, improve the dimensional stability, and secure the subsequent process yield.
- the constituent material of the transparent conductive layer is not particularly limited as long as it contains an inorganic substance, and is selected from the group consisting of indium, tin, zinc, gallium, antimony, titanium, silicon, zirconium, magnesium, aluminum, gold, silver, copper, palladium and tungsten.
- a metal oxide of at least one selected metal is preferably used.
- the metal oxide may further contain a metal atom shown in the above group, if necessary.
- ITO indium oxide
- ATO tin oxide
- ATO tin oxide
- the thickness of the transparent conductive layer is not particularly limited, but the thickness is preferably 10 nm or more in order to obtain a continuous coating having a surface resistance of 1 ⁇ 10 3 ⁇ / ⁇ or less and good conductivity.
- the film thickness is preferably 15 to 35 nm, and more preferably 20 to 30 nm, because if the film thickness is too thick, the transparency is lowered.
- the thickness of the transparent conductive layer is less than 10 nm, the electric resistance of the film surface becomes high and it becomes difficult to form a continuous film. If the thickness of the transparent conductive layer exceeds 35 nm, the transparency may be deteriorated.
- the method for forming the transparent conductive layer is not particularly limited, and a conventionally known method can be adopted. Specifically, a dry process such as a vacuum deposition method, a sputtering method, or an ion plating method can be exemplified. Also, an appropriate method can be adopted depending on the required film thickness.
- the transparent conductive layer can be crystallized by performing a heat annealing treatment (for example, at 80 to 150° C. for about 30 to 90 minutes in an air atmosphere), if necessary. By crystallizing the transparent conductive layer, the resistance of the transparent conductive layer is lowered, and the transparency and durability are improved.
- the means for converting the amorphous transparent conductive layer into a crystalline material is not particularly limited, but an air circulation oven, an IR heater or the like is used.
- a transparent conductive film having a transparent conductive layer formed on a substrate film is immersed in hydrochloric acid having a concentration of 5% by weight at 20°C for 15 minutes, then washed with water and dried for 15 mm.
- the resistance between terminals was measured by a tester, and when the resistance between terminals did not exceed 10 k ⁇ , it was determined that the conversion of the ITO film into the crystalline material was completed.
- the surface resistance can be measured by the 4-terminal method according to JIS K7194.
- the transparent conductive layer may be patterned by etching or the like.
- the patterning of the transparent conductive layer can be performed using a conventionally known photolithography technique.
- An acid is preferably used as the etching liquid.
- the acid include inorganic acids such as hydrogen chloride, hydrogen bromide, sulfuric acid, nitric acid and phosphoric acid, organic acids such as acetic acid, mixtures thereof, and aqueous solutions thereof.
- the transparent conductive layer be patterned in a stripe shape.
- the annealing treatment of the transparent conductive layer is preferably performed after the transparent conductive layer is patterned.
- the base film is transported in a state of being laminated via a pressure-sensitive adhesive layer on a protective film to form a transparent conductive layer on the base film, and the roll is formed.
- -It is preferable to continuously process the laminate with a transparent conductive layer having a long shape by a toe roll.
- Metal nanowires can also be used as the material forming the transparent conductive layer.
- the metal nanowire is a conductive material that is made of metal and has a needle-like or thread-like shape and a diameter of nanometer.
- the metal nanowire may be linear or curved. If a transparent conductive layer composed of metal nanowires is used, the metal nanowires will have a mesh-like shape, so that even with a small amount of metal nanowires, a good electrical conduction path can be formed, and the electrical resistance can be improved. It is possible to obtain a transparent conductive film having a small size. Furthermore, since the metal nanowires have a mesh shape, openings can be formed in the gaps of the mesh, and a transparent conductive film having a high light transmittance can be obtained.
- the ratio of the thickness d and the length L of the metal nanowire is preferably in the range of 10 to 100,000, more preferably in the range of 50 to 100,000, and particularly preferably. Is in the range of 100 to 10,000.
- the “thickness of the metal nanowire” means the diameter of the metal nanowire when the cross section is circular, and the short diameter when the cross section is elliptic, and When it is a polygon, it means the longest diagonal.
- the thickness and length of the metal nanowire can be confirmed by a scanning electron microscope or a transmission electron microscope.
- the thickness of the metal nanowire is preferably less than 500 nm, more preferably less than 200 nm, particularly preferably within the range of 10 to 100 nm, and most preferably within the range of 10 to 50 nm. Within such a range, a transparent conductive layer having a high light transmittance can be formed.
- the length of the metal nanowire is preferably in the range of 2.5 to 1000 ⁇ m, more preferably in the range of 10 to 500 ⁇ m, and particularly preferably in the range of 20 to 100 ⁇ m. Within such a range, a transparent conductive film having high conductivity can be obtained.
- any appropriate metal can be used as long as it has high conductivity.
- the metal forming the metal nanowire include silver, gold, copper, nickel and the like.
- a material obtained by plating these metals with gold for example, gold plating may be used.
- silver or copper is preferable from the viewpoint of conductivity.
- any appropriate method can be adopted as the method for producing the metal nanowire.
- a method of reducing silver nitrate in a solution a method of applying an applied voltage or current from the tip of the probe to the precursor surface, pulling out the metal nanowire at the tip of the probe, continuously forming the metal nanowire, etc.
- a silver nanowire can be synthesized by liquid-phase reduction of a silver salt such as silver nitrate in the presence of a polyol such as ethylene glycol and polyvinylpyrrolidone.
- Uniform silver nanowires include, for example, Xia, Y. et al. Chem. Mater. (2002), 14, 4736-4745, Xia, Y. et al. Mass production is possible according to the method described in Nano letters (2003) 3(7), 955-960.
- the transparent conductive layer can be formed by applying the transparent conductive layer-forming composition containing the metal nanowires onto the transparent substrate. More specifically, a dispersion liquid (composition for forming a transparent conductive layer) in which the metal nanowires are dispersed in a solvent is applied on the transparent substrate, and then the applied layer is dried to give a transparent conductive layer. Can be formed.
- Examples of the above solvent include water, alcohol solvents, ketone solvents, ether solvents, hydrocarbon solvents, aromatic solvents and the like. From the viewpoint of reducing environmental load, it is preferable to use water.
- the dispersion concentration of the metal nanowires in the composition for forming a transparent conductive layer containing the metal nanowires is preferably in the range of 0.1 to 1% by mass. Within such a range, it is possible to form a transparent conductive layer having excellent conductivity and light transmittance.
- the transparent conductive layer-forming composition containing the metal nanowires may further contain any appropriate additive depending on the purpose.
- the additive include a corrosion inhibitor that prevents corrosion of the metal nanowires and a surfactant that prevents aggregation of the metal nanowires.
- the type, number and amount of additives used can be appropriately set according to the purpose.
- the transparent conductive layer-forming composition may contain any appropriate binder resin, if necessary, as long as the effects of the present invention can be obtained.
- any appropriate method can be adopted as a method for applying the composition for forming a transparent conductive layer containing the metal nanowires.
- the coating method include spray coating, bar coating, roll coating, die coating, inkjet coating, screen coating, dip coating, letterpress printing, intaglio printing, and gravure printing.
- any suitable drying method for example, natural drying, blast drying, heat drying
- the drying temperature is typically in the range of 100 to 200°C
- the drying time is typically in the range of 1 to 10 minutes.
- the thickness of the transparent conductive layer is preferably in the range of 0.01 to 10 ⁇ m, more preferably in the range of 0.05 to 3 ⁇ m, and particularly preferably. Is in the range of 0.1 to 1 ⁇ m. Within such a range, a transparent conductive film having excellent conductivity and light transmittance can be obtained.
- the total light transmittance of the transparent conductive layer is preferably 85% or more, more preferably 90% or more, and further preferably 95% or more.
- the pressure-sensitive adhesive layer can be used without particular limitation as long as it has transparency. Specifically, for example, acrylic-based polymers, silicone-based polymers, polyesters, polyurethanes, polyamides, polyvinyl ethers, vinyl acetate/vinyl chloride copolymers, modified polyolefins, epoxy-based, fluorine-based, natural rubber, rubber such as synthetic rubber, etc.
- a polymer having the above polymer as a base polymer can be appropriately selected and used.
- an acrylic pressure-sensitive adhesive is preferably used because it is excellent in optical transparency, exhibits appropriate wettability, cohesiveness, adhesiveness and other adhesive properties, and is also excellent in weather resistance and heat resistance.
- the method for forming the pressure-sensitive adhesive layer is not particularly limited, a method in which the pressure-sensitive adhesive composition is applied to a release liner, dried, and then transferred to a protective film (transfer method), the protective film is directly applied to the adhesive composition, Examples thereof include a drying method (direct copying method) and a coextrusion method.
- a tackifier, a plasticizer, a filler, an antioxidant, an ultraviolet absorber, a silane coupling agent, or the like can be appropriately used if necessary.
- the preferable thickness of the pressure-sensitive adhesive layer is 5 ⁇ m to 100 ⁇ m, more preferably 10 ⁇ m to 50 ⁇ m, and further preferably 15 ⁇ m to 35 ⁇ m.
- the protective film is preferably formed of an amorphous resin in consideration of handleability such as winding with a roll.
- an amorphous resin it is preferable to use a cycloolefin resin which is excellent in transparency, mechanical strength, thermal stability, moisture barrier property, isotropy and the like.
- the cycloolefin resin is also preferable from the viewpoint of suppressing curling after the heat treatment step and improving dimensional stability.
- the glass transition temperature of the amorphous resin forming the protective film is preferably 130°C or higher, more preferably 140°C or higher. As a result, it is possible to suppress the occurrence of curl after the heat treatment process, improve the dimensional stability, and secure the subsequent process yield.
- the protective film is subjected to an etching treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, chemical conversion, oxidation, or undercoating on the surface in advance, and an adhesive layer on the protective film, etc. You may make it improve the adhesiveness with. Further, before forming the pressure-sensitive adhesive layer, the surface of the protective film may be removed and cleaned by solvent cleaning or ultrasonic cleaning, if necessary.
- an etching treatment such as sputtering, corona discharge, flame, ultraviolet irradiation, electron beam irradiation, chemical conversion, oxidation, or undercoating on the surface in advance, and an adhesive layer on the protective film, etc. You may make it improve the adhesiveness with.
- the surface of the protective film may be removed and cleaned by solvent cleaning or ultrasonic cleaning, if necessary.
- the thickness of the protective film is preferably 10 to 150 ⁇ m, more preferably 30 to 110 ⁇ m, and further preferably 40 to 100 ⁇ m. Within this thickness range, while ensuring the mechanical strength of the protective film, wrinkles are formed in the base film under the influence of heat shrinkage of the protective film during transport of the laminate during heating processing of the transparent conductive layer. It can be reduced.
- the above-mentioned base film and protective film (hereinafter also collectively referred to as “optical film”) can be produced by, for example, a solution casting film forming method.
- FIG. 5 is an explanatory diagram showing a schematic configuration of the optical film manufacturing apparatus 31 of the present embodiment
- FIG. 6 is a flowchart showing a flow of the optical film manufacturing method.
- the method for producing an optical film of the present embodiment is a method for producing an optical film by a solution casting film forming method, and includes a stirring preparation step (S31), a casting step (S32), a peeling step (S33), and a first drying.
- ⁇ Stirring preparation step> In the stirring preparation step, at least the resin and the solvent are stirred in the stirring tank 51 of the stirring device 50 to prepare the dope cast on the support 33 (endless belt).
- the resin for example, cycloolefin resin can be used.
- the solvent a mixed solvent of a good solvent and a poor solvent can be used.
- the good solvent means an organic solvent having a property of dissolving the resin (solubility), and 1,3-dioxolane, THF (tetrahydrofuran), methyl ethyl ketone, acetone, methyl acetate, methylene chloride (dichloromethane), etc. Equivalent to.
- the poor solvent means a solvent which does not have the property of dissolving the resin by itself, and methanol, ethanol and the like correspond to this.
- the dope prepared in the stirring preparation step is sent to the casting die 32 by a conduit through a pressurization type quantitative gear pump or the like, and is transferred indefinitely on a support 33 composed of a rotation-driven stainless steel endless belt.
- the dope is cast from the casting die 32 to the casting position.
- the cast dope is dried on the support 33 to form a cast film 35 (web).
- the inclination of the casting die 32, that is, the dope discharge direction from the casting die 32 to the support 33 is an angle of 0° to 90° with respect to the normal to the surface of the support 33 (the surface on which the dope is cast). It may be appropriately set to be within the range.
- the support 33 is held by a pair of rolls 33a and 33b and a plurality of rolls (not shown) located between them.
- One or both of the rolls 33a and 33b is provided with a drive device (not shown) that applies a tension to the support body 33, whereby the support body 33 is used in a tensioned state.
- the casting film 35 formed by the dope cast on the support 33 is heated on the support 33, and the casting film 35 can be peeled from the support 33 by the peeling roll 34. Evaporate the solvent to.
- To evaporate the solvent there are a method of blowing air from the web side, a method of transferring heat from the back surface of the support 33 by a liquid, a method of transferring heat from the front and back sides by radiant heat, etc., and these may be used alone or in combination as appropriate. Good.
- the residual solvent amount of the casting film 35 on the support 33 at the time of peeling is preferably in the range of 50 to 120 mass% depending on the strength of the drying conditions, the length of the support 33, and the like.
- the residual solvent amount of is determined.
- the residual solvent amount is defined by the following formula.
- Amount of residual solvent (mass %) (mass before heat treatment of web ⁇ mass after heat treatment of web)/(mass after heat treatment of web) ⁇ 100
- the heat treatment at the time of measuring the residual solvent amount means performing heat treatment at 115° C. for 1 hour.
- the casting film 35 separated from the support 33 is dried by the drying device 36.
- the drying device 36 the casting film 35 is conveyed by a plurality of conveying rolls arranged in a zigzag shape when viewed from the side, and the casting film 35 is dried in the meantime.
- the drying method by the drying device 36 is not particularly limited, and the casting film 35 is generally dried by using hot air, infrared rays, heating rolls, microwaves or the like. From the viewpoint of simplicity, a method of drying the casting film 35 with hot air is preferable.
- the first drying step may be performed as needed.
- the stretching step the casting film 35 dried by the drying device 36 is stretched by the tenter 37.
- the stretching direction at this time is either a film transport direction (MD direction; Machine Direction), a width direction (TD direction; Transverse Direction) perpendicular to the transport direction in the film plane, or both of these directions.
- MD direction film transport direction
- TD direction width direction
- Transverse Direction width direction perpendicular to the transport direction in the film plane
- ⁇ Second drying step> The casting film 35 stretched by the tenter 37 is dried by the drying device 38.
- the drying device 38 the casting film 35 is conveyed by a plurality of conveying rolls arranged in a zigzag shape when viewed from the side, and the casting film 35 is dried in the meantime.
- the drying method in the drying device 38 is not particularly limited, and the casting film 35 is generally dried using hot air, infrared rays, heating rolls, microwaves, or the like. From the viewpoint of simplicity, a method of drying the casting film 35 with hot air is preferable.
- the casting film 35 is dried by the drying device 38 and then conveyed as the optical film F toward the winding device 41.
- the cutting unit 39 and the embossing unit 40 are arranged in this order between the drying device 38 and the winding device 41.
- a cutting process is performed in which both ends in the width direction are cut by a slitter while conveying the film-formed optical film F.
- the portions left after cutting the both ends constitute a product portion that is a film product.
- the portion cut from the optical film F is collected by the shooter and reused again as a part of the raw material for film formation.
- embossing is applied to both ends of the optical film F in the width direction by the embossing section 40.
- the embossing is performed by pressing a heated embossing roller against both ends of the optical film F. Fine irregularities are formed on the surface of the embossing roller, and by pressing the embossing roller against both ends of the optical film F, the irregularities are formed at both ends.
- the optical film F on which the embossing process is completed is wound by the winding device 41 to obtain the original roll (film roll) of the optical film F. That is, in the winding step, the film roll is manufactured by winding the optical film F on the core while conveying the optical film F.
- a winding method of the optical film F a generally used winder may be used, and there are methods of controlling tension such as a constant torque method, a constant tension method, a taper tension method, and a program tension control method with a constant internal stress. You can use them properly.
- the winding length of the optical film F is preferably 1000 to 7200 m.
- the width at that time is preferably 1000 to 3200 mm, and the film thickness may be appropriately adjusted in the range of 10 to 150 ⁇ m.
- Fine particles (Aerosil R812: manufactured by Nippon Aerosil, primary average particle diameter: 7 nm, apparent specific gravity 50 g/L) 4 parts by mass Dichloromethane 76 parts by mass Cycloolefin polymer solution 10 parts by mass
- the dope for film formation prepared above was uniformly cast on a stainless belt support at a temperature of 31° C. and a width of 1800 mm using an endless belt casting device.
- the temperature of the stainless belt support was controlled at 28°C.
- the solvent was evaporated until the amount of residual solvent in the cast film was 30% by mass. Then, the cast film (web) was peeled from the stainless belt support with a peeling tension of 128 N/m. While the peeled web is being dried, it is stretched at a draw ratio of 20% (1.20 times) in the longitudinal direction by a conveying tension, and then conveyed to a tenter stretching device, and is stretched in the width direction of 40% (1.40 times). Was transported in the tenter. At this time, the drying conditions from peeling to the tenter were adjusted so that the residual solvent amount during stretching was 5% by mass. Further, the temperature of the tenter stretching device was set to 135° C., and the stretching speed was set to 200%/min.
- the stretched web (film) was introduced into a drying device, and drying was completed while being conveyed in the drying device by a large number of rollers. After that, both ends of the obtained film in the width direction were slit and then embossed to produce a protective film P-1 having a dry film thickness of 60 ⁇ m.
- ⁇ Preparation of base film F-1> The dope used in the production of the protective film P-1 was cast on a stainless belt support. Then, the solvent was evaporated on the stainless belt support until the amount of residual solvent in the cast film was 30% by mass. Then, the cast film (web) was peeled from the stainless belt support with a peeling tension of 128 N/m. The peeled web was introduced into the drying zone, and the drying was completed while being conveyed by a large number of rollers. Then, while applying heat of 160° C. to the web, the film was stretched by 5% in the width direction using a tenter, and slits were formed at both ends in the width direction of the obtained film, followed by embossing to obtain a dry film thickness. A base film F-1 having a thickness of 18 ⁇ m was produced.
- the pressure-sensitive adhesive S-1 obtained as described above was applied onto the release-treated surface of the release-treated PET film and heated at 120° C. for 60 seconds to form a pressure-sensitive adhesive layer having a thickness of 20 ⁇ m. Then, a PET film was attached to the protective film P-1 produced above through an adhesive layer. After that, the PET film was peeled off to prepare a protective film P-1 with an adhesive layer in which an adhesive layer was formed on one surface of the protective film P-1.
- Silver nanowire aqueous dispersion composition (Cambrios Technologies Corporation) containing 0.5% w/v of silver nanowires (minor axis diameter about 70 nm to 80 nm, aspect ratio 100 or more) synthesized by the above method in an aqueous medium.
- ClearOhmTM, Ink-A AQ) manufactured by Co., Ltd. is applied on the surface of the base film F-1 of the laminated film L-1 by a slot die coater so that the film thickness after drying becomes 1.5 ⁇ m. Dried. After that, pressure treatment was performed at a pressure of 2000 kN/m 2 to form a transparent conductive layer A on the base film F-1 to obtain a laminate with a transparent conductive layer. Then, the laminate with the transparent conductive layer was wound into a roll.
- the protective film P-1 was peeled off together with the pressure-sensitive adhesive S-1 while feeding and transporting the roll-shaped laminated body with the transparent conductive layer prepared above.
- a transparent conductive film M-1 in which the transparent conductive layer A was supported by the base film F-1 was obtained.
- the obtained transparent conductive film M-1 was wound into a roll.
- the transparent conductive layer A was formed on the substrate film to prepare a roll-shaped laminate with a transparent conductive layer. Then, the roll-shaped laminated body with the transparent conductive layer was fed out and the protective film was peeled off together with the pressure-sensitive adhesive to obtain transparent conductive films M-2 to M15. Finally, the obtained transparent conductive films M-2 to M-15 were wound into a roll.
- Adhesive S-2 was prepared in the same manner as Adhesive S-1 except that the epoxy cross-linking agent (trade name "Tetrad C (registered trademark)" manufactured by Mitsubishi Gas Chemical Co., Ltd.) was changed to 4 parts by weight. ..
- Thickness measurement The thickness of the protective film and the base film was measured using a micro gauge type thickness meter (manufactured by Mitutoyo).
- the thermal shrinkage in the width direction of the base film and the protective film was measured as follows. Specifically, the base film and the protective film are cut in a width direction of 100 mm and a length direction of 100 mm (the cut film is referred to as a “test piece”), and cross scratches (x marks) are provided at two ends in the width direction. The length (mm) between the two points of the central portion of the cross flaw before heating was measured by a CNC three-dimensional measuring machine (LEGEX774 manufactured by Mitutoyo Corporation). Then, the test piece was put into an oven and heat-treated (140° C., 90 minutes).
- test piece The produced transparent conductive film was cut into a width direction of 100 mm and a length direction of 100 mm (the cut film is referred to as a “test piece”), and the test piece was heated at 120° C. by a hot air circulation oven. A heat treatment was performed for 40 minutes. Then, the surface resistance of the test piece was measured at 9 points by the four-terminal method according to JIS K7194 and evaluated based on the following evaluation criteria. "Evaluation criteria" ⁇ : The surface resistance was 110 ⁇ / ⁇ or more in 0 of 9 places. ⁇ : The surface resistance was 110 ⁇ / ⁇ or more in 1 of 9 places. X: The surface resistance was 110 ⁇ / ⁇ or more in 2 out of 9 places.
- the produced transparent conductive film was cut into a width direction of 200 mm and a length direction of 100 mm (the cut film is referred to as a “test piece”), and the test piece was heated to 120 with respect to the test piece by a hot air circulation oven. A heat treatment was performed at 40° C. for 40 minutes. After that, the test piece was bent 180 degrees in the width direction (with the longitudinal direction as a bending axis) between two glass plates so as to have a bending diameter of 3 mm ⁇ , and fixed, and left for 500 hours in an environment of 60° C. and 90% RH. ..
- the surface resistance of the bent portion of the test piece was measured by the four-terminal method according to JIS K7194, and evaluated based on the following evaluation criteria.
- evaluation criteria ⁇ : The surface resistance was 110 ⁇ / ⁇ or less.
- X The surface resistance was larger than 200 ⁇ / ⁇ .
- Table 1 shows the evaluation results of Examples 1 to 7 and Comparative Examples 1 to 8.
- Comparative Examples 5 and 6 the bending current durability is poor (x).
- Comparative Example 6 since the thickness of the base film was 3 ⁇ m and the base film was too thin, when the transparent conductive film having the transparent conductive layer formed on the base film was bent and conveyed by a roll, It is considered that the material film is easily cracked, and as a result, the transparent conductive layer is broken, resulting in defective conduction.
- Comparative Example 5 since the thickness of the base film is 50 ⁇ m and the base film is too thick, the transparent conductive layer on the base film is rolled when the transparent conductive film is bent and conveyed by a roll. It is thought that the wire is stretched and ruptured in the circumferential direction to cause a current failure.
- the thickness of the substrate film was 5 ⁇ m or more and 40 ⁇ m or less, and the bending resistance of the transparent conductive film was good ( ⁇ or ⁇ ). From this, in Examples 1 to 7, it is possible to suppress breakage of the transparent electrode layer when the transparent conductive film is bent and conveyed by a roll, and a thin transparent conductive film is produced at a high roll-to-roll rate. It can be said that it can be manufactured by sex.
- the heat shrinkage A in the width direction of the substrate film was 0.01% or more and 0.20% or less, and a good result ( ⁇ or ⁇ ) was obtained in the energization test. Has been obtained. From this, it can be said that in Examples 1 to 7, the transparent conductive film can be manufactured by suppressing breakage of the transparent conductive layer during the heat processing of the transparent conductive layer and the peeling of the protective film.
- Comparative Examples 1 and 2 the transparent conductive film was deformed when the protective film was peeled off.
- A/B is as large as 0.60, and the difference in heat shrinkage between the base film and the protective film is small. Therefore, the protective film is peeled off from the base film by utilizing the difference in heat shrinkage. Becomes difficult. Therefore, it is considered that as a result of peeling the protective film with a high peeling force, the transparent conductive film was pulled toward the protective film and deformed.
- A/B is as small as 0.01, and the heat shrinkage B of the protective film is larger than the heat shrinkage A of the base film.
- the protective film undergoes large heat shrinkage to peel off the end portion of the protective film, and it becomes difficult to peel the protective film from the base film evenly in the width direction during peeling. As a result, it is considered that when the protective film was peeled off, the base film was wrinkled and the transparent conductive film was deformed.
- the protective film and the base film are laminated with the adhesive S-2 having a weaker adhesive force than the adhesive S-1 to form a transparent conductive film.
- a layered laminate is being produced.
- the adhesive strength of the adhesive S-2 is weak, the protective film spontaneously peeled during the transportation of the laminate with the transparent conductive layer, and the peeled protective film was wound around the transportation roll and the remaining film was broken. , Various evaluations could not be performed.
- the heat shrinkage rate A of the base film and the heat shrinkage rate B of the protective film are set to be equal to those in Example 3 of Patent Document 2 described above.
- the protective film cannot be peeled off from the base film by utilizing the difference in the heat shrinkage, and thus the protection It is considered that the transparent conductive film was deformed as a result of peeling the film with a high peeling force.
- Table 2 shows the evaluation results of Examples 8 to 11. For reference, the results of evaluation of wrinkles during conveyance of the laminated film based on the same evaluation criteria for Example 1 are also shown in Table 2.
- the prepared curable resin composition containing spherical particles was applied to the surface of the base film F-1 of the laminated film L-1 to form a coating layer.
- the coating layer was irradiated with ultraviolet rays from the side where the coating layer was formed to form a cured resin layer having a thickness of 1.0 ⁇ m.
- the laminated film L-1 with the cured resin layer was put into a winding type sputtering device, and an amorphous indium tin oxide layer having a thickness of 27 nm (composition: SnO 2 10 wt%; Hereinafter, it is also referred to as ITO) to form a laminate with a transparent conductive layer.
- ITO amorphous indium tin oxide layer having a thickness of 27 nm
- the laminated film L-1 with the cured resin layer is placed facing the ITO target in the vacuum chamber of the magnetron type sputtering device, Sputter deposition was performed at an applied voltage of DC 9 kW at 1 m/min in an environment of a vacuum degree of 2 ⁇ 10 ⁇ 3 torr obtained by completely replacing air with argon.
- an ITO conductive film is formed as a transparent conductive layer B on the surface of the cured resin layer formed on the base film F-1.
- the protective film P-1 with the pressure sensitive adhesive S-1 was peeled off while being transported, to prepare a transparent conductive film M-20. Then, the produced transparent conductive film M-20 was wound into a roll.
- Change rate of surface resistance value (%) ⁇ (surface resistance value after bending 50,000 times-surface resistance value before bending)/(surface resistance value before bending) ⁇ x 100 "Evaluation criteria"
- Table 3 shows the evaluation results of Example 12. For comparison, Table 3 also shows the results of evaluation of repeated bending durability of Example 1 based on the same evaluation criteria.
- Example 1 a conductive film containing silver nanowires is used as the transparent conductive layer A, whereas in Example 12, an ITO conductive film is used as the transparent conductive layer B. It can be seen that the conductive film containing silver nanowires has excellent repeated bending durability as compared with the ITO conductive film and is less likely to break. From this point, it can be said that it is desirable to use a conductive film containing silver nanowires as the transparent conductive layer.
- the laminated film described in the present embodiment can be expressed as follows.
- a laminated film for supporting a transparent conductive layer of a transparent conductive film has a protective film that supports the base film via an adhesive layer,
- the base film and the protective film each include a cycloolefin resin,
- the thickness of the base film is 5 ⁇ m or more and 40 ⁇ m or less
- the heat shrinkage A (%) in the width direction of the base film when heated at 140° C. for 90 minutes is 0.01% or more and 0.20% or less
- B (%) 0.02 ⁇ A/B ⁇ 0.50 Is a laminated film.
- the laminated body with the transparent conductive layer described in the present embodiment can be expressed as follows.
- a laminate with a transparent conductive layer comprising a transparent conductive layer located on the base film of the laminated film according to any one of 1 to 3 above.
- the method for manufacturing the transparent conductive film described in this embodiment can be expressed as follows.
- the laminated film for supporting the transparent conductive layer of the present invention can be used for manufacturing a transparent conductive film used for a touch sensor panel of a touch panel display device, for example.
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Abstract
Description
前記透明導電層を支持するための基材フィルムと、
前記基材フィルムを粘着剤層を介して支持する保護フィルムとを有し、
前記基材フィルムおよび前記保護フィルムは、シクロオレフィン樹脂をそれぞれ含み、
前記基材フィルムの膜厚は、5μm以上40μm以下であり、
前記基材フィルムの、140℃90分加熱時の幅手方向の熱収縮率A(%)が、0.01%以上0.20%以下であり、
前記保護フィルムの、140℃90分加熱時の幅手方向の熱収縮率をB(%)としたときに、
0.02≦A/B≦0.50
である。
図1は、本実施形態のタッチパネル表示装置1の概略の構成を示す断面図である。タッチパネル表示装置1は、表示部2上にタッチセンサーパネル3を有して構成されている。表示部2は、例えば液晶表示装置で構成されているが、OLED(Organic light-Emitting Diode)とも呼ばれる有機EL(Electro-Luminescence)表示装置など、他の表示装置で構成されていてもよい。
図3は、透明導電性フィルム12の製造方法の流れを示すフローチャートである。また、図4は、透明導電性フィルム12の製造工程を示す断面図である。上記の透明導電性フィルム12は、積層フィルム準備工程(S1)と、透明導電層形成工程(S2)と、保護フィルム剥離工程(S3)とを含む。
S1では、積層フィルム20を準備する。この積層フィルム20は、保護フィルム14と基材フィルム16とを粘着剤層15を介して積層して構成されている。基材フィルム16は、後述するように5μm以上40μm以下の厚みを有する薄型のフィルムで構成されている。ここでは、積層フィルム20を、予めロール状に巻き取っておく。なお、基材フィルム16の少なくとも一方の面には、硬化樹脂層(ハードコート層)が形成されていてもよい。このような積層フィルム20の詳細については後述する。
S2では、ロール状に巻き取られた積層フィルム20を繰り出し、繰り出した積層フィルム20の基材フィルム16上に透明導電層17を形成して透明導電層付き積層体10を得る。例えば、真空装置内で積層フィルム20を搬送し、スパッタリングや蒸着などの真空プロセスによって基材フィルム16上に透明導電層17を成膜することにより、透明導電層付き積層体10が得られる。なお、透明導電層17は、エッチングによって所望の形状にパターニングされてもよい。また、透明導電層17を構成する組成物を基材フィルム16の表面に塗布して乾燥させることにより、透明導電層17を形成して透明導電層付き積層体10を得るようにしてもよい。いずれにしても、得られた透明導電層付き積層体10は、ロール状に巻き取られる。
S3では、ロール状に巻き取られた透明導電層付き積層体10を繰り出し、透明導電層付き積層体10から保護フィルム14を粘着剤層15とともに剥離する。これにより、薄型の基材フィルム16上に透明導電層17を有する薄型の透明導電性フィルム12が得られる。得られた透明導電性フィルム12は、ロール状に巻き取られる。
次に、上述した積層フィルム20の詳細について説明する。積層フィルム20は、透明導電性フィルム12に含まれる透明導電層17の支持用の積層フィルムである。この積層フィルム20は、透明導電層17を支持するための基材フィルム16と、基材フィルム16を粘着剤層15を介して支持する保護フィルム14とを有している。
0.02≦A/B≦0.50
である。この条件式を満足することにより、基材フィルム16と保護フィルム14との熱収縮率の差を利用して保護フィルム14を基材フィルム16から剥離することが可能となる。したがって、粘着剤層15の粘着力を弱めなくても、保護フィルム14を容易に剥離することが可能となる。
次に、上述した透明導電性層付き積層体10を構成する各層の材料等について説明する。
(基材フィルム)
基材フィルムは、光学特性の制御が容易な点で、シクロオレフィン樹脂を含むことが好ましい。
透明導電層の構成材料は、無機物を含む限り特に限定されず、インジウム、スズ、亜鉛、ガリウム、アンチモン、チタン、珪素、ジルコニウム、マグネシウム、アルミニウム、金、銀、銅、パラジウム、タングステンからなる群より選択される少なくとも1種の金属の金属酸化物が好適に用いられる。当該金属酸化物には、必要に応じて、さらに上記群に示された金属原子を含んでいてもよい。例えば酸化スズを含有する酸化インジウム(ITO)、アンチモンを含有する酸化スズ(ATO)などが好ましく用いられる。
透明導電層を構成する材料として、金属ナノワイヤーを用いることもできる。金属ナノワイヤーとは、材質が金属であり、形状が針状または糸状であり、径がナノメートルサイズの導電物質をいう。金属ナノワイヤーは直線状であってもよく、曲線状であってもよい。金属ナノワイヤーで構成された透明導電層を用いれば、金属ナノワイヤーが網の目状となることにより、少量の金属ナノワイヤーであっても良好な電気伝導経路を形成することができ、電気抵抗の小さい透明導電性フィルムを得ることができる。さらに、金属ナノワイヤーが網の目状となることにより、網の目の隙間に開口部を形成して、光透過率の高い透明導電性フィルムを得ることができる。
粘着剤層としては、透明性を有するものであれば特に制限なく使用できる。具体的には、例えば、アクリル系ポリマー、シリコーン系ポリマー、ポリエステル、ポリウレタン、ポリアミド、ポリビニルエーテル、酢酸ビニル/塩化ビニルコポリマー、変性ポリオレフィン、エポキシ系、フッ素系、天然ゴム、合成ゴム等のゴム系などのポリマーをベースポリマーとするものを適宜に選択して用いることができる。特に、光学的透明性に優れ、適度な濡れ性、凝集性および接着性等の粘着特性を示し、耐候性や耐熱性等にも優れるという点からは、アクリル系粘着剤が好ましく用いられる。
保護フィルムは、ロールによる巻き取りなどの取り扱い性等を考慮して、非晶性樹脂で形成されることが好ましい。非晶性樹脂としては、透明性、機械的強度、熱安定性、水分遮断性、等方性などに優れるシクロオレフィン樹脂を用いることが好ましい。シクロオレフィン樹脂は、熱処理工程後のカール発生を抑制し、寸法安定性を向上させる観点でも好ましい。
上記した基材フィルムおよび保護フィルム(以下、まとめて「光学フィルム」とも記載する)は、例えば溶液流延製膜法によって製造することができる。図5は、本実施形態の光学フィルムの製造装置31の概略の構成を示す説明図であり、図6は、上記光学フィルムの製造方法の流れを示すフローチャートである。本実施形態の光学フィルムの製造方法は、溶液流延製膜法によって光学フィルムを製造する方法であり、攪拌調製工程(S31)、流延工程(S32)、剥離工程(S33)、第1乾燥工程(S34)、延伸工程(S35)、第2乾燥工程(S36)、切断工程(S37)、エンボス加工工程(S38)、巻取工程(S39)を含む。以下、各工程について説明する。
攪拌調製工程では、攪拌装置50の攪拌槽51にて、少なくとも樹脂および溶媒を攪拌し、支持体33(エンドレスベルト)上に流延するドープを調製する。上記樹脂として、例えばシクロオレフィン樹脂を用いることができる。溶媒としては、良溶媒および貧溶媒の混合溶媒を用いることができる。なお、良溶媒とは、樹脂を溶解させる性質(溶解性)を有する有機溶媒を言い、1,3-ジオキソラン、THF(テトラヒドロフラン)、メチルエチルケトン、アセトン、酢酸メチル、塩化メチレン(ジクロロメタン)などがこれに相当する。一方、貧溶媒とは、単独では樹脂を溶解させる性質を有していない溶媒を言い、メタノールやエタノールなどがこれに相当する。
流延工程では、攪拌調製工程で調製されたドープを、加圧型定量ギヤポンプ等を通して、導管によって流延ダイ32に送液し、無限に移送する回転駆動ステンレス鋼製エンドレスベルトよりなる支持体33上の流延位置に流延ダイ32からドープを流延する。そして、流延したドープを支持体33上で乾燥させて、流延膜35(ウェブ)を形成する。流延ダイ32の傾き、すなわち、流延ダイ32から支持体33へのドープの吐出方向は、支持体33の面(ドープが流延される面)の法線に対する角度で0°~90°の範囲内となるように適宜設定されればよい。
上記の流延工程にて、支持体33上で流延膜35が剥離可能な膜強度となるまで乾燥固化あるいは冷却凝固させた後、剥離工程では、流延膜35を、自己支持性を持たせたまま剥離ロール34によって剥離する。
ここで、残留溶媒量を測定する際の加熱処理とは、115℃で1時間の加熱処理を行うことを表す。
支持体33から剥離された流延膜35は、乾燥装置36にて乾燥される。乾燥装置36内では、側面から見て千鳥状に配置された複数の搬送ロールによって流延膜35が搬送され、その間に流延膜35が乾燥される。乾燥装置36での乾燥方法は、特に制限はなく、一般的に熱風、赤外線、加熱ロール、マイクロ波等を用いて流延膜35を乾燥させる。簡便さの点から、熱風で流延膜35を乾燥させる方法が好ましい。なお、第1乾燥工程は、必要に応じて行われればよい。
延伸工程では、乾燥装置36にて乾燥された流延膜35を、テンター37によって延伸する。このときの延伸方向としては、フィルム搬送方向(MD方向;Machine Direction)、フィルム面内で上記搬送方向に垂直な幅手方向(TD方向;Transverse Direction)、これらの両方向、のいずれかである。延伸工程では、流延膜35の両側縁部をクリップ等で固定して延伸するテンター方式が、フィルムの平面性や寸法安定性を向上させるために好ましい。なお、テンター37内では、延伸に加えて乾燥を行ってもよい。
テンター37にて延伸された流延膜35は、乾燥装置38にて乾燥される。乾燥装置38内では、側面から見て千鳥状に配置された複数の搬送ロールによって流延膜35が搬送され、その間に流延膜35が乾燥される。乾燥装置38での乾燥方法は、特に制限はなく、一般的に熱風、赤外線、加熱ロール、マイクロ波等を用いて流延膜35を乾燥させる。簡便さの点から、熱風で流延膜35を乾燥させる方法が好ましい。
乾燥装置38と巻取装置41との間には、切断部39およびエンボス加工部40がこの順で配置されている。切断部39では、製膜された光学フィルムFを搬送しながら、その幅手方向の両端部を、スリッターによって切断する切断工程が行われる。光学フィルムFにおいて、両端部の切断後に残った部分は、フィルム製品となる製品部を構成する。一方、光学フィルムFから切断された部分は、シュータにて回収され、再び原材料の一部としてフィルムの製膜に再利用される。
最後に、エンボス加工が終了した光学フィルムFを、巻取装置41によって巻き取り、光学フィルムFの元巻(フィルムロール)を得る。すなわち、巻取工程では、光学フィルムFを搬送しながら巻芯に巻き取ることにより、フィルムロールが製造される。光学フィルムFの巻き取り方法は、一般に使用されているワインダーを用いればよく、定トルク法、定テンション法、テーパーテンション法、内部応力一定のプログラムテンションコントロール法等の張力をコントロールする方法があり、それらを使い分ければよい。光学フィルムFの巻長は、1000~7200mであることが好ましい。また、その際の幅は1000~3200mm幅であることが好ましく、膜厚は10~150μmの範囲で適宜調整されればよい。
以下、本発明の具体的な実施例について説明するが、本発明はこれらの実施例に限定されるわけではない。
<保護フィルムP-1の作製>
(ドープの調製)
下記組成物をミキシングタンクに投入し、攪拌して各成分を溶解した後、平均孔径34μmの濾紙および平均孔径10μmの焼結金属フィルターで濾過してシクロオレフィン重合体溶液を調製した。
〈ドープ組成〉
シクロオレフィン重合体(JSR社製「アートン」(登録商標))
150質量部
ジクロロメタン 380質量部
〈微粒子分散液〉
微粒子(アエロジルR812:日本アエロジル社製、一次平均粒子径:7nm、見掛け比重50g/L)
4質量部
ジクロロメタン 76質量部
シクロオレフィン重合体溶液 10質量部
次いで、無端ベルト流延装置を用い、上記で調製した製膜用ドープを、温度31℃、1800mm幅でステンレスベルト支持体上に均一に流延した。ステンレスベルト支持体の温度は、28℃に制御した。
上記した保護フィルムP-1の作製で用いたドープをステンレスベルト支持体上に流延した。そして、ステンレスベルト支持体上で、流延(キャスト)したフィルム中の残留溶媒量が30質量%になるまで溶媒を蒸発させた。次いで、剥離張力128N/mで、ステンレスベルト支持体上から流延膜(ウェブ)を剥離した。剥離したウェブを乾燥ゾーンに導入し、多数のローラーで搬送させながら乾燥を終了させた。そして、ウェブに160℃の熱を付与しながら、テンターを用いて幅手方向に5%延伸し、得られたフィルムの幅手方向の両端部をスリットした後、エンボス加工を施し、乾燥膜厚が18μmの基材フィルムF-1を作製した。
(粘着剤S-1の調製)
通常の溶液重合により、ブチルアクリレート/アクリル酸=100/6(重量比)にて重量平均分子量60万のアクリル系ポリマーを得た。このアクリル系ポリマー100重量部に対し、エポキシ系架橋剤(三菱瓦斯化学製 商品名「テトラッドC(登録商標)」)6重量部を加えて、アクリル系粘着剤を準備した。
離型処理されたPETフィルムの離型処理面上に前記のようにして得た粘着剤S-1を塗布し、120℃で60秒加熱して、厚み20μmの粘着剤層を形成した。次いで、前記で作製した保護フィルムP-1に、粘着剤層を介してPETフィルムを貼り合わせた。その後、PETフィルムを剥がし、保護フィルムP-1の一方の面に粘着剤層が形成された粘着剤層付きの保護フィルムP-1を作製した。
(透明導電層Aの形成)
Y.Sun、B.Gates、B.Mayers、&Y.Xia,“Crystalline silver nanowires by soft solution processing”、Nano letters、(2002)、2(2) 165~168に記載されるポリオールを用いた方法の後、ポリビニルピロリドン(PVP)の存在下で、エチレングリコールに硫酸銀を溶解し、これを還元することによって銀ナノワイヤーを得た。すなわち、本実施例では、米国仮出願第60/815,627号(Cambrios Technologies Corporation)に記載される修正されたポリオール方法によって合成された銀ナノワイヤーを用いた。
上記方法で合成された銀ナノワイヤー(短軸径約70nm~80nm、アスペクト比100以上)を水性媒体中に0.5%w/v含有する銀ナノワイヤー水分散体組成物(Cambrios Technologies Corporation社製 ClearOhmTM,Ink-A AQ)を、スロットダイ塗工機を使用して、積層フィルムL-1の基材フィルムF-1面上に、乾燥後膜厚が1.5μmになるように塗布し、乾燥させた。その後、圧力2000kN/m2で加圧処理を行い、基材フィルムF-1上に透明導電層Aを形成し、透明導電層付き積層体を得た。その後、透明導電層付き積層体をロール状に巻き取った。
上記で作成したロール状の透明導電層付き積層体を繰り出して搬送しながら、保護フィルムP-1を粘着剤S-1とともに剥離した。これにより、透明導電層Aを基材フィルムF-1で支持した透明導電性フィルムM-1を得た。最後に、得られた透明導電性フィルムM-1をロール状に巻き取った。
基材フィルムの熱収縮率Aおよび保護フィルムの熱収縮率Bが、表1に記載の値となるように、基材フィルムおよび保護フィルムの作製時に、支持体からウェブを剥離する際の残留溶媒量、膜厚、テンターでの長手方向および幅手方向の延伸倍率および延伸温度を調整した以外は、実施例1と同様の方法で、基材フィルムF-2~F-10および保護フィルムP-2~P-8をそれぞれ作製した。そして、表1に記載の組み合わせとなるように、基材フィルムF-1~F-10および保護フィルムP-1~P-8を適宜選択して粘着剤S-1または粘着剤S-2を介して積層し、積層フィルムL-2~L-15を得た。なお、粘着剤S-2の調製方法については後述する。
エポキシ系架橋剤(三菱瓦斯化学製 商品名「テトラッドC(登録商標)」)を4重量部に変更した以外は、粘着剤S-1の調製と同様にして、粘着剤S-2を調製した。
(1)厚みの測定
保護フィルムおよび基材フィルムの厚みの測定は、マイクロゲージ式厚み計(ミツトヨ社製)を用いて行った。
基材フィルムおよび保護フィルムの幅手方向の熱収縮率を以下のように測定した。具体的には、基材フィルムおよび保護フィルムを、幅手方向100mm、長手方向100mmに切り取り(切り取ったフィルムを「試験片」と呼ぶ)、幅手方向の両端2点にクロスキズ(×印)を付け、クロスキズの中央部2点間の加熱前の長さ(mm)を、CNC三次元測定機(株式会社ミツトヨ社製 LEGEX774)によって測定した。その後、試験片をオーブンに投入し、加熱処理(140℃、90分間)を行った。室温で1時間放冷後に再度、2点間の加熱後の長さ(mm)をCNC三次元測定機によって測定し、その測定値を下記式に代入することにより、幅手方向の熱収縮率を求めた。
熱収縮率(%)=[{加熱前の長さ(mm)-加熱後の長さ(mm)}/加熱前の長さ(mm)]×100
粘着剤層付きの保護フィルムを剥離する際の透明導電性フィルムの変形を下記評価基準に基づいて評価した。
《評価基準》
○:保護フィルムの剥離時に、透明導電性フィルムに変形が全く発生せず、巻き取り後も変形が発生しなかった。
△:保護フィルムの剥離時に、透明導電性フィルムに変形が発生したが、巻き取り後は変形が発生しなかった。
×:保護フィルムの剥離時に、透明導電性フィルムに変形が発生し、巻き取り後も変形が残留していた。
作製した透明導電性フィルムを、幅手方向100mm、長手方向100mmに切り取り(切り取ったフィルムを「試験片」と呼ぶ)、熱風循環式オーブンにより、試験片に対して120℃で40分間の加熱処理を実施した。その後、試験片の表面抵抗を9か所でJIS K7194に準じて四端子法にて測定し、下記の評価基準に基づいて評価した。
《評価基準》
○:表面抵抗が110Ω/□以上である箇所が、9か所中0か所であった。
△:表面抵抗が110Ω/□以上である箇所が、9か所中1か所であった。
×:表面抵抗が110Ω/□以上である箇所が、9か所中2か所以上であった。
作製した透明導電性フィルムを、幅手方向200mm、長手方向100mmに切り取り(切り取ったフィルムを「試験片」と呼ぶ)、熱風循環式オーブンにより、試験片に対して120℃で40分間の加熱処理を実施した。その後、屈曲径3mmΦとなるように2枚のガラス板の間で試験片を幅手方向に(長手方向を折り曲げ軸として)180度折り曲げて固定し、60℃90%RHの環境下で500時間放置した。その後、試験片の折り曲げた部分の表面抵抗をJIS K7194に準じて四端子法にて測定し、下記の評価基準に基づいて評価した。
《評価基準》
○:表面抵抗が110Ω/□以下であった。
△:表面抵抗が110Ω/□よりも大きく、200Ω/□以下であった。
×:表面抵抗が200Ω/□よりも大きかった。
保護フィルムの膜厚が表2に記載の値となるように、保護フィルムの作製時に、支持体からウェブを剥離する際の残留溶媒量、膜厚、テンターでの長手方向および幅手方向の延伸倍率および延伸温度を調整した以外は、実施例1と同様の方法で、保護フィルムP-9~P-12をそれぞれ作製した。そして、各保護フィルムP-9~P-12上に粘着剤S-1を介して基材フィルムF-1を積層して積層フィルムL-16~L-19を作製し、積層フィルムL-16~L-19上に透明導電層Aを形成した後、保護フィルムP-9~P-12を剥離して、透明導電性フィルムM-16~M-19を作製した。
(6)積層フィルム搬送中のシワ
透明導電膜を形成する工程において、積層フィルムの搬送状態を観察し、下記の評価基準に基づいて評価した。
《評価基準》
◎:積層フィルムの搬送中にシワが発生しない。
○:積層フィルムの搬送中に弱いしわが発生するが、積層フィルムを巻き取ったときにはシワが消失している。
×:積層フィルム搬送中に弱いしわが発生し、積層フィルムを巻き取った後もシワが残る。
透明導電層Aを透明導電層Bに置き換えた以外は、実施例1と同様にして、透明導電性フィルムM-20を作製した。より詳しくは、以下の通りである。
(硬化樹脂層形成用の樹脂組成物の調製)
紫外線硬化性樹脂組成物(DIC社製 商品名「UNIDIC(登録商標)RS29-120」)を100重量部と、最頻粒子径が1.9μmであるアクリル系球状粒子(綜研化学社製 商品名「MX-180TA」)を0.2重量部とを含む、球状粒子入り硬化性樹脂組成物を準備した。
準備した球状粒子入り硬化性樹脂組成物を、積層フィルムL-1の基材フィルムF-1の表面に塗布し、塗布層を形成した。次いで、塗布層が形成された側から塗布層に紫外線を照射して、厚みが1.0μmとなるように硬化樹脂層を形成した。
硬化樹脂層のついた積層フィルムL-1を巻き取り式スパッタ装置に投入し、硬化樹脂層の表面に、厚みが27nmの非晶質のインジウム・スズ酸化物層(組成:SnO2 10wt%;以下、ITOとも称する)を成膜して、透明導電層付き積層体を作製した。より詳しくは、硬化樹脂層の表面をグロー放電して前処理した後、マグネトロン式スパッタ装置の真空槽内に、硬化樹脂層のついた積層フィルムL-1をITOターゲットに対峙して配置し、空気をアルゴンに完全置換して得た真空度2×10-3トールの環境下、印加電圧DC9kWで1m/minでスパッタ蒸着を行った。次いで、特開平11-243296号公報の段落〔0046〕~〔0050〕を参照して、基材フィルムF-1上に形成した硬化樹脂層の表面にITOの導電膜を透明導電層Bとして形成して、透明導電層付き積層体を得た後、搬送しながら粘着剤S-1のついた保護フィルムP-1を剥離し、透明導電性フィルムM-20を作製した。そして、作製した透明導電性フィルムM-20をロール状に巻き取った。
(7)繰り返し屈曲耐久性
作製した透明導電性フィルムM-20を熱風循環式オーブンに投入し、120℃で40分間加熱処理を実施した。その後、耐久試験機(ユアサシステム機器社製、製品名「面状体無負荷U字伸縮試験機」)を用いて、最少屈曲径:3mmφ、速度:30回/分、屈曲回数:5万回、試験温度:23℃の条件で、透明導電層を内側にして繰り返し屈曲させた。その後、サンプルの表面抵抗をJIS K7194に準じて四端子法によって測定し、下記の評価基準に基づいて評価した。なお、表面抵抗値の変化率は、下記の計算式から算出した。
表面抵抗値の変化率(%)={(5万回折り曲げ後の表面抵抗値-折り曲げ前の表面抵抗値)/(折り曲げ前の表面抵抗値)}×100
《評価基準》
◎:表面抵抗値の変化率が、10%以上20%未満であった。
○:表面抵抗値の変化率が、20%以上30%未満であった。
×:表面抵抗値の変化率が、30%以上であった。
以上のことから、本実施形態で説明した積層フィルムは、以下のように表現することができる。
前記透明導電層を支持するための基材フィルムと、
前記基材フィルムを粘着剤層を介して支持する保護フィルムとを有し、
前記基材フィルムおよび前記保護フィルムは、シクロオレフィン樹脂をそれぞれ含み、
前記基材フィルムの膜厚は、5μm以上40μm以下であり、
前記基材フィルムの、140℃90分加熱時の幅手方向の熱収縮率A(%)が、0.01%以上0.20%以下であり、
前記保護フィルムの、140℃90分加熱時の幅手方向の熱収縮率をB(%)としたときに、
0.02≦A/B≦0.50
であることを特徴とする積層フィルム。
前記透明導電層付き積層体を繰り出して、前記透明導電層付き積層体から前記保護フィルムを剥離し、前記基材フィルム上に前記透明導電層を有する透明導電性フィルムをロール状に巻き取る工程とを有することを特徴とする透明導電性フィルムの製造方法。
12 透明導電性フィルム
14 保護フィルム
15 粘着剤層
16 基材フィルム
17 透明導電層
20 積層フィルム
Claims (3)
- 透明導電性フィルムの透明導電層の支持用の積層フィルムであって、
前記透明導電層を支持するための基材フィルムと、
前記基材フィルムを粘着剤層を介して支持する保護フィルムとを有し、
前記基材フィルムおよび前記保護フィルムは、シクロオレフィン樹脂をそれぞれ含み、
前記基材フィルムの膜厚は、5μm以上40μm以下であり、
前記基材フィルムの、140℃90分加熱時の幅手方向の熱収縮率A(%)が、0.01%以上0.20%以下であり、
前記保護フィルムの、140℃90分加熱時の幅手方向の熱収縮率をB(%)としたときに、
0.02≦A/B≦0.50
である、積層フィルム。 - 前記保護フィルムの膜厚は、40μm以上100μm以下であり、かつ、前記基材フィルムの膜厚よりも厚い、請求項1に記載の積層フィルム。
- 前記透明導電層としての、金属ナノワイヤーを含む導電性膜の支持用である、請求項1または2に記載の積層フィルム。
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