WO2023100553A1 - 転写フィルム、導体パターンを有する積層体及び導体パターンを有する積層体の製造方法、転写フィルムの製造方法 - Google Patents
転写フィルム、導体パターンを有する積層体及び導体パターンを有する積層体の製造方法、転写フィルムの製造方法 Download PDFInfo
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
-
- 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
- G03F7/42—Stripping or agents therefor
-
- 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
-
- 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
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
Definitions
- the present invention relates to a transfer film, a laminate having a conductor pattern, a method for producing a laminate having a conductor pattern, and a method for producing a transfer film.
- a display device with a touch panel such as a capacitive input device (organic electroluminescence (EL) display device, liquid crystal display device, etc.)
- the electrode pattern corresponding to the sensor in the visible part the wiring of the peripheral wiring part and the lead-out wiring part
- a conductive layer pattern such as is provided inside the touch panel.
- Wiring patterns are also formed by etching and plating processes in printed circuit board wiring and the like. In general, the formation of a patterned layer requires a small number of steps to obtain a desired pattern shape. A method in which the photosensitive composition layer is exposed through a mask and then developed is widely used.
- Patent Document 1 a photosensitive element (transfer film) consisting of a support film (support), a photosensitive resin composition layer (photosensitive composition layer) and a protective film, which satisfies predetermined requirements. sexual elements are disclosed.
- the protective film When using a transfer film having a protective film, the protective film is peeled off. At this time, the peeled protective film is often wound into a roll, and from the viewpoint of productivity, it is desirable that winding failures are less likely to occur. Moreover, when forming a pattern using a transfer film, it is required to suppress the occurrence of pattern defects. When the inventors of the present invention examined the transfer film disclosed in Patent Document 1, they found that there is room for improvement in terms of compatibility between the ease of winding of the protective film and the suppression of the occurrence of pattern defects.
- an object of the present invention is to provide a transfer film in which winding defects of the protective film are less likely to occur when the protective film is peeled off and wound, and pattern defects are suppressed during pattern formation.
- Another object of the present invention is to provide a laminate having a conductor pattern, a method for producing a laminate having a conductor pattern, and a method for producing a transfer film.
- the present inventor has completed the present invention as a result of diligent studies aimed at solving the above problems. That is, the inventors have found that the above problems can be solved by the following configuration.
- the protective film contains polypropylene,
- the transfer film wherein the arithmetic mean roughness Ra1 of the surface of the protective film on the photosensitive composition layer side is smaller than the arithmetic mean roughness Ra2 of the surface of the protective film opposite to the photosensitive composition layer.
- Manufacture of a laminate having a conductor pattern further comprising a removal step of removing the conductive layer exposed by the resist pattern stripping step and forming a conductor pattern on the substrate when the plating step is included.
- a method Between the bonding step and the exposure step, or between the exposure step and the development step, a laminate having a conductor pattern, further comprising a temporary support peeling step for peeling the temporary support.
- Production method [8] forming a photosensitive composition layer on the temporary support;
- a method for producing a transfer film comprising a step of bonding a protective film to the surface of the photosensitive composition layer opposite to the temporary support,
- the protective film contains polypropylene,
- the arithmetic average roughness Ra1 of the surface of the protective film on the photosensitive composition layer side is smaller than the arithmetic average roughness Ra2 of the surface of the protective film opposite to the photosensitive composition layer, of the transfer film Production method.
- the present invention it is possible to provide a transfer film in which winding defects of the protective film are less likely to occur when the protective film is peeled off and wound up, and the occurrence of pattern defects during pattern formation is suppressed. Further, according to the present invention, it is possible to provide a laminate having a conductor pattern, a method for producing a laminate having a conductor pattern, and a method for producing a transfer film.
- a numerical range represented by "to” means a range including the numerical values before and after “to” as lower and upper limits.
- the upper limit or lower limit described in a certain numerical range may be replaced with the upper limit or lower limit of the numerical range described in other steps.
- the upper limit or lower limit described in a certain numerical range may be replaced with the values shown in the examples.
- process is not only an independent process, but even if it cannot be clearly distinguished from other processes, it is included in this term as long as the intended purpose of the process is achieved. .
- “transparent” means that the average transmittance of visible light with a wavelength of 400 to 700 nm is 80% or more, preferably 90% or more.
- the transmittance is a value measured using a spectrophotometer, and can be measured using a spectrophotometer U-3310 manufactured by Hitachi, Ltd., for example.
- the weight average molecular weight (Mw) and number average molecular weight (Mn) are measured using TSKgel GMHxL, TSKgel G4000HxL, or TSKgel G2000HxL (all trade names manufactured by Tosoh Corporation). ), using THF (tetrahydrofuran) as an eluent, a differential refractometer as a detector, and polystyrene as a standard substance, a value converted using polystyrene as a standard substance measured by a gel permeation chromatography (GPC) analyzer.
- the ratio of polymer constitutional units is the mass ratio.
- the molecular weight of compounds having a molecular weight distribution is the weight average molecular weight (Mw).
- Mw weight average molecular weight
- the content of metal elements is a value measured using an inductively coupled plasma (ICP) spectroscopic analyzer.
- ICP inductively coupled plasma
- the refractive index is a value measured using an ellipsometer at a wavelength of 550 nm.
- the hue is a value measured using a color difference meter (CR-221, manufactured by Minolta Co., Ltd.).
- (meth)acryl is a concept that includes both acryl and methacryl
- (meth)acryloxy group is a concept that includes both acryloxy and methacryloxy groups.
- alkali-soluble means that the solubility in 100 g of a 1% by mass aqueous solution of sodium carbonate at 22°C is 0.1 g or more.
- water-soluble means that the solubility in 100 g of water at pH 7.0 at a liquid temperature of 22°C is 0.1 g or more.
- water-soluble resin is intended a resin that satisfies the solubility conditions set forth above.
- the “solid content” of the composition means a component that forms a composition layer formed using the composition, and when the composition contains a solvent (organic solvent, water, etc.), the solvent means all ingredients except In addition, as long as it is a component that forms a composition layer, a liquid component is also regarded as a solid content.
- a solvent organic solvent, water, etc.
- the transfer film of the present invention has a temporary support, a photosensitive composition layer, and a protective film in this order.
- the protective film contains polypropylene, and the arithmetic average roughness Ra1 of the surface of the protective film on the photosensitive composition layer side is the opposite side to the photosensitive composition layer side of the protective film. A point smaller than the arithmetic mean roughness Ra2 of the surface of .
- the transfer film of the present invention facilitates winding of the protective film when the protective film is peeled off and wound, and the mechanism by which the occurrence of pattern defects is suppressed during pattern formation is not necessarily clear, but the present inventors We speculate as follows.
- the transfer film of the present invention has the above characteristics, when the protective film is peeled off and wound up, blocking is unlikely to occur even if the protective film is rolled and wound up, and winding defects are unlikely to occur. be done.
- the transfer film since the transfer film has the characteristic points, the irregularities on the surface of the photosensitive composition layer on the protective film side derived from the arithmetic mean roughness Ra1 are reduced while making it difficult for the winding failure to occur. .
- air bubbles are less likely to occur at the interface between the other member and the photosensitive composition layer, and pattern defects are less likely to occur. Conceivable.
- the transfer film of the present invention has a temporary support, a composition layer disposed on the temporary support, and a protective film in this order.
- the composition layer is not particularly limited as long as it includes a photosensitive composition layer.
- the photosensitive composition layer may be a negative photosensitive composition layer or a chemically amplified photosensitive composition layer, but is preferably a negative photosensitive composition layer.
- the composition layer may have a single-layer structure, or may have a structure of two or more layers.
- examples of the composition layer include a thermoplastic resin layer, an intermediate layer, and a refractive index adjusting layer.
- the transfer film of the present invention examples are shown below, but are not limited thereto.
- the photosensitive composition layer is preferably a negative photosensitive composition layer. It is also preferred that the photosensitive composition layer is a colored resin layer.
- the transfer film of the present invention may be used as a transfer film for a wiring protective film as described later, or may be used as a transfer film for an etching resist.
- the configuration of the transfer film is preferably the configuration (1) or (2) described above, for example.
- the configuration of the transfer film is preferably, for example, the configurations (2) to (4) described above.
- the photosensitive composition layer is arranged on the side opposite to the temporary support side.
- the total thickness of the other layers is preferably 0.1 to 30%, more preferably 0.1 to 20%, with respect to the thickness of the photosensitive composition layer.
- the maximum width of the undulation of the transfer film is preferably 300 ⁇ m or less, more preferably 200 ⁇ m or less, and even more preferably 60 ⁇ m or less.
- the lower limit of the maximum width of the undulation is 0 ⁇ m or more, preferably 0.1 ⁇ m or more, and more preferably 1 ⁇ m or more.
- the maximum width of waviness of the transfer film is a value measured by the following procedure. First, the transfer film is cut in a direction perpendicular to the main surface so as to have a size of 20 cm long and 20 cm wide, and the protective film is peeled off to prepare a test sample.
- test sample is placed on a flat and horizontal stage so that the surface of the temporary support faces the stage.
- surface of the sample sample is scanned with a laser microscope (for example, VK-9700SP manufactured by Keyence Co., Ltd.) for the center 10 cm square range of the test sample to obtain a three-dimensional surface image.
- a laser microscope for example, VK-9700SP manufactured by Keyence Co., Ltd.
- Subtract the minimum concave height from the maximum convex height observed in the dimensional surface image is performed for 10 test samples, and the arithmetic average value is taken as the "maximum waviness width of the transfer film".
- the transfer film of the present invention will be described below by giving an example of a specific embodiment.
- the transfer film of the first embodiment below has a configuration that can be suitably used as a transfer film for a wiring protective film
- the transfer film of the second embodiment below is a transfer film for a wiring protective film and an etching resist. It is a structure that can be suitably used for a transfer film for.
- excellent winding properties of the protective film when the protective film is peeled off and wound up, the difficulty in winding up the protective film is also referred to as "excellent winding properties of the protective film," and it means that the occurrence of pattern defects is suppressed during pattern formation. , it is also called “excellent in pattern defect suppression".
- the transfer film 10 shown in FIG. 1 has a temporary support 1, a composition layer 2 including a photosensitive composition layer 3 and a refractive index adjusting layer 5, and a protective film 7 in this order. Although the transfer film 10 shown in FIG. 1 has the refractive index adjustment layer 5, the refractive index adjustment layer 5 may not be provided. Each element constituting the transfer film will be described below.
- the transfer film has a temporary support.
- a temporary support is a member that supports the composition layer, and is finally removed by a peeling treatment.
- the temporary support may have a single layer structure or a multilayer structure.
- the temporary support is preferably a film, more preferably a resin film.
- the temporary support is preferably a film that has flexibility and does not undergo significant deformation, shrinkage, or elongation under pressure or under pressure and heat.
- the film include polyethylene terephthalate film (eg, biaxially stretched polyethylene terephthalate film), polymethyl methacrylate film, cellulose triacetate film, polystyrene film, polyimide film, and polycarbonate film.
- polyethylene terephthalate film is preferable as the temporary support.
- it is preferable that the film used as the temporary support does not have deformation such as wrinkles, scratches, or the like.
- the temporary support preferably has high transparency in terms of pattern exposure through the temporary support, and the transmittance at 313 nm, 365 nm, 313 nm, 405 nm and 436 nm is preferably 60% or more, and More preferably, 80% or more is even more preferable, and 90% or more is most preferable. Preferred transmittance values include, for example, 87%, 92%, and 98%. From the viewpoint of pattern formability during pattern exposure through the temporary support and transparency of the temporary support, it is preferable that the haze of the temporary support is small. Specifically, the haze value of the temporary support is preferably 2% or less, more preferably 0.5% or less, still more preferably 0.4% or less, and particularly preferably 0.1% or less.
- the haze of the temporary support is not limited to this when the temporary support is peeled off during exposure, which will be described later. Further, the haze of the temporary support is preferably 0.05% or more, more preferably 0.1% or more, from the viewpoint of transportability during production of the temporary support.
- the above haze is a total light haze (%) conforming to JIS K 7136:2000, and can be measured as a total light haze using a haze meter (device name: HZ-2, manufactured by Suga Test Instruments Co., Ltd.). .
- haze is measured by measuring the temporary support after the above treatment.
- the number of fine particles, foreign substances and defects contained in the temporary support is small.
- the number of fine particles having a diameter of 1 ⁇ m or more, foreign matter, and defects in the temporary support is preferably 50/10 mm 2 or less, more preferably 10/10 mm 2 or less, further preferably 3/10 mm 2 or less, and 0 pcs/10 mm 2 is particularly preferred.
- the thickness of the temporary support is not particularly limited, it is preferably 5 to 300 ⁇ m, more preferably 5 to 150 ⁇ m, even more preferably 5 to 50 ⁇ m, most preferably 5 to 25 ⁇ m from the viewpoint of ease of handling and versatility.
- the thickness of the temporary support is calculated as an average value of arbitrary five points measured by cross-sectional observation with a SEM (Scanning Electron Microscope).
- the side of the temporary support that contacts the composition layer may be surface-modified by UV irradiation, corona discharge, plasma, or the like.
- the exposure dose is preferably 10-2000 mJ/cm 2 , more preferably 50-1000 mJ/cm 2 .
- Light sources for UV irradiation include low-pressure mercury lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, carbon arc lamps, metal halide lamps, xenon lamps, chemical lamps, electrodeless discharge lamps, and, A light emitting diode (LED) etc. can be mentioned.
- the temporary support may be subjected to an undercoating treatment to form an undercoat layer containing polyvinylidene chloride resin, styrene-butadiene rubber, gelatin, or the like, from the viewpoint of adhesion to the composition layer or the like.
- Examples of the temporary support include a biaxially stretched polyethylene terephthalate film with a thickness of 16 ⁇ m, a biaxially stretched polyethylene terephthalate film with a thickness of 12 ⁇ m, and a biaxially stretched polyethylene terephthalate film with a thickness of 9 ⁇ m.
- Preferred forms of the temporary support include, for example, paragraphs [0017] to [0018] of JP-A-2014-085643, paragraphs [0019] to [0026] of JP-A-2016-027363, International Publication No. 2012/ No. 081680, paragraphs [0041] to [0057], and WO 2018/179370, paragraphs [0029] to [0040], the contents of these publications are incorporated herein.
- a layer containing fine particles may be provided on the surface of the temporary support in order to impart handleability.
- the lubricant layer may be provided on one side or both sides of the temporary support.
- the diameter of the particles contained in the lubricant layer is preferably 0.05 to 0.8 ⁇ m.
- the film thickness of the lubricant layer is preferably 0.05 to 1.0 ⁇ m.
- Commercially available temporary supports include Lumirror 16KS40, Lumirror 16FB40 (manufactured by Toray Industries, Inc.), Cosmoshine A4100, Cosmoshine A4160, Cosmoshine A4300, and Cosmoshine A8300 (manufactured by Toyobo Co., Ltd.). can.
- the transfer film has a photosensitive composition layer.
- a pattern can be formed on the transfer material by performing exposure and development after transferring the photosensitive composition layer onto the transfer material.
- a negative type is preferable as the photosensitive composition layer.
- the negative photosensitive composition layer is a photosensitive composition layer in which the exposed portion becomes less soluble in a developer upon exposure. When the photosensitive composition layer is a negative photosensitive composition layer, the formed pattern corresponds to the cured layer.
- the photosensitive composition layer may contain a binder polymer.
- binder polymers include (meth)acrylic resins, styrene resins, epoxy resins, amide resins, amidoepoxy resins, alkyd resins, phenolic resins, ester resins, urethane resins, epoxy resins and (meth)acrylic acid. Epoxy acrylate resin obtained and acid-modified epoxy acrylate resin obtained by reaction of epoxy acrylate resin and acid anhydride are mentioned.
- the binder polymer is a (meth)acrylic resin because of its excellent alkali developability and film formability.
- the (meth)acrylic resin means a resin having a structural unit derived from a (meth)acrylic compound.
- the content of structural units derived from the (meth)acrylic compound is preferably 50% by mass or more, more preferably 70% by mass or more, and still more preferably 90% by mass or more, based on all the structural units of the (meth)acrylic resin.
- the (meth)acrylic resin may be composed only of structural units derived from the (meth)acrylic compound, or may have structural units derived from polymerizable monomers other than the (meth)acrylic compound. . That is, the upper limit of the content of structural units derived from the (meth)acrylic compound is 100% by mass or less with respect to all structural units of the (meth)acrylic resin.
- (Meth)acrylic compounds include, for example, (meth)acrylic acid, (meth)acrylic acid esters, (meth)acrylamides, and (meth)acrylonitrile.
- (meth)acrylic acid esters include (meth)acrylic acid alkyl ester, (meth)acrylic acid tetrahydrofurfuryl ester, (meth)acrylic acid dimethylaminoethyl ester, (meth)acrylic acid diethylaminoethyl ester, (meth) ) glycidyl acrylate, benzyl (meth)acrylate, 2,2,2-trifluoroethyl (meth)acrylate, and 2,2,3,3-tetrafluoropropyl (meth)acrylate, ( Meth)acrylic acid alkyl esters are preferred.
- (Meth)acrylamides include, for example, acrylamides such as diacetone acrylamide.
- the alkyl group of the (meth)acrylic acid alkyl ester may be linear or branched. Specific examples include methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, pentyl (meth)acrylate, hexyl (meth)acrylate, ( meth)heptyl acrylate, octyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, nonyl (meth)acrylate, decyl (meth)acrylate, undecyl (meth)acrylate, and (meth)acrylic acid Examples thereof include (meth)acrylic acid alkyl esters having an alkyl group having 1 to 12 carbon atoms such as dodecyl.
- an alkyl (meth)acrylic acid ester having an alkyl group having 1 to 4 carbon atoms is preferable, and methyl (meth)acrylate or ethyl (meth)acrylate is more preferable.
- the (meth)acrylic resin may have a structural unit other than the structural unit derived from the (meth)acrylic compound.
- the polymerizable monomer forming the structural unit is not particularly limited as long as it is a compound other than the (meth)acrylic compound copolymerizable with the (meth)acrylic compound.
- Examples include styrene, vinyl toluene, and ⁇ - Styrene compounds optionally having a substituent at the ⁇ -position or aromatic ring such as methylstyrene, vinyl alcohol esters such as acrylonitrile and vinyl-n-butyl ether, maleic acid, maleic anhydride, monomethyl maleate, maleic acid Maleic acid monoesters such as monoethyl and monoisopropyl maleate, fumaric acid, cinnamic acid, ⁇ -cyanocinnamic acid, itaconic acid, and crotonic acid. These polymerizable monomers may be used singly or in combination of two or more.
- the (meth)acrylic resin preferably has a constitutional unit having an acid group from the viewpoint of improving alkali developability.
- Acid groups include, for example, carboxy groups, sulfo groups, phosphoric acid groups, and phosphonic acid groups.
- the (meth)acrylic resin more preferably has a structural unit having a carboxy group, and more preferably has a structural unit derived from the above (meth)acrylic acid.
- the content of the structural unit having an acid group (preferably a structural unit derived from (meth)acrylic acid) in the (meth)acrylic resin is excellent in developability, relative to the total mass of the (meth)acrylic resin, 10 mass % or more is preferable.
- the upper limit is not particularly limited, it is preferably 50% by mass or less, more preferably 40% by mass or less, from the viewpoint of excellent alkali resistance.
- the (meth)acrylic resin more preferably has structural units derived from the (meth)acrylic acid alkyl ester described above.
- the content of structural units derived from (meth)acrylic acid alkyl ester in the (meth)acrylic resin is 1 to 90% by mass is preferable, 1 to 50% by mass is more preferable, and 1 to 30% by mass is even more preferable.
- the (meth)acrylic resin a resin having both a structural unit derived from (meth)acrylic acid and a structural unit derived from a (meth)acrylic acid alkyl ester is preferable, and a structural unit derived from (meth)acrylic acid and A resin composed only of structural units derived from a (meth)acrylic acid alkyl ester is more preferable.
- an acrylic resin having a structural unit derived from methacrylic acid, a structural unit derived from methyl methacrylate, and a structural unit derived from ethyl acrylate is also preferable.
- the (meth)acrylic resin may have at least one selected from the group consisting of a structural unit derived from methacrylic acid and a structural unit derived from a methacrylic acid alkyl ester, from the viewpoint that the effects of the present invention are more excellent.
- it has both a structural unit derived from methacrylic acid and a structural unit derived from a methacrylic acid alkyl ester.
- the total content of the structural units derived from methacrylic acid and the structural units derived from methacrylic acid alkyl esters in the (meth)acrylic resin is 40% by mass or more is preferable, and 60% by mass or more is more preferable.
- the upper limit is not particularly limited, and may be 100% by mass or less, preferably 80% by mass or less.
- the (meth)acrylic resin has at least one selected from the group consisting of structural units derived from methacrylic acid and structural units derived from methacrylic acid alkyl esters, and acrylic acid It is also preferable to have at least one selected from the group consisting of structural units derived from and structural units derived from acrylic acid alkyl esters. From the point of view that the effect of the present invention is more excellent, the total content of the structural units derived from methacrylic acid and the structural units derived from the methacrylic acid alkyl ester is is preferably 60/40 to 80/20 in mass ratio with respect to the total content of
- the (meth)acrylic resin preferably has an ester group at its terminal from the viewpoint of excellent developability of the photosensitive composition layer after transfer.
- the terminal portion of the (meth)acrylic resin is composed of a site derived from the polymerization initiator used in the synthesis.
- a (meth)acrylic resin having an ester group at its terminal can be synthesized by using a polymerization initiator that generates a radical having an ester group.
- the binder polymer is preferably, for example, a binder polymer having an acid value of 60 mgKOH/g or more from the viewpoint of developability.
- the binder polymer is, for example, a resin having a carboxy group with an acid value of 60 mgKOH/g or more (so-called carboxy group-containing resin) because it thermally crosslinks with a cross-linking component by heating and easily forms a strong film. More preferably, it is a (meth)acrylic resin having a carboxyl group with an acid value of 60 mgKOH/g or more (so-called carboxyl group-containing (meth)acrylic resin).
- the binder polymer is a resin having a carboxyl group
- a thermally crosslinkable compound such as a blocked isocyanate compound and thermally crosslinking
- the three-dimensional crosslinking density can be increased.
- the carboxy group of the resin having a carboxy group is dehydrated and made hydrophobic, the wet heat resistance can be improved.
- the carboxy group-containing (meth)acrylic resin having an acid value of 60 mgKOH/g or more is not particularly limited as long as it satisfies the acid value conditions described above, and can be appropriately selected from known (meth)acrylic resins.
- a carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more paragraphs [0033] to [0052] of JP-A-2010-237589
- carboxy group-containing acrylic resins having an acid value of 60 mgKOH/g or more can be preferably used.
- styrene-acrylic copolymer refers to a resin having a structural unit derived from a styrene compound and a structural unit derived from a (meth)acrylic compound, and a structural unit derived from the styrene compound.
- the total content of structural units derived from the (meth)acrylic compound is preferably 30% by mass or more, more preferably 50% by mass or more, based on all the structural units of the copolymer.
- the content of structural units derived from a styrene compound is preferably 1% by mass or more, more preferably 5% by mass or more, and still more preferably 5 to 80% by mass, based on all the structural units of the copolymer. Further, the content of the structural unit derived from the (meth)acrylic compound is preferably 5% by mass or more, more preferably 10% by mass or more, and 20 to 95% by mass, based on the total structural units of the copolymer. is more preferred.
- the binder polymer preferably has an aromatic ring structure, and more preferably has a structural unit having an aromatic ring structure, from the viewpoint that the effects of the present invention are more excellent.
- Monomers that form structural units having an aromatic ring structure include monomers having an aralkyl group, styrene, and polymerizable styrene derivatives (e.g., methylstyrene, vinyltoluene, tert-butoxystyrene, acetoxystyrene, 4-vinylbenzoic acid , styrene dimers, and styrene trimers).
- a monomer having an aralkyl group or styrene is preferred.
- the aralkyl group includes a substituted or unsubstituted phenylalkyl group (excluding a benzyl group), a substituted or unsubstituted benzyl group, and the like, and a substituted or unsubstituted benzyl group is preferred.
- Examples of monomers having a phenylalkyl group include phenylethyl (meth)acrylate.
- Examples of monomers having a benzyl group include (meth)acrylates having a benzyl group, such as benzyl (meth)acrylate and chlorobenzyl (meth)acrylate; vinyl monomers having a benzyl group, such as vinylbenzyl chloride, and vinyl benzyl alcohol and the like. Among them, benzyl (meth)acrylate is preferred.
- the binder polymer more preferably has a structural unit (a structural unit derived from styrene) represented by the following formula (S), from the viewpoint that the effect of the present invention is more excellent.
- the content of the structural unit having an aromatic ring structure is 5 to 90 mass with respect to all structural units of the binder polymer, from the viewpoint that the effects of the present invention are more excellent. %, more preferably 10 to 70% by mass, more preferably 20 to 60% by mass. Further, the content of structural units having an aromatic ring structure in the binder polymer is preferably 5 to 70 mol%, preferably 10 to 60 mol%, based on the total structural units of the binder polymer, from the viewpoint that the effects of the present invention are more excellent. is more preferred, and 20 to 60 mol % is even more preferred.
- the content of the structural unit represented by the above formula (S) in the binder polymer is preferably 5 to 70 mol%, based on the total structural units of the binder polymer, from the viewpoint that the effect of the present invention is more excellent, and 10 ⁇ 60 mol% is more preferred, 20 to 60 mol% is even more preferred, and 20 to 50 mol% is particularly preferred.
- the above-mentioned "structural unit” shall be synonymous with the "monomer unit”.
- the above-mentioned "monomer unit” may be modified after polymerization by a polymer reaction or the like. The same applies to the following.
- the binder polymer preferably has an aliphatic hydrocarbon ring structure from the viewpoint that the effects of the present invention are more excellent. That is, the binder polymer preferably has structural units having an aliphatic hydrocarbon ring structure.
- the aliphatic hydrocarbon ring structure may be monocyclic or polycyclic.
- the binder polymer more preferably has a ring structure in which two or more aliphatic hydrocarbon rings are condensed.
- rings constituting the aliphatic hydrocarbon ring structure in the constituent unit having the aliphatic hydrocarbon ring structure include tricyclodecane ring, cyclohexane ring, cyclopentane ring, norbornane ring, and isoboron ring. Among them, a ring obtained by condensing two or more aliphatic hydrocarbon rings is preferable, and a tetrahydrodicyclopentadiene ring (tricyclo[5.2.1.0 2,6 ]decane ring) is more preferred.
- Monomers that form structural units having an aliphatic hydrocarbon ring structure include dicyclopentanyl (meth)acrylate, cyclohexyl (meth)acrylate, and isobornyl (meth)acrylate.
- the binder polymer more preferably has a structural unit represented by the following formula (Cy) from the viewpoint of more excellent effects of the present invention. It is more preferable to have a structural unit represented by (Cy).
- RM represents a hydrogen atom or a methyl group
- R Cy represents a monovalent group having an aliphatic hydrocarbon ring structure
- RM in formula (Cy) is preferably a methyl group.
- R Cy in the formula (Cy) is preferably a monovalent group having an aliphatic hydrocarbon ring structure with 5 to 20 carbon atoms from the viewpoint of better effects of the present invention, and an aliphatic A monovalent group having an aliphatic hydrocarbon ring structure is more preferred, and a monovalent group having an aliphatic hydrocarbon ring structure having 8 to 14 carbon atoms is even more preferred.
- the aliphatic hydrocarbon ring structure in R Cy of formula (Cy) is a cyclopentane ring structure, a cyclohexane ring structure, a tetrahydrodicyclopentadiene ring structure, a norbornane ring structure, or An isoboron ring structure is preferred, a cyclohexane ring structure or a tetrahydrodicyclopentadiene ring structure is more preferred, and a tetrahydrodicyclopentadiene ring structure is even more preferred.
- the aliphatic hydrocarbon ring structure in R Cy of formula (Cy) is preferably a ring structure in which two or more aliphatic hydrocarbon rings are condensed, from the viewpoint that the effects of the present invention are more excellent. More preferably, it is a condensed ring of 1 to 4 aliphatic hydrocarbon rings.
- the binder polymer may have one type of structural unit having an aliphatic hydrocarbon ring structure, or may have two or more types.
- the content of the structural unit having an aliphatic hydrocarbon ring structure is based on all the structural units of the binder polymer from the viewpoint that the effects of the present invention are more excellent. 5 to 90% by mass is preferable, 10 to 80% by mass is more preferable, and 20 to 70% by mass is even more preferable.
- the content of the structural unit having an aliphatic hydrocarbon ring structure in the binder polymer is preferably 5 to 70 mol%, based on the total structural units of the binder polymer, from the viewpoint that the effect of the present invention is more excellent, and 10 to 60 mol % is more preferred, and 20 to 50 mol % is even more preferred.
- the content of the structural unit represented by the above formula (Cy) in the binder polymer is preferably 5 to 70 mol% with respect to the total structural units of the binder polymer, from the viewpoint that the effect of the present invention is more excellent, and 10 ⁇ 60 mol% is more preferred, and 20 to 50 mol% is even more preferred.
- the total content of structural units having an aromatic ring structure and structural units having an aliphatic hydrocarbon ring structure is from the viewpoint that the effects of the invention are more excellent, it is preferably 10 to 90% by mass, more preferably 20 to 80% by mass, and even more preferably 40 to 75% by mass, based on the total structural units of the binder polymer.
- the total content of structural units having an aromatic ring structure and structural units having an aliphatic hydrocarbon ring structure in the binder polymer is 10 with respect to all structural units of the binder polymer, from the viewpoint that the effects of the present invention are more excellent.
- the total content of the structural units represented by the formula (S) and the structural units represented by the formula (Cy) in the binder polymer is the total structural units of the binder polymer from the viewpoint that the effects of the present invention are more excellent. is preferably 10 to 80 mol%, more preferably 20 to 70 mol%, and even more preferably 40 to 60 mol%.
- the molar amount nS of the structural unit represented by the formula (S) and the molar amount nCy of the structural unit represented by the formula (Cy) in the binder polymer are determined by the following formula from the viewpoint that the effect of the present invention is more excellent.
- the binder polymer preferably has a constitutional unit having an acid group from the viewpoint that the effects of the present invention are more excellent.
- the acid group include a carboxy group, a sulfo group, a phosphonic acid group, and a phosphoric acid group, with the carboxy group being preferred.
- the structural unit having an acid group a structural unit derived from (meth)acrylic acid shown below is preferable, and a structural unit derived from methacrylic acid is more preferable.
- the binder polymer may have one type of structural unit having an acid group, or may have two or more types.
- the content of the structural unit having an acid group is 5 to 50% by mass based on the total structural units of the binder polymer from the viewpoint that the effects of the present invention are more excellent.
- the content of the structural unit having an acid group in the binder polymer is preferably 5 to 70 mol%, more preferably 10 to 50 mol%, based on the total structural units of the binder polymer, from the viewpoint that the effects of the present invention are more excellent. More preferably, 20 to 40 mol % is even more preferable.
- the content of structural units derived from (meth)acrylic acid in the binder polymer is preferably 5 to 70 mol%, preferably 10 to 50, based on the total structural units of the binder polymer, from the viewpoint that the effects of the present invention are more excellent.
- mol % is more preferred, and 20 to 40 mol % is even more preferred.
- the binder polymer preferably has a reactive group, and more preferably has a structural unit having a reactive group, from the viewpoint that the effects of the present invention are more excellent.
- the reactive group is preferably a radically polymerizable group, more preferably an ethylenically unsaturated group.
- the binder polymer preferably has a structural unit having an ethylenically unsaturated group in its side chain.
- the term "main chain” refers to the relatively longest bond chain in the molecule of the polymer compound that constitutes the resin
- side chain refers to an atomic group branched from the main chain. show.
- the ethylenically unsaturated group is more preferably an allyl group or a (meth)acryloxy group. Examples of structural units having a reactive group include, but are not limited to, those shown below.
- the binder polymer may have one type of structural unit having a reactive group, or may have two or more types.
- the content of the structural unit having a reactive group is 5 to 70 mass with respect to all structural units of the binder polymer, from the viewpoint that the effect of the present invention is more excellent. %, more preferably 10 to 50% by mass, even more preferably 20 to 40% by mass.
- the content of the structural unit having a reactive group in the binder polymer is preferably 5 to 70 mol%, preferably 10 to 60 mol%, based on the total structural units of the binder polymer, from the viewpoint that the effect of the present invention is more excellent. is more preferred, and 20 to 50 mol % is even more preferred.
- a reactive group into the binder polymer functional groups such as a hydroxyl group, a carboxyl group, a primary amino group, a secondary amino group, an acetoacetyl group, and a sulfo group may be added to epoxy compounds and blocked isocyanate.
- functional groups such as a hydroxyl group, a carboxyl group, a primary amino group, a secondary amino group, an acetoacetyl group, and a sulfo group may be added to epoxy compounds and blocked isocyanate.
- compounds, isocyanate compounds, vinylsulfone compounds, aldehyde compounds, methylol compounds, and carboxylic acid anhydrides may be added to epoxy compounds and blocked isocyanate.
- glycidyl (meth)acrylate is added to a part of the carboxy group of the resulting polymer by polymer reaction. to introduce a (meth)acryloxy group into the polymer.
- a binder polymer having (meth)acryloxy groups in side chains can be obtained.
- the polymerization reaction is preferably carried out under temperature conditions of 70 to 100°C, more preferably under temperature conditions of 80 to 90°C.
- an azo initiator is preferable, and for example, V-601 (trade name) or V-65 (trade name) manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd. is more preferable.
- the polymer reaction is preferably carried out under temperature conditions of 80 to 110°C. In the polymer reaction, it is preferable to use a catalyst such as an ammonium salt.
- the binder polymer the following polymers are preferable because the effects of the present invention are more excellent.
- the content ratio (a to d) of each structural unit shown below, the weight average molecular weight Mw, and the like can be appropriately changed depending on the purpose.
- a 1.0 to 20 wt%, b: 20 to 60 wt%, c: 5.0 to 25 wt%, and d: 10 to 50 wt% are preferred.
- the binder polymer may contain a polymer having a structural unit having a carboxylic anhydride structure (hereinafter also referred to as "polymer X").
- the carboxylic anhydride structure may be either a linear carboxylic anhydride structure or a cyclic carboxylic anhydride structure, but is preferably a cyclic carboxylic anhydride structure.
- the ring of the cyclic carboxylic anhydride structure is preferably a 5- to 7-membered ring, more preferably a 5- or 6-membered ring, and even more preferably a 5-membered ring.
- a structural unit having a carboxylic anhydride structure is a structural unit containing in the main chain a divalent group obtained by removing two hydrogen atoms from a compound represented by the following formula P-1, or a structural unit represented by the following formula P-1 It is preferably a structural unit in which a monovalent group obtained by removing one hydrogen atom from the represented compound is bonded to the main chain directly or via a divalent linking group.
- R A1a represents a substituent
- n 1a R A1a may be the same or different
- Examples of the substituent represented by RA1a include an alkyl group.
- Z 1a is preferably an alkylene group having 2 to 4 carbon atoms, more preferably an alkylene group having 2 or 3 carbon atoms, and still more preferably an alkylene group having 2 carbon atoms.
- n1a represents an integer of 0 or more.
- Z 1a represents an alkylene group having 2 to 4 carbon atoms
- n 1a is preferably an integer of 0 to 4, more preferably an integer of 0 to 2, even more preferably 0.
- multiple R A1a may be the same or different.
- two or more RA1a groups may combine with each other to form a ring, but preferably do not combine with each other to form a ring.
- the structural unit having a carboxylic anhydride structure is preferably a structural unit derived from an unsaturated carboxylic anhydride, more preferably a structural unit derived from an unsaturated cyclic carboxylic anhydride, and an unsaturated aliphatic cyclic carboxylic acid anhydride.
- Structural units derived from acid anhydride are more preferred, structural units derived from maleic anhydride or itaconic anhydride are particularly preferred, and structural units derived from maleic anhydride are most preferred.
- Rx represents a hydrogen atom, a methyl group, a CH2OH group, or a CF3 group
- Me represents a methyl group
- the structural unit having a carboxylic anhydride structure in the polymer X may be of one type alone, or may be of two or more types.
- the total content of structural units having a carboxylic anhydride structure is preferably 0 to 60 mol%, more preferably 5 to 40 mol%, more preferably 10 to 35 mol%, relative to the total structural units of the polymer X. preferable.
- the photosensitive composition layer may contain only one type of polymer X, or may contain two or more types.
- the content of the polymer X is 0.1 to 30% by mass with respect to the total mass of the photosensitive composition layer, from the viewpoint that the effects of the present invention are more excellent.
- 0.2 to 20% by mass is more preferable, 0.5 to 20% by mass is still more preferable, and 1 to 20% by mass is even more preferable.
- the weight average molecular weight (Mw) of the binder polymer is preferably 5,000 or more, more preferably 10,000 or more, still more preferably 10,000 to 50,000, and 15,000, from the viewpoint of more excellent effects of the present invention. ⁇ 30,000 is particularly preferred.
- the acid value of the binder polymer is preferably 10-200 mgKOH/g, more preferably 60-200 mgKOH/g, still more preferably 60-150 mgKOH/g, and particularly preferably 70-130 mgKOH/g.
- the acid value of the binder polymer is a value measured according to the method described in JIS K0070:1992. From the viewpoint of developability, the degree of dispersion of the binder polymer is preferably 1.0 to 6.0, more preferably 1.0 to 5.0, still more preferably 1.0 to 4.0, and 1.0 to 3.0. 0.0 is particularly preferred.
- the photosensitive composition layer may contain only one type of binder polymer, or may contain two or more types.
- the content of the binder polymer is preferably 10 to 90% by mass, more preferably 20 to 80% by mass, more preferably 30 to 70% by mass, based on the total mass of the photosensitive composition layer, from the viewpoint that the effect of the present invention is more excellent. is more preferred.
- the photosensitive composition layer may contain a polymerizable compound.
- a polymerizable compound is a compound having a polymerizable group. Examples of the polymerizable group include radically polymerizable groups and cationic polymerizable groups, with radically polymerizable groups being preferred.
- the polymerizable compound preferably contains a radically polymerizable compound having an ethylenically unsaturated group (hereinafter also simply referred to as "ethylenically unsaturated compound").
- a (meth)acryloxy group is preferred as the ethylenically unsaturated group.
- the ethylenically unsaturated compound in the present specification is a compound other than the above binder polymer, and preferably has a molecular weight of less than 5,000.
- One preferred embodiment of the polymerizable compound is a compound represented by the following formula (M) (also simply referred to as "compound M”).
- Q 2 -R 1 -Q 1 Formula (M) Q 1 and Q 2 each independently represent a (meth)acryloyloxy group, and R 1 represents a divalent linking group having a chain structure.
- Q 1 and Q 2 in formula ( M ) are preferably the same group from the viewpoint of ease of synthesis.
- Q 1 and Q 2 in formula (M) are preferably acryloyloxy groups from the viewpoint of reactivity.
- R 1 in formula (M) is an alkylene group, an alkyleneoxyalkylene group (-L 1 -OL 1 -), or a polyalkyleneoxyalkylene group (-(L 1 -O) p -L 1 -) is preferred, a hydrocarbon group having 2 to 20 carbon atoms or a polyalkyleneoxyalkylene group is more preferred, an alkylene group having 4 to 20 carbon atoms is even more preferred, and 6 to 6 carbon atoms. 18 straight-chain alkylene groups are particularly preferred.
- the hydrocarbon group may at least partially have a chain structure, and the portion other than the chain structure is not particularly limited. 5 linear alkylene group, arylene group, ether bond, and combinations thereof, preferably an alkylene group or a group in which two or more alkylene groups and one or more arylene groups are combined. , an alkylene group is more preferred, and a linear alkylene group is even more preferred.
- Each L 1 above independently represents an alkylene group, preferably an ethylene group, a propylene group or a butylene group, more preferably an ethylene group or a 1,2-propylene group.
- p represents an integer of 2 or more, preferably an integer of 2-10.
- the number of atoms in the shortest linking chain linking Q 1 and Q 2 in compound M is preferably 3 to 50, more preferably 4 to 40, from the viewpoint of more excellent effects of the present invention. 6 to 20 are more preferred, and 8 to 12 are particularly preferred.
- the number of atoms in the shortest linking chain linking Q1 and Q2 refers to the number of atoms in R1 linking Q1 to the atom in R1 linking Q2 . It is the shortest number of atoms.
- compound M examples include 1,3-butanediol di(meth)acrylate, tetramethylene glycol di(meth)acrylate, neopentyl glycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,7-heptanediol di(meth)acrylate, 1,8-octanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, 1,10-decanediol di(meth)acrylate, hydrogenation Bisphenol A di(meth)acrylate, hydrogenated bisphenol F di(meth)acrylate, polyethylene glycol di(meth)acrylate, polypropylene glycol di(meth)acrylate, poly(ethylene glycol/propylene glycol) di(meth)acrylate , and polybutylene glycol di(meth)acrylate.
- ester monomers can also be used as mixtures.
- 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, and 1,10-decanediol di(meth)acrylate are preferred because the effects of the present invention are more excellent.
- a bifunctional or higher ethylenically unsaturated compound can be mentioned.
- the term "bifunctional or higher ethylenically unsaturated compound” means a compound having two or more ethylenically unsaturated groups in one molecule.
- a (meth)acryloyl group is preferred as the ethylenically unsaturated group in the ethylenically unsaturated compound.
- a (meth)acrylate compound is preferable as the ethylenically unsaturated compound.
- the bifunctional ethylenically unsaturated compound is not particularly limited and can be appropriately selected from known compounds.
- Examples of bifunctional ethylenically unsaturated compounds other than the compound M include tricyclodecanedimethanol di(meth)acrylate, dioxane glycol di(meth)acrylate, and 1,4-cyclohexanediol di(meth)acrylate. be done.
- bifunctional ethylenically unsaturated compounds include tricyclodecanedimethanol diacrylate (trade name: NK Ester A-DCP, manufactured by Shin-Nakamura Chemical Co., Ltd.), tricyclodecanedimenanol dimethacrylate ( Product name: NK Ester DCP, manufactured by Shin-Nakamura Chemical Co., Ltd.), 1,9-nonanediol diacrylate (product name: NK Ester A-NOD-N, manufactured by Shin-Nakamura Chemical Co., Ltd.), 1,6 -Hexanediol diacrylate (trade name: NK Ester A-HD-N, manufactured by Shin-Nakamura Chemical Co., Ltd.) and dioxane glycol diacrylate (KAYARAD R-604 manufactured by Nippon Kayaku Co., Ltd.).
- the trifunctional or higher ethylenically unsaturated compound is not particularly limited and can be appropriately selected from known compounds.
- Examples of tri- or higher ethylenically unsaturated compounds include dipentaerythritol (tri/tetra/penta/hexa) (meth)acrylate, pentaerythritol (tri/tetra) (meth)acrylate, trimethylolpropane tri(meth)acrylate, Ditrimethylolpropane tetra(meth)acrylate, isocyanuric acid (meth)acrylate, and (meth)acrylate compounds having a glycerin tri(meth)acrylate skeleton can be mentioned.
- (tri/tetra/penta/hexa) (meth)acrylate is a concept that includes tri(meth)acrylate, tetra(meth)acrylate, penta(meth)acrylate, and hexa(meth)acrylate.
- (tri/tetra)(meth)acrylate” is a concept that includes tri(meth)acrylate and tetra(meth)acrylate.
- Examples of the polymerizable compound include caprolactone-modified (meth)acrylate compounds (KAYARAD (registered trademark) DPCA-20 manufactured by Nippon Kayaku Co., Ltd., A-9300-1CL manufactured by Shin-Nakamura Chemical Co., Ltd., etc.), (meth) ) Alkylene oxide modified compounds of acrylate compounds (KAYARAD (registered trademark) RP-1040 manufactured by Nippon Kayaku Co., Ltd., ATM-35E, A-9300 manufactured by Shin-Nakamura Chemical Co., Ltd., EBECRYL (registered trademark) manufactured by Daicel Allnex Co., Ltd. ) 135, etc.), and ethoxylated glycerin triacrylate (NK Ester A-GLY-9E, etc. manufactured by Shin-Nakamura Chemical Co., Ltd.).
- KAYARAD registered trademark
- DPCA-20 Alkylene oxide modified compounds of acrylate compounds
- ATM-35E A-9300 manufactured by Shin-Naka
- the polymerizable compound also includes urethane (meth)acrylate compounds.
- Urethane (meth)acrylates include urethane di(meth)acrylates, such as propylene oxide-modified urethane di(meth)acrylates, and ethylene oxide and propylene oxide-modified urethane di(meth)acrylates.
- Urethane (meth)acrylates also include trifunctional or higher urethane (meth)acrylates.
- the lower limit of the number of functional groups is more preferably 6 or more, and still more preferably 8 or more.
- the upper limit of the number of functional groups is preferably 20 or less.
- Trifunctional or higher urethane (meth)acrylates include, for example, 8UX-015A (manufactured by Taisei Fine Chemical Co., Ltd.), UA-32P (manufactured by Shin-Nakamura Chemical Co., Ltd.), U-15HA (manufactured by Shin-Nakamura Chemical Co., Ltd. ), UA-1100H (manufactured by Shin-Nakamura Chemical Co., Ltd.), AH-600 (trade name) manufactured by Kyoeisha Chemical Co., Ltd., and UA-306H, UA-306T, UA-306I, UA-510H , and UX-5000 (both manufactured by Nippon Kayaku Co., Ltd.).
- One preferred embodiment of the polymerizable compound is an ethylenically unsaturated compound having an acid group.
- Acid groups include phosphate groups, sulfo groups, and carboxy groups. Among these, a carboxy group is preferable as the acid group.
- Examples of the ethylenically unsaturated compound having an acid group include tri- to tetra-functional ethylenically unsaturated compounds having an acid group [pentaerythritol tri- and tetraacrylate (PETA) having a carboxyl group introduced into its skeleton (acid value: 80- 120 mg KOH/g)], 5- to 6-functional ethylenically unsaturated compounds having acid groups (dipentaerythritol penta and hexaacrylate (DPHA) skeletons with carboxy groups introduced [acid value: 25-70 mg KOH/g)] etc. If necessary, these trifunctional or higher ethylenically unsaturated compounds having an acid group may be used in combination with a difunctional ethylenically unsaturated compound having an acid group.
- PETA penentaerythritol tri- and tetraacrylate
- DPHA dipentaerythritol penta and hex
- the ethylenically unsaturated compound having an acid group at least one selected from the group consisting of bifunctional or higher ethylenically unsaturated compounds having a carboxy group and carboxylic acid anhydrides thereof is preferable.
- the ethylenically unsaturated compound having an acid group is at least one selected from the group consisting of a bifunctional or higher ethylenically unsaturated compound having a carboxyl group and its carboxylic acid anhydride, the developability and film strength are improved. increase.
- the bifunctional or higher ethylenically unsaturated compound having a carboxy group is not particularly limited and can be appropriately selected from known compounds.
- Examples of bifunctional or higher ethylenically unsaturated compounds having a carboxy group include Aronix (registered trademark) TO-2349 (manufactured by Toagosei Co., Ltd.), Aronix (registered trademark) M-520 (manufactured by Toagosei Co., Ltd.), Aronix (registered trademark) M-510 (manufactured by Toagosei Co., Ltd.) can be mentioned.
- the ethylenically unsaturated compound having an acid group is preferably a polymerizable compound having an acid group described in paragraphs [0025] to [0030] of JP-A-2004-239942. incorporated into the specification.
- the polymerizable compound for example, a compound obtained by reacting a polyhydric alcohol with an ⁇ , ⁇ -unsaturated carboxylic acid, a compound obtained by reacting a glycidyl group-containing compound with an ⁇ , ⁇ -unsaturated carboxylic acid, urethane Urethane monomers such as (meth)acrylate compounds having bonds, ⁇ -chloro- ⁇ -hydroxypropyl- ⁇ '-(meth)acryloyloxyethyl-o-phthalate, ⁇ -hydroxyethyl- ⁇ '-(meth)acryloyloxyethyl Phthalic acid compounds such as -o-phthalate and ⁇ -hydroxypropyl- ⁇ '-(meth)acryloyloxyethyl-o-phthalate, and (meth)acrylic acid alkyl esters are also included. These are used alone or in combination of two or more.
- Compounds obtained by reacting a polyhydric alcohol with an ⁇ , ⁇ -unsaturated carboxylic acid include, for example, 2,2-bis(4-((meth)acryloxypolyethoxy)phenyl)propane, 2,2-bis Bisphenol A-based (meth)acrylate compounds such as (4-((meth)acryloxypolypropoxy)phenyl)propane and 2,2-bis(4-((meth)acryloxypolyethoxypolypropoxy)phenyl)propane , polyethylene glycol di(meth)acrylate having 2 to 14 ethylene oxide groups, polypropylene glycol di(meth)acrylate having 2 to 14 propylene oxide groups, and 2 to 14 ethylene oxide groups.
- 2,2-bis(4-((meth)acryloxypolyethoxy)phenyl)propane 2,2-bis Bisphenol A-based (meth)acrylate compounds such as (4-((meth)acryloxypolypropoxy)phenyl)propane and 2,2-bis(
- an ethylenically unsaturated compound having a tetramethylolmethane structure or a trimethylolpropane structure is preferable, such as tetramethylolmethane tri(meth)acrylate, tetramethylolmethane tetra(meth)acrylate, trimethylolpropane tri(meth)acrylate, or Di(trimethylolpropane)tetraacrylate is more preferred.
- Examples of the polymerizable compound include caprolactone-modified compounds of ethylenically unsaturated compounds (e.g., KAYARAD (registered trademark) DPCA-20 manufactured by Nippon Kayaku Co., Ltd., A-9300-1CL manufactured by Shin-Nakamura Chemical Co., Ltd., etc.), Alkylene oxide modified compounds of ethylenically unsaturated compounds (for example, KAYARAD RP-1040 manufactured by Nippon Kayaku Co., Ltd., ATM-35E, A-9300 manufactured by Shin-Nakamura Chemical Co., Ltd., EBECRYL (registered trademark) manufactured by Daicel Allnex Co., Ltd. ) 135, etc.), ethoxylated glycerin triacrylate (A-GLY-9E, etc., manufactured by Shin-Nakamura Chemical Co., Ltd.), and the like.
- KAYARAD registered trademark
- DPCA-20 Alkylene oxide modified compounds of ethylenically
- a compound containing an ester bond is also preferable from the viewpoint of excellent developability of the photosensitive composition layer after transfer.
- the ethylenically unsaturated compound containing an ester bond is not particularly limited as long as it contains an ester bond in the molecule. Saturated compounds are preferred, and tetramethylolmethane tri(meth)acrylate, tetramethylolmethane tetra(meth)acrylate, trimethylolpropane tri(meth)acrylate, or di(trimethylolpropane)tetraacrylate are more preferred.
- the ethylenically unsaturated compounds include an ethylenically unsaturated compound having an aliphatic group having 6 to 20 carbon atoms, and an ethylenically unsaturated compound having the above tetramethylolmethane structure or trimethylolpropane structure. and preferably a compound.
- Ethylenically unsaturated compounds having an aliphatic structure with 6 or more carbon atoms include 1,9-nonanediol di(meth)acrylate, 1,10-decanediol di(meth)acrylate, and tricyclodecanedimethanol di(meth)acrylate. (Meth)acrylates are mentioned.
- the polymerizable compound is a polymerizable compound having an aliphatic hydrocarbon ring structure (preferably a bifunctional ethylenically unsaturated compound).
- a polymerizable compound having a ring structure in which two or more aliphatic hydrocarbon rings are condensed preferably a structure selected from the group consisting of a tricyclodecane structure and a tricyclodecene structure.
- Bifunctional ethylenically unsaturated compounds having a ring structure in which two or more aliphatic hydrocarbon rings are condensed are preferred, and tricyclodecanedimethanol di(meth)acrylate is even more preferred.
- a cyclopentane structure, a cyclohexane structure, a tricyclodecane structure, a tricyclodecene structure, a norbornane structure, or an isoboron structure is preferable from the viewpoint that the effects of the present invention are more excellent.
- the molecular weight of the polymerizable compound is preferably 200 to 3,000, more preferably 250 to 2,600, still more preferably 280 to 2,200, and particularly preferably 300 to 2,200.
- the content ratio of polymerizable compounds having a molecular weight of 300 or less is 30 mass with respect to the content of all polymerizable compounds contained in the photosensitive composition layer. % or less is preferable, 25 mass % or less is more preferable, and 20 mass % or less is even more preferable.
- the photosensitive composition layer preferably contains a bifunctional or higher ethylenically unsaturated compound, and more preferably contains a trifunctional or higher ethylenically unsaturated compound. , trifunctional or tetrafunctional ethylenically unsaturated compounds are further preferred.
- the photosensitive composition layer has a bifunctional ethylenically unsaturated compound having an aliphatic hydrocarbon ring structure and a structural unit having an aliphatic hydrocarbon ring. It preferably contains a binder polymer.
- the photosensitive composition layer preferably contains a compound represented by formula (M) and an ethylenically unsaturated compound having an acid group. ,9-nonanediol diacrylate, tricyclodecanedimethanol diacrylate, and a polyfunctional ethylenically unsaturated compound having a carboxylic acid group. More preferably, it contains decanedimethanol diacrylate and a succinic acid modified form of dipentaerythritol pentaacrylate.
- the photosensitive composition layer comprises a compound represented by the formula (M), an ethylenically unsaturated compound having an acid group, and a thermally crosslinkable compound described later. It preferably contains a compound represented by formula (M), an ethylenically unsaturated compound having an acid group, and a blocked isocyanate compound described later.
- the photosensitive composition layer is composed of a bifunctional ethylenically unsaturated compound (preferably a bifunctional (meth)acrylate compound) and a trifunctional or higher ethylenically unsaturated compound (preferably a trifunctional or higher (meth)acrylate compound).
- the mass ratio of the content of the difunctional ethylenically unsaturated compound and the content of the trifunctional or higher ethylenically unsaturated compound is preferably 10:90 to 90:10, and 30: 70 to 70:30 is more preferred.
- the content of the bifunctional ethylenically unsaturated compound is preferably 20 to 80% by mass, more preferably 30 to 70% by mass, based on the total amount of all ethylenically unsaturated compounds.
- the bifunctional ethylenically unsaturated compound in the photosensitive composition layer is preferably 10 to 60% by mass, more preferably 15 to 40% by mass.
- the photosensitive composition layer contains the compound M and a bifunctional ethylenically unsaturated compound having an aliphatic hydrocarbon ring structure from the viewpoint of rust prevention. preferably included.
- the photosensitive composition layer contains the compound M and ethylene preferably contains a polyunsaturated compound, compound M, a bifunctional ethylenically unsaturated compound having an aliphatic hydrocarbon ring structure, and more preferably containing an ethylenically unsaturated compound having an acid group, compound M, It further preferably contains a bifunctional ethylenically unsaturated compound having an aliphatic hydrocarbon ring structure, a trifunctional or higher ethylenically unsaturated compound, and an ethylenically unsaturated compound having an acid group, compound M, aliphatic carbonization It particularly preferably contains a bifunctional ethylenically unsaturated compound having a hydrogen
- the photosensitive composition layer has 1, 9 - preferably contains nonanediol diacrylate and a polyfunctional ethylenically unsaturated compound having a carboxylic acid group, 1,9-nonanediol diacrylate, tricyclodecanedimethanol diacrylate, and a carboxylic acid group It preferably contains a polyfunctional ethylenically unsaturated compound, including 1,9-nonanediol diacrylate, tricyclodecanedimethanol diacrylate, dipentaerythritol hexaacrylate, and an ethylenically unsaturated compound having a carboxylic acid group.
- the urethane acrylate compound More preferably, it contains 1,9-nonanediol diacrylate, tricyclodecanedimethanol diacrylate, an ethylenically unsaturated compound having a carboxylic acid group, and a urethane acrylate compound.
- the photosensitive composition layer may contain a monofunctional ethylenically unsaturated compound as the ethylenically unsaturated compound.
- the content of the bifunctional or higher ethylenically unsaturated compound in the ethylenically unsaturated compound is preferably 60 to 100% by mass with respect to the total content of all ethylenically unsaturated compounds contained in the photosensitive composition layer. , more preferably 80 to 100% by mass, and even more preferably 90 to 100% by mass.
- Polymerizable compounds may be used singly or in combination of two or more.
- the content of the polymerizable compound (especially ethylenically unsaturated compound) in the photosensitive composition layer is preferably 1 to 70% by mass, more preferably 5 to 70% by mass, based on the total mass of the photosensitive composition layer. , more preferably 5 to 60% by mass, particularly preferably 5 to 50% by mass.
- the photosensitive composition layer may contain a polymerization initiator.
- a photopolymerization initiator is preferable as the polymerization initiator.
- the photopolymerization initiator is not particularly limited, and known photopolymerization initiators can be used.
- a photopolymerization initiator having an oxime ester structure hereinafter also referred to as an “oxime photopolymerization initiator”
- a photopolymerization initiator having an ⁇ -aminoalkylphenone structure hereinafter, “ ⁇ - Also referred to as "aminoalkylphenone-based photopolymerization initiator”.
- a photopolymerization initiator having an ⁇ -hydroxyalkylphenone structure hereinafter also referred to as an " ⁇ -hydroxyalkylphenone-based polymerization initiator”
- an acylphosphine oxide structure A photopolymerization initiator having Also referred to as "agent”.
- the photopolymerization initiator is selected from the group consisting of oxime-based photopolymerization initiators, ⁇ -aminoalkylphenone-based photopolymerization initiators, ⁇ -hydroxyalkylphenone-based polymerization initiators, and N-phenylglycine-based photopolymerization initiators. It preferably contains at least one selected from the group consisting of oxime-based photopolymerization initiators, ⁇ -aminoalkylphenone-based photopolymerization initiators, and N-phenylglycine-based photopolymerization initiators. is more preferable.
- photopolymerization initiator for example, paragraphs [0031] to [0042] of JP-A-2011-95716, and paragraphs [0064] to [0081] of JP-A-2015-014783 A polymerization initiator may be used.
- photopolymerization initiators include 1-[4-(phenylthio)phenyl]-1,2-octanedione-2-(O-benzoyloxime) [trade name: IRGACURE (registered trademark) OXE-01, BASF company], 1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazol-3-yl]ethanone-1-(O-acetyloxime) [trade name: IRGACURE (registered trademark) OXE-02 , manufactured by BASF], IRGACURE (registered trademark) OXE03 (manufactured by BASF), IRGACURE (registered trademark) OXE04 (manufactured by BASF), 2-(dimethylamino)-2-[(4-methylphenyl)methyl]-1 -[4-(4-morpholinyl)phenyl]-1-butanone [trade name: Omnirad (registered trademark) 379EG, IGM Resins B
- oxime ester [trade name: Lunar (registered trademark) 6, manufactured by DKSH Japan], 1-[4-(phenylthio)phenyl]-3-cyclopentylpropane-1,2-dione -2-(O-benzoyloxime) (trade name: TR-PBG-305, manufactured by Changzhou Power Electronics New Materials Co., Ltd.), 1,2-propanedione, 3-cyclohexyl-1-[9-ethyl-6- (2-furanylcarbonyl)-9H-carbazol-3-yl]-, 2-(O-acetyloxime) (trade name: TR-PBG-326, manufactured by Changzhou Tenryu Electric New Materials Co., Ltd.), 3-cyclohexyl -1-(6-(2-(benzoyloxyimino)hexanoyl)-9-ethyl-9H-carbazol-3-yl)-propane-1,2-dione-2-(O-benzoyloxime) (trade name:
- a photoinitiator may be used individually by 1 type, and can also use 2 or more types. When two or more are used, an oxime photopolymerization initiator and at least one selected from ⁇ -aminoalkylphenone photopolymerization initiators and ⁇ -hydroxyalkylphenone polymerization initiators can be used. preferable.
- the content of the photopolymerization initiator is preferably 0.1% by mass or more, preferably 0.5% by mass, based on the total mass of the photosensitive composition layer. % or more, and even more preferably 1.0 mass % or more.
- the upper limit thereof is preferably 10% by mass or less, more preferably 5% by mass or less, relative to the total mass of the photosensitive composition layer.
- the photosensitive composition layer may contain a heterocyclic compound.
- the heterocyclic ring contained in the heterocyclic compound may be either monocyclic or polycyclic heterocyclic ring.
- a nitrogen atom, an oxygen atom, and a sulfur atom are mentioned as a heteroatom which a heterocyclic compound has.
- the heterocyclic compound preferably has at least one atom selected from the group consisting of a nitrogen atom, an oxygen atom and a sulfur atom, more preferably a nitrogen atom.
- heterocyclic compounds examples include triazole compounds, benzotriazole compounds, tetrazole compounds, thiadiazole compounds, triazine compounds, rhodanine compounds, thiazole compounds, benzothiazole compounds, benzimidazole compounds, benzoxazole compounds, and pyrimidine compounds.
- the heterocyclic compound is at least one selected from the group consisting of triazole compounds, benzotriazole compounds, tetrazole compounds, thiadiazole compounds, triazine compounds, rhodanine compounds, thiazole compounds, benzimidazole compounds, and benzoxazole compounds.
- At least one compound selected from the group consisting of triazole compounds, benzotriazole compounds, tetrazole compounds, thiadiazole compounds, thiazole compounds, benzothiazole compounds, benzimidazole compounds, and benzoxazole compounds is more preferred.
- heterocyclic compound Preferred specific examples of the heterocyclic compound are shown below.
- triazole compounds and benzotriazole compounds include the following compounds.
- the following compounds can be exemplified as thiadiazole compounds.
- triazine compounds include the following compounds.
- the following compounds can be exemplified as rhodanine compounds.
- the following compounds can be exemplified as thiazole compounds.
- the following compounds can be exemplified as benzimidazole compounds.
- a heterocyclic compound may be used individually by 1 type, and can also use 2 or more types together.
- the content of the heterocyclic compound is preferably 0.01 to 20.0% by mass, more preferably 0.10 to 10.0% by mass, based on the total mass of the photosensitive composition layer. 0% by mass is more preferable, 0.30 to 8.0% by mass is still more preferable, and 0.50 to 5.0% by mass is particularly preferable.
- the photosensitive composition layer may contain an aliphatic thiol compound. Since the photosensitive composition layer contains an aliphatic thiol compound, the aliphatic thiol compound undergoes an en-thiol reaction between a radically polymerizable compound having an ethylenically unsaturated group, and curing shrinkage of the film formed. is suppressed and the stress is relieved.
- aliphatic thiol compound a monofunctional aliphatic thiol compound or a polyfunctional aliphatic thiol compound (that is, a bifunctional or higher aliphatic thiol compound) is preferable.
- polyfunctional aliphatic thiol compounds are preferable as the aliphatic thiol compound from the viewpoint of adhesion of the formed pattern (especially adhesion after exposure).
- polyfunctional aliphatic thiol compound means an aliphatic compound having two or more thiol groups (also referred to as “mercapto groups”) in the molecule.
- a low-molecular-weight compound having a molecular weight of 100 or more is preferable as the polyfunctional aliphatic thiol compound.
- the molecular weight of the polyfunctional aliphatic thiol compound is more preferably 100 to 1,500, still more preferably 150 to 1,000.
- the number of functional groups of the polyfunctional aliphatic thiol compound is, for example, preferably 2 to 10 functional, more preferably 2 to 8 functional, and even more preferably 2 to 6 functional, from the viewpoint of adhesion of the pattern to be formed.
- polyfunctional aliphatic thiol compounds include trimethylolpropane tris(3-mercaptobutyrate), 1,4-bis(3-mercaptobutyryloxy)butane, pentaerythritol tetrakis(3-mercaptobutyrate), 1,3,5-tris(3-mercaptobutyryloxyethyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, trimethylolethane tris(3-mercaptobutyrate ), tris [(3-mercaptopropionyloxy) ethyl] isocyanurate, trimethylolpropane tris (3-mercaptopropionate), pentaerythritol tetrakis (3-mercaptopropionate), tetraethylene glycol bis (3-mercaptopropionate pionate), dipentaerythritol hexakis(3-mercaptopropionat
- polyfunctional aliphatic thiol compounds include trimethylolpropane tris(3-mercaptobutyrate), 1,4-bis(3-mercaptobutyryloxy)butane, and 1,3,5- At least one compound selected from the group consisting of tris(3-mercaptobutyryloxyethyl)-1,3,5-triazine-2,4,6(1H,3H,5H)-trione is preferred.
- Examples of monofunctional aliphatic thiol compounds include 1-octanethiol, 1-dodecanethiol, ⁇ -mercaptopropionic acid, methyl-3-mercaptopropionate, 2-ethylhexyl-3-mercaptopropionate, n- Octyl-3-mercaptopropionate, methoxybutyl-3-mercaptopropionate, and stearyl-3-mercaptopropionate.
- the photosensitive composition layer may contain a single aliphatic thiol compound, or may contain two or more aliphatic thiol compounds.
- the content of the aliphatic thiol compound is preferably 5% by mass or more, more preferably 5 to 50% by mass, based on the total mass of the photosensitive composition layer. 5 to 30% by mass is more preferable, and 8 to 20% by mass is particularly preferable.
- the photosensitive composition layer preferably contains a thermally crosslinkable compound from the viewpoint of the strength of the resulting cured film and the adhesiveness of the resulting uncured film.
- a thermally crosslinkable compound having an ethylenically unsaturated group which will be described later, is not treated as an ethylenically unsaturated compound, but as a thermally crosslinkable compound.
- Thermally crosslinkable compounds include epoxy compounds, oxetane compounds, methylol compounds, and blocked isocyanate compounds. Among them, a blocked isocyanate compound is preferable from the viewpoint of the strength of the cured film to be obtained and the adhesiveness of the uncured film to be obtained.
- the blocked isocyanate compound reacts with a hydroxy group and a carboxy group, for example, when at least one of the binder polymer and the radically polymerizable compound having an ethylenically unsaturated group has at least one of a hydroxy group and a carboxy group, The hydrophilicity of the formed film tends to decrease, and the function as a protective film tends to be strengthened.
- the blocked isocyanate compound refers to "a compound having a structure in which the isocyanate group of isocyanate is protected (so-called masked) with a blocking agent".
- the dissociation temperature of the blocked isocyanate compound is not particularly limited, but is preferably 90 to 160°C, more preferably 100 to 150°C.
- the dissociation temperature of the blocked isocyanate means "the temperature of the endothermic peak associated with the deprotection reaction of the blocked isocyanate when measured by DSC (Differential Scanning Calorimetry) analysis using a differential scanning calorimeter".
- DSC Different Scanning Calorimetry
- a differential scanning calorimeter for example, a differential scanning calorimeter (model: DSC6200) manufactured by Seiko Instruments Inc. can be preferably used. However, the differential scanning calorimeter is not limited to this.
- the blocking agent having a dissociation temperature of 90 to 160° C. is preferably at least one selected from oxime compounds and pyrazole compounds from the viewpoint of storage stability.
- the blocked isocyanate compound preferably has an isocyanurate structure, for example, from the viewpoint of improving the brittleness of the film and improving the adhesion to the transferred material.
- a blocked isocyanate compound having an isocyanurate structure can be obtained, for example, by converting hexamethylene diisocyanate into an isocyanurate for protection.
- blocked isocyanate compounds having an isocyanurate structure a compound having an oxime structure using an oxime compound as a blocking agent tends to have a dissociation temperature within a preferred range and produces less development residue than compounds having no oxime structure. It is preferable because it is easy to
- the blocked isocyanate compound may have a polymerizable group.
- the polymerizable group is not particularly limited, and any known polymerizable group can be used, and a radically polymerizable group is preferred.
- Polymerizable groups include groups having ethylenically unsaturated groups such as (meth)acryloxy groups, (meth)acrylamide groups, and styryl groups, and epoxy groups such as glycidyl groups. Among them, the polymerizable group is preferably an ethylenically unsaturated group, more preferably a (meth)acryloxy group, and still more preferably an acryloxy group.
- a commercial item can be used as a block isocyanate compound.
- blocked isocyanate compounds include Karenz (registered trademark) AOI-BM, Karenz (registered trademark) MOI-BM, Karenz (registered trademark) MOI-BP, etc. (manufactured by Showa Denko K.K.), block type Duranate series (eg, Duranate (registered trademark) TPA-B80E, Duranate (registered trademark) SBN-70D, Duranate (registered trademark) WT32-B75P, etc., manufactured by Asahi Kasei Chemicals Corporation).
- a blocked isocyanate compound having an NCO value of 4.5 mmol/g or more (hereinafter sometimes referred to as a first blocked isocyanate compound) is preferable from the viewpoint of achieving a more excellent effect of the present invention.
- the NCO value of the first blocked isocyanate compound is preferably 5.0 mmol/g or more, more preferably 5.3 mmol/g or more.
- the upper limit of the NCO value of the first blocked isocyanate compound is preferably 8.0 mmol/g or less, more preferably 6.0 mmol/g or less, and further less than 5.8 mmol/g, from the viewpoint that the effects of the present invention are more excellent.
- the NCO value of the blocked isocyanate compound in the present invention means the number of moles of isocyanate groups contained per 1 g of the blocked isocyanate compound, and is a value calculated from the structural formula of the blocked isocyanate compound.
- the first blocked isocyanate compound preferably has a ring structure from the viewpoint that the effects of the present invention are more excellent.
- the ring structure includes an aliphatic hydrocarbon ring, an aromatic hydrocarbon ring and a heterocyclic ring, and from the viewpoint that the effect of the present invention is more excellent, an aliphatic hydrocarbon ring and an aromatic hydrocarbon ring are preferable.
- a hydrogen ring is more preferred.
- the aliphatic hydrocarbon ring examples include cyclopentane ring and cyclohexane ring, and among them, cyclohexane ring is preferred.
- Specific examples of the aromatic hydrocarbon ring include benzene ring and naphthalene ring, with benzene ring being preferred.
- a specific example of the heterocyclic ring is an isocyanurate ring.
- the number of rings is preferably from 1 to 2, more preferably 1, from the viewpoint of the effect of the present invention being more excellent.
- the first blocked isocyanate compound contains a condensed ring, the number of rings constituting the condensed ring is counted. For example, the number of rings in the naphthalene ring is counted as two.
- the number of blocked isocyanate groups possessed by the first blocked isocyanate compound is preferably 2 to 5, more preferably 2 to 3, more preferably 2, in terms of the strength of the pattern formed and the effect of the present invention being more excellent. is more preferred.
- the first blocked isocyanate compound is preferably a blocked isocyanate compound represented by the formula Q from the viewpoint that the effects of the present invention are more excellent.
- B 1 and B 2 each independently represent a blocked isocyanate group.
- B 1 and B 2 are preferably the same group.
- a 1 and A 2 each independently represent a single bond or an alkylene group having 1 to 10 carbon atoms, preferably an alkylene group having 1 to 10 carbon atoms.
- the alkylene group may be linear, branched or cyclic, preferably linear.
- the number of carbon atoms in the alkylene group is 1 to 10, preferably 1 to 5, more preferably 1 to 3, and even more preferably 1, from the viewpoint that the effects of the present invention are more excellent.
- a 1 and A 2 are preferably the same group.
- L 1 represents a divalent linking group.
- divalent linking groups include divalent hydrocarbon groups.
- divalent hydrocarbon groups include divalent saturated hydrocarbon groups, divalent aromatic hydrocarbon groups, and groups formed by linking two or more of these groups.
- the divalent saturated hydrocarbon group may be linear, branched, or cyclic, and preferably cyclic, from the viewpoint of more excellent effects of the present invention.
- the number of carbon atoms in the divalent saturated hydrocarbon group is preferably 4 to 15, more preferably 5 to 10, and even more preferably 5 to 8, from the viewpoint that the effects of the present invention are more excellent.
- the divalent aromatic hydrocarbon group preferably has 5 to 20 carbon atoms, such as a phenylene group.
- a divalent aromatic hydrocarbon group may have a substituent (for example, an alkyl group).
- the divalent linking group includes a linear, branched or cyclic divalent saturated hydrocarbon group having 5 to 10 carbon atoms, a cyclic saturated hydrocarbon group having 5 to 10 carbon atoms and 1 to 1 carbon atoms.
- a group linked to a chain alkylene group is preferable, a cyclic divalent saturated hydrocarbon group having 5 to 10 carbon atoms, or a phenylene group which may have a substituent is more preferable, a cyclohexylene group or An optionally substituted phenylene group is more preferred, and a cyclohexylene group is particularly preferred.
- the blocked isocyanate compound represented by the formula Q is particularly preferably the blocked isocyanate compound represented by the formula QA from the viewpoint that the effects of the present invention are more excellent.
- B 1a and B 2a each independently represent a blocked isocyanate group.
- Preferred embodiments of B 1a and B 2a are the same as B 1 and B 2 in Formula Q.
- a 1a and A 2a each independently represent a divalent linking group.
- Preferred embodiments of the divalent linking group for A 1a and A 2a are the same as those for A 1 and A 2 in Formula Q.
- L 1a represents a cyclic divalent saturated hydrocarbon group or a divalent aromatic hydrocarbon group.
- the number of carbon atoms in the cyclic divalent saturated hydrocarbon group in L 1a is preferably 5 to 10, more preferably 5 to 8, still more preferably 5 to 6, and particularly preferably 6.
- Preferred embodiments of the divalent aromatic hydrocarbon group for L 1a are the same as for L 1 in Formula Q.
- L 1a is preferably a cyclic divalent saturated hydrocarbon group, more preferably a cyclic divalent saturated hydrocarbon group having 5 to 10 carbon atoms, and a cyclic divalent saturated hydrocarbon group having 5 to 10 carbon atoms.
- a hydrogen group is more preferred, a cyclic divalent saturated hydrocarbon group having 5 to 6 carbon atoms is particularly preferred, and a cyclohexylene group is most preferred.
- L 1a is a cyclohexylene group
- the blocked isocyanate compound represented by formula QA is an isomer mixture of cis and trans isomers (hereinafter also referred to as "cis-trans isomer mixture"). good too.
- first blocked isocyanate compound Specific examples of the first blocked isocyanate compound are shown below, but the first blocked isocyanate compound is not limited to these.
- the thermally crosslinkable compounds may be used singly or in combination of two or more.
- the content of the heat-crosslinkable compound is preferably 1 to 50% by mass, more preferably 5 to 30% by mass, based on the total mass of the photosensitive composition layer. .
- the photosensitive composition layer may contain a surfactant.
- surfactants include those described in paragraph [0017] of Japanese Patent No. 4502784 and paragraphs [0060] to [0071] of JP-A-2009-237362.
- surfactants examples include hydrocarbon-based surfactants, fluorine-based surfactants, and silicone-based surfactants. From the viewpoint of improving environmental friendliness, the surfactant preferably does not contain a fluorine atom. As the surfactant, a hydrocarbon-based surfactant or a silicone-based surfactant is preferred. Moreover, as surfactant, a nonionic surfactant is preferable. Examples of commercially available fluorosurfactants include MEGAFACE F-171, F-172, F-173, F-176, F-177, F-141, F-142, F-143, and F-144.
- an acrylic compound that has a molecular structure with a functional group containing a fluorine atom and in which the portion of the functional group containing the fluorine atom is cleaved and the fluorine atom volatilizes when heat is applied can also be suitably used.
- a fluorosurfactant include Megafac DS series manufactured by DIC Corporation (The Chemical Daily (February 22, 2016), Nikkei Sangyo Shimbun (February 23, 2016)), for example, Megafac and DS-21.
- the fluorosurfactant it is also preferable to use a polymer of a fluorine atom-containing vinyl ether compound having a fluorinated alkyl group or a fluorinated alkylene ether group and a hydrophilic vinyl ether compound.
- a block polymer can also be used as the fluorosurfactant.
- the fluorine-based surfactant has a structural unit derived from a (meth)acrylate compound having a fluorine atom and 2 or more (preferably 5 or more) alkyleneoxy groups (preferably ethyleneoxy groups and propyleneoxy groups).
- a fluorine-containing polymer compound containing a structural unit derived from a (meth)acrylate compound can also be preferably used.
- a fluoropolymer having an ethylenically unsaturated bond-containing group in a side chain can also be used.
- Megafac RS-101, RS-102, RS-718K, RS-72-K manufactured by DIC Corporation
- DIC Corporation Megafac RS-101, RS-102, RS-718K, RS-72-K (manufactured by DIC Corporation) and the like.
- fluorosurfactant from the viewpoint of improving environmental suitability, compounds having a linear perfluoroalkyl group having 7 or more carbon atoms, such as perfluorooctanoic acid (PFOA) and perfluorooctane sulfonic acid (PFOS), are used.
- PFOA perfluorooctanoic acid
- PFOS perfluorooctane sulfonic acid
- Surfactants derived from alternative materials are preferred.
- Hydrocarbon surfactants include glycerol, trimethylolpropane, trimethylolethane, their ethoxylates and propoxylates (e.g., glycerol propoxylate, glycerol ethoxylate, etc.), polyoxyethylene lauryl ether, polyoxyethylene stearyl ether , polyoxyethylene oleyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene nonylphenyl ether, polyethylene glycol dilaurate, polyethylene glycol distearate, sorbitan fatty acid ester, and the like.
- Pluronic L10, L31, L61, L62, 10R5, 17R2, 25R2, Tetronic 304, 701, 704, 901, 904, 150R1, HYDROPALAT WE 3323 (manufactured by BASF), Solsperse 20000 (manufactured by BASF) Nippon Lubrizol Co., Ltd.), NCW-101, NCW-1001, NCW-1002 (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.), Pionin D-1105, D-6112, D-6112-W, D -6315 (manufactured by Takemoto Oil & Fat Co., Ltd.), Olphine E1010, Surfynol 104, 400, 440 (manufactured by Nissin Chemical Industry Co., Ltd.) and the like.
- silicone-based surfactants include straight-chain polymers composed of siloxane bonds, and modified siloxane polymers in which organic groups are introduced into side chains and terminals.
- silicone surfactants include: EXP. S-309-2, EXP. S-315, EXP. S-503-2, EXP. S-505-2 (manufactured by DIC Corporation), DOWSIL 8032 ADDITIVE, Toray Silicone DC3PA, Toray Silicone SH7PA, Toray Silicone DC11PA, Toray Silicone SH21PA, Toray Silicone SH28PA, Toray Silicone SH29PA, Toray Silicone SH30PA, Toray Silicone SH8400 ( Above, Dow Corning Toray Co., Ltd.) and X-22-4952, X-22-4272, X-22-6266, KF-351A, K354L, KF-355A, KF-945, KF-640, KF -642, KF-643, X-22-6191, X-22-4515, KF-6004, KF-6001, KF-6002, KP-101, KP-103, KP-104, KP-105, KP-106 , K
- One type of surfactant may be used alone, or two or more types may be used.
- the content of the surfactant is preferably 0.01 to 3.0% by mass, more preferably 0.01 to 1.0% by mass, based on the total mass of the photosensitive composition layer. 0% by mass is more preferable, and 0.05 to 0.80% by mass is even more preferable.
- the photosensitive composition layer may contain a polymerization inhibitor.
- a polymerization inhibitor means a compound having a function of delaying or inhibiting a polymerization reaction.
- the polymerization inhibitor for example, known compounds used as polymerization inhibitors can be used.
- polymerization inhibitors include phenothiazine, bis-(1-dimethylbenzyl)phenothiazine, and phenothiazine compounds such as 3,7-dioctylphenothiazine; bis[3-(3-tert-butyl-4-hydroxy-5- methylphenyl)propionic acid][ethylenebis(oxyethylene)]2,4-bis[(laurylthio)methyl]-o-cresol, 1,3,5-tris(3,5-di-t-butyl-4- hydroxybenzyl), 1,3,5-tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl), 2,4-bis-(n-octylthio)-6-(4-hydroxy-3 ,5-di-t-butylanilino)-1,3,5-triazine and hindered phenol compounds such as pentaerythritol tetrakis 3-(3,5-di-tert
- the polymerization inhibitor is preferably at least one selected from the group consisting of phenothiazine compounds, nitroso compounds or salts thereof, and hindered phenol compounds, and phenothiazine, bis[ 3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionic acid], [ethylenebis(oxyethylene)]2,4-bis[(laurylthio)methyl]-o-cresol, 1,3, More preferred are 5-tris(3,5-di-t-butyl-4-hydroxybenzyl), p-methoxyphenol, and N-nitrosophenylhydroxylamine aluminum salt.
- a polymerization inhibitor may be used individually by 1 type, and can also use 2 or more types together.
- the content of the polymerization inhibitor is preferably 0.001 to 5.0% by mass, more preferably 0.01 to 3.0% by mass, based on the total mass of the photosensitive composition layer. 0% by mass is more preferable, and 0.02 to 2.0% by mass is even more preferable.
- the content of the polymerization inhibitor is preferably 0.005 to 5.0% by mass, more preferably 0.01 to 3.0% by mass, and 0.01 to 1.0% by mass with respect to the total mass of the polymerizable compound. % by mass is more preferred.
- the photosensitive composition layer may contain a hydrogen donating compound.
- the hydrogen-donating compound has actions such as further improving the sensitivity of the photopolymerization initiator to actinic rays and suppressing inhibition of polymerization of the polymerizable compound by oxygen.
- Examples of hydrogen-donating compounds include amines and amino acid compounds.
- amines examples include M.I. R. Sander et al., "Journal of Polymer Society", Vol. JP-A-60-084305, JP-A-62-018537, JP-A-64-033104, and Research Disclosure 33825. More specifically, 4,4′-bis(diethylamino)benzophenone, tris(4-dimethylaminophenyl)methane (alias: leuco crystal violet), triethanolamine, p-dimethylaminobenzoic acid ethyl ester, p-formyl dimethylaniline and p-methylthiodimethylaniline.
- At least one selected from the group consisting of 4,4′-bis(diethylamino)benzophenone and tris(4-dimethylaminophenyl)methane is used as the amine, since the effects of the present invention are more excellent. preferable.
- Amino acid compounds include, for example, N-phenylglycine, N-methyl-N-phenylglycine, N-ethyl-N-phenylglycine. Among them, N-phenylglycine is preferable as the amino acid compound because the effects of the present invention are more excellent.
- the hydrogen-donating compound for example, an organometallic compound (such as tributyltin acetate) described in JP-B-48-042965, a hydrogen donor described in JP-B-55-034414, and JP-A-6 Also included are sulfur compounds (such as trithiane) described in JP-A-308727.
- organometallic compound such as tributyltin acetate
- hydrogen donor such as JP-B-55-034414
- JP-A-6 also included are sulfur compounds (such as trithiane) described in JP-A-308727.
- the hydrogen-donating compounds may be used singly or in combination of two or more.
- the content of the hydrogen-donating compound is based on the total weight of the photosensitive composition layer, from the viewpoint of improving the curing speed due to the balance between the polymerization growth speed and the chain transfer. 0.01 to 10.0% by mass is preferable, 0.01 to 8.0% by mass is more preferable, and 0.03 to 5.0% by mass is even more preferable.
- the photosensitive composition layer may contain a certain amount of impurities.
- impurities include sodium, potassium, magnesium, calcium, iron, manganese, copper, aluminum, titanium, chromium, cobalt, nickel, zinc, tin, halogens and ions thereof.
- halide ions chloride ions, bromide ions, iodide ions
- sodium ions, and potassium ions are likely to be mixed as impurities, so the following content is preferable.
- the content of impurities in the photosensitive composition layer is preferably 80 ppm or less, more preferably 10 ppm or less, and even more preferably 2 ppm or less on a mass basis.
- the content of impurities in the photosensitive composition layer can be 1 ppb or more or 0.1 ppm or more on a mass basis.
- an aspect in which all the above impurities are 0.6 ppm on a mass basis can be mentioned.
- the amount of impurities can be made within the above range.
- Impurities can be quantified by known methods such as ICP (Inductively Coupled Plasma) emission spectroscopy, atomic absorption spectroscopy, and ion chromatography.
- ICP Inductively Coupled Plasma
- the content of compounds such as benzene, formaldehyde, trichlorethylene, 1,3-butadiene, carbon tetrachloride, chloroform, N,N-dimethylformamide, N,N-dimethylacetamide, and hexane in the photosensitive composition layer is Less is preferred.
- the content of these compounds in the photosensitive composition layer is preferably 100 ppm or less, more preferably 20 ppm or less, and even more preferably 4 ppm or less, based on mass.
- the lower limit can be 10 ppb or more, and can be 100 ppb or more on a mass basis.
- the content of these compounds can be suppressed in the same manner as the metal impurities described above. Moreover, it can quantify by a well-known measuring method.
- the water content in the photosensitive composition layer is preferably 0.01 to 1.0% by mass, more preferably 0.05 to 0.5% by mass, from the viewpoint of improving reliability and lamination properties.
- the photosensitive composition layer may contain residual monomers of each constitutional unit of the alkali-soluble resin described above.
- the content of the residual monomer is preferably 5,000 mass ppm or less, more preferably 2,000 mass ppm or less, and 500 mass ppm or less with respect to the total mass of the alkali-soluble resin, from the viewpoints of patterning properties and reliability. is more preferred.
- the lower limit is not particularly limited, it is preferably 1 mass ppm or more, more preferably 10 mass ppm or more.
- the residual monomer of each structural unit of the alkali-soluble resin is preferably 3,000 ppm by mass or less, more preferably 600 ppm by mass or less, relative to the total mass of the photosensitive composition layer, from the viewpoints of patterning properties and reliability. , 100 ppm by mass or less is more preferable. Although the lower limit is not particularly limited, it is preferably 0.1 mass ppm or more, more preferably 1 mass ppm or more.
- the amount of residual monomers in synthesizing the alkali-soluble resin by polymer reaction is also within the above range.
- the content of glycidyl acrylate is preferably within the above range.
- the amount of residual monomers can be measured by known methods such as liquid chromatography and gas chromatography.
- the photosensitive composition layer may contain components (hereinafter also referred to as "other components") other than the components described above.
- Other ingredients include, for example, colorants, antioxidants, and particles (eg, metal oxide particles).
- other additives described in paragraphs [0058] to [0071] of JP-A-2000-310706 can also be mentioned.
- metal oxide particles are preferred.
- Metals in metal oxide particles also include semimetals such as B, Si, Ge, As, Sb, and Te.
- the average primary particle size of the particles is preferably 1 to 200 nm, more preferably 3 to 80 nm, for example, from the viewpoint of the transparency of the cured film.
- the average primary particle diameter of particles is calculated by measuring the particle diameters of 200 arbitrary particles using an electron microscope and arithmetically averaging the measurement results. When the shape of the particles is not spherical, the longest side is taken as the particle diameter.
- the photosensitive composition layer may contain only one type of particles having different metal species and different sizes, or may contain two or more types.
- the photosensitive composition layer does not contain particles, or when the photosensitive composition layer contains particles, the content of the particles is more than 0% by weight and 35% by weight based on the total weight of the photosensitive composition layer.
- the content of particles is more preferably more than 0% by mass and 10% by mass or less with respect to the total mass of the photosensitive composition, and it does not contain particles, or More preferably, the content is more than 0% by mass and 5% by mass or less relative to the total mass of the photosensitive composition layer, and does not contain particles, or the content of particles is 0 mass relative to the total mass of the photosensitive composition layer % to 1% by mass or less, and it is particularly preferred to contain no particles.
- the photosensitive composition layer may contain a slight amount of coloring agent (pigment, dye, etc.), it is preferred that the photosensitive composition layer does not substantially contain coloring agent, for example, from the viewpoint of transparency.
- the content of the colorant is preferably less than 1% by mass, more preferably less than 0.1% by mass, relative to the total mass of the photosensitive composition layer.
- antioxidants examples include 1-phenyl-3-pyrazolidone (alias: phenidone), 1-phenyl-4,4-dimethyl-3-pyrazolidone, and 1-phenyl-4-methyl-4-hydroxymethyl- 3-pyrazolidones such as 3-pyrazolidone; polyhydroxybenzenes such as hydroquinone, catechol, pyrogallol, methylhydroquinone, and chlorohydroquinone; paramethylaminophenol, paraaminophenol, parahydroxyphenylglycine, and paraphenylenediamine be done.
- 3-pyrazolidones are preferable, and 1-phenyl-3-pyrazolidone is more preferable as the antioxidant, because the effects of the present invention are more excellent.
- the content of the antioxidant is preferably 0.001% by mass or more, more preferably 0.005% by mass or more, relative to the total mass of the photosensitive composition layer. , more preferably 0.01% by mass or more.
- the upper limit is not particularly limited, it is preferably 1% by mass or less.
- the thickness of the photosensitive composition layer is not particularly limited, it is often 30 ⁇ m or less. 0 ⁇ m or less is particularly preferable.
- the lower limit is preferably 0.60 ⁇ m or more, more preferably 1.5 ⁇ m or more, from the viewpoint of excellent strength of the film obtained by curing the photosensitive composition layer.
- the thickness of the photosensitive composition layer can be calculated, for example, as an average value of arbitrary five points measured by cross-sectional observation with a scanning electron microscope (SEM).
- the refractive index of the photosensitive composition layer is preferably 1.41 to 1.59, more preferably 1.47 to 1.56.
- the photosensitive composition layer is preferably achromatic. Specifically, total reflection (incidence angle 8°, light source: D-65 (2° field of view)) has an L * value of 10 to 90 in the CIE1976 (L*, a*, b*) color space.
- the a * value is preferably -1.0 to 1.0
- the b * value is preferably -1.0 to 1.0.
- the pattern obtained by curing the photosensitive composition layer is preferably achromatic. Specifically, total reflection (incidence angle 8°, light source: D-65 (2° field of view)) can be used in the CIE1976 (L*, a*, b*) color space, where the L * value of the pattern is 10 to 90.
- the a * value of the pattern is preferably ⁇ 1.0 to 1.0
- the b * value of the pattern is preferably ⁇ 1.0 to 1.0.
- the visible light transmittance per 1.0 ⁇ m thick of the photosensitive composition layer is preferably 80% or more, more preferably 90% or more, and most preferably 95% or more.
- the average transmittance at a wavelength of 400 nm to 800 nm, the minimum transmittance at a wavelength of 400 nm to 800 nm, and the transmittance at a wavelength of 400 nm preferably satisfy the above.
- Preferred transmittance values include, for example, 87%, 92%, and 98%. The same applies to the transmittance per 1 ⁇ m of the cured film of the photosensitive composition layer.
- the moisture permeability of the pattern obtained by curing the photosensitive composition layer (cured film of the photosensitive composition layer) at a film thickness of 40 ⁇ m is determined from the viewpoint of rust prevention of electrodes or wiring and the reliability of the device. , is preferably 500 g/m 2 /24 hr or less, more preferably 300 g/m 2 /24 hr or less, and even more preferably 100 g/m 2 /24 hr or less.
- Moisture permeability is a cured film obtained by exposing the photosensitive composition layer to an i-line exposure amount of 300 mJ/cm 2 and then post-baking at 145°C for 30 minutes to cure the photosensitive composition layer.
- Moisture permeability is measured according to the cup method of JIS Z0208.
- the above moisture permeability is preferable under any of the test conditions of temperature 40° C./humidity 90%, temperature 65° C./humidity 90%, and temperature 80° C./humidity 95%.
- Specific preferred values include, for example, 80 g/m 2 /24 hr, 150 g/m 2 /24 hr, 220 g/m 2 /24 hr, and the like.
- the dissolution rate of the photosensitive composition layer in a 1.0% aqueous solution of sodium carbonate is preferably 0.01 ⁇ m/sec or more, more preferably 0.10 ⁇ m/sec or more, more preferably 0.20 ⁇ m/sec, from the viewpoint of suppressing residue during development. Seconds or more are more preferable. From the viewpoint of the edge shape of the pattern, it is preferably 5.0 ⁇ m/second or less, more preferably 4.0 ⁇ m/second or less, and even more preferably 3.0 ⁇ m/second or less. Specific preferable numerical values include, for example, 1.8 ⁇ m/second, 1.0 ⁇ m/second, and 0.7 ⁇ m/second.
- the dissolution rate per unit time of the photosensitive composition layer in a 1.0% by mass sodium carbonate aqueous solution shall be measured as follows.
- a photosensitive composition layer (thickness in the range of 1.0 to 10 ⁇ m) formed on a glass substrate from which the solvent has been sufficiently removed is treated with a 1.0% by mass sodium carbonate aqueous solution at 25 ° C.
- shower development is carried out until the substance layer is completely dissolved (however, the maximum is 2 minutes). It is obtained by dividing the film thickness of the photosensitive composition layer by the time required for the photosensitive composition layer to completely dissolve. In addition, when it does not melt completely in 2 minutes, it calculates similarly from the film thickness change amount until then.
- the dissolution rate of the cured film of the photosensitive composition layer (film thickness in the range of 1.0 to 10 ⁇ m) in a 1.0% aqueous sodium carbonate solution is preferably 3.0 ⁇ m/second or less, more preferably 2.0 ⁇ m/second or less. It is preferably 1.0 ⁇ m/sec or less, more preferably 0.2 ⁇ m/sec or less.
- the cured film of the photosensitive composition layer is a film obtained by exposing the photosensitive composition layer with i-rays at an exposure amount of 300 mJ/cm 2 . Specific preferable numerical values include, for example, 0.8 ⁇ m/second, 0.2 ⁇ m/second, and 0.001 ⁇ m/second.
- a 1/4 MINJJX030PP shower nozzle manufactured by Ikeuchi Co., Ltd. is used, and the shower spray pressure is 0.08 MPa. Under the above conditions, the shower flow rate per unit time is 1,800 mL/min.
- the swelling ratio of the photosensitive composition layer after exposure to a 1.0% by mass sodium carbonate aqueous solution is preferably 100% or less, more preferably 50% or less, and even more preferably 30% or less, from the viewpoint of improving pattern formability.
- the swelling ratio of the photosensitive resin layer after exposure to a 1.0% by mass sodium carbonate aqueous solution is measured as follows. A photosensitive resin layer (thickness in the range of 1.0 to 10 ⁇ m in film thickness) formed on a glass substrate from which the solvent has been sufficiently removed is exposed with an ultra-high pressure mercury lamp at 500 mj/cm 2 (i-line measurement).
- the entire glass substrate is immersed in a 1.0% by mass sodium carbonate aqueous solution at 25° C., and the film thickness is measured after 30 seconds have elapsed. Then, the ratio of the film thickness after immersion to the film thickness before immersion is calculated. Specific preferable values include, for example, 4%, 13%, and 25%.
- the number of foreign substances having a diameter of 1.0 ⁇ m or more in the photosensitive composition layer is preferably 10/mm 2 or less, more preferably 5/mm 2 or less.
- the number of foreign objects shall be measured as follows. Any five regions (1 mm ⁇ 1 mm) on the surface of the photosensitive composition layer from the normal direction of the surface of the photosensitive composition layer are visually observed using an optical microscope, and each region The number of foreign substances having a diameter of 1.0 ⁇ m or more is measured, and the number of foreign substances is calculated by arithmetically averaging them. Specific preferable numerical values include, for example, 0/mm 2 , 1/mm 2 , 4/mm 2 , and 8/mm 2 .
- the haze of a solution obtained by dissolving a 1.0 cm3 photosensitive resin layer in 1.0 liter of an aqueous solution of 1.0% by weight sodium carbonate at 30°C is 60% or less. is preferably 30% or less, more preferably 10% or less, and most preferably 1% or less. Haze shall be measured as follows. First, a 1.0% by mass sodium carbonate aqueous solution is prepared and the liquid temperature is adjusted to 30°C. A photosensitive resin layer of 1.0 cm 3 is placed in 1.0 L of sodium carbonate aqueous solution. Stir at 30° C. for 4 hours, taking care not to introduce air bubbles.
- the haze of the solution in which the photosensitive resin layer is dissolved is measured. Haze is measured using a haze meter (product name “NDH4000”, manufactured by Nippon Denshoku Industries Co., Ltd.) using a liquid measurement unit and a liquid measurement dedicated cell with an optical path length of 20 mm. Specific preferable numerical values include, for example, 0.4%, 1.0%, 9%, and 24%.
- the transfer film has a protective film.
- the protective film contains polypropylene.
- the protective film is not particularly limited as long as it contains polypropylene, and may contain other resins than polypropylene. Examples of other resins include polyolefin resins such as polyethylene, polyester resins such as polyethylene terephthalate, polycarbonate resins, and polystyrene resins.
- the protective film is preferably a polyolefin film containing polypropylene, more preferably a polypropylene film or a polyethylene film containing polypropylene, and still more preferably a polypropylene film.
- the arithmetic mean roughness Ra1 of the surface of the protective film on the photosensitive composition layer side is smaller than the arithmetic mean roughness Ra2 of the surface of the protective film opposite to the photosensitive composition layer side.
- the arithmetic mean roughness Ra1 is not particularly limited as long as it is smaller than the arithmetic mean roughness Ra2, but in terms of excellent pattern defect suppression properties, the arithmetic mean roughness Ra1 is preferably 0.090 ⁇ m or less, more preferably 0.050 ⁇ m or less. preferable.
- the lower limit of the arithmetic mean roughness Ra1 is 0.000 ⁇ m or more, and is often 0.005 ⁇ m or more.
- Arithmetic mean roughness Ra2 is not particularly limited as long as it is greater than arithmetic mean roughness Ra1, but is preferably more than 0.050 ⁇ m, more preferably more than 0.060 ⁇ m, more preferably more than 0.060 ⁇ m, in terms of excellent windability of the protective film, and 0.070 ⁇ m Greater than 0.080 ⁇ m is particularly preferred.
- the upper limit of the arithmetic mean roughness Ra2 is preferably 0.200 ⁇ m or less, more preferably less than 0.150 ⁇ m, even more preferably 0.120 ⁇ m or less, from the viewpoint of excellent inspectability when inspecting defects in the transfer film. 0.100 ⁇ m or less is particularly preferred.
- the ratio of the arithmetic mean roughness Ra2 to the arithmetic mean roughness Ra1 is greater than 1, preferably 1.3 or more, and more preferably 1.7 or more.
- the upper limit of the above ratio is not particularly set, it is preferably 5.0 or less, more preferably 3.0 or less.
- the arithmetic mean roughness Ra2 of the protective film is obtained by measuring the surface roughness of the surface of the transfer film opposite to the photosensitive composition layer.
- the arithmetic mean roughness Ra2 is obtained by measuring the surface unevenness with a fine shape measuring instrument (ET-350K, manufactured by Kosaka Laboratory Co., Ltd.), and from the obtained contour curve, JIS B 0601: 2001 compliant and the arithmetic mean roughness Ra is obtained.
- a three-dimensional analysis software (TDA-22, manufactured by Kosaka Laboratory Ltd.) is used for calculating the arithmetic mean roughness Ra.
- the arithmetic mean roughness Ra1 of the protective film is obtained by peeling the protective film at the interface between the protective film and the photosensitive composition layer in the transfer film, and the surface of the protective film on the side that was in contact with the photosensitive composition layer. , and obtained by measuring in the same manner as the arithmetic mean roughness Ra2.
- the thickness of the protective film is preferably 1 to 100 ⁇ m, more preferably 5 to 50 ⁇ m, even more preferably 5 to 40 ⁇ m, particularly preferably 10 to 30 ⁇ m.
- the thickness of the protective film is preferably 1 ⁇ m or more, more preferably 10 ⁇ m or more, from the viewpoint of excellent mechanical strength.
- the thickness is preferably 100 ⁇ m or less, more preferably 30 ⁇ m or less, from the viewpoints of relatively low cost and the ability to reduce air bubbles during production, which will be described later. By reducing air bubbles during manufacturing, the pattern defect suppressing property can be improved.
- the number of fisheyes with a diameter of 80 ⁇ m or more contained in the protective film is preferably 5/m 2 or less.
- fish eye refers to foreign matter, undissolved matter, and oxidative degradation products of the material when producing a film by methods such as heat melting, kneading, extrusion, biaxial stretching, and casting. is captured in the film.
- the number of particles having a diameter of 3 ⁇ m or more contained in the protective film is preferably 30 particles/mm 2 or less, more preferably 10 particles/mm 2 or less, and even more preferably 5 particles/mm 2 or less. This makes it possible to suppress defects caused by the unevenness caused by the particles contained in the protective film being transferred to the photosensitive composition layer or the conductive layer.
- the cured film obtained by curing the photosensitive composition layer has a breaking elongation at 120° C. of 15% or more, and the arithmetic average roughness Ra of the surface of the temporary support on the photosensitive composition layer side is 50 nm or less. It is also preferable that the surface of the protective film facing the photosensitive composition layer has an arithmetic mean roughness Ra of 150 nm or less.
- the transfer film preferably satisfies the following formula (1).
- X represents the value (%) of the elongation at break at 120 ° C. of the cured film obtained by curing the photosensitive composition layer
- Y is the photosensitive composition layer side of the temporary support. It represents the value (nm) of the arithmetic mean roughness Ra of the surface. More preferably, X ⁇ Y is 750 or less. Specific values of X include 18%, 25%, 30%, and 35%. Specific numerical values of X ⁇ Y include 4 nm, 8 nm, 15 nm, and 30 nm. Specific numerical values of X ⁇ Y include 150, 200, 300, 360, 900, and the like.
- the elongation at break at 120°C is at least twice as large as the elongation at break at 23°C of the cured film obtained by curing the photosensitive composition layer.
- the elongation at break was measured by exposing a photosensitive composition layer having a thickness of 20 ⁇ m to 120 mJ/cm 2 with an ultra-high pressure mercury lamp and curing it, then additionally exposing it to 400 mJ/cm 2 with a high pressure mercury lamp, and heating at 145° C. for 30 minutes. Post-cured films are measured by a tensile test.
- the transfer film preferably satisfies the following formula (2).
- Y represents the value (nm) of the arithmetic mean roughness Ra of the surface of the temporary support on the photosensitive composition layer side
- Z represents the photosensitive composition layer side of the protective film.
- R represents the value (nm) of the arithmetic mean roughness Ra of the surface of
- the transfer film may have a refractive index adjusting layer.
- a known refractive index adjusting layer can be applied as the refractive index adjusting layer.
- materials contained in the refractive index adjusting layer include binder polymers, polymerizable compounds, metal salts, and particles.
- the method for controlling the refractive index of the refractive index adjustment layer is not particularly limited, and examples include a method using a resin having a predetermined refractive index alone, a method using a resin and particles, and a composite of a metal salt and a resin. A method using
- binder polymer and polymerizable compound examples include the binder polymer and polymerizable compound described in the section "Photosensitive composition layer" above.
- Particles include, for example, metal oxide particles and metal particles.
- the type of metal oxide particles is not particularly limited, and known metal oxide particles can be used.
- Metals in metal oxide particles also include semimetals such as B, Si, Ge, As, Sb, and Te.
- the average primary particle size of the particles is preferably 1 to 200 nm, more preferably 3 to 80 nm, for example, from the viewpoint of the transparency of the cured film.
- the average primary particle diameter of particles is calculated by measuring the particle diameters of 200 arbitrary particles using an electron microscope and arithmetically averaging the measurement results. When the shape of the particles is not spherical, the longest side is taken as the particle diameter.
- metal oxide particles include zirconium oxide particles ( ZrO2 particles), Nb2O5 particles, titanium oxide particles ( TiO2 particles), silicon dioxide particles ( SiO2 particles ) , and composites thereof. At least one selected from the group consisting of particles is preferred. Among these, at least one selected from the group consisting of zirconium oxide particles and titanium oxide particles is more preferable as the metal oxide particles, for example, from the viewpoint that the refractive index can be easily adjusted.
- metal oxide particles include calcined zirconium oxide particles (manufactured by CIK Nanotech Co., Ltd., product name: ZRPGM15WT%-F04), calcined zirconium oxide particles (manufactured by CIK Nanotech Co., Ltd., product name: ZRPGM15WT%-F74), Baked zirconium oxide particles (manufactured by CIK Nanotech Co., Ltd., product name: ZRPGM15WT%-F75), calcined zirconium oxide particles (manufactured by CIK Nanotech Co., Ltd., product name: ZRPGM15WT%-F76), zirconium oxide particles (Nanouse OZ-S30M, Nissan Kagaku Kogyo Co., Ltd.), and zirconium oxide particles (Nanouse OZ-S30K, Nissan Chemical Industries, Ltd.).
- the particles may be used singly or in combination of two or more.
- the content of particles in the refractive index adjusting layer is preferably 1 to 95% by mass, more preferably 20 to 90% by mass, still more preferably 40 to 85% by mass, relative to the total mass of the refractive index adjusting layer.
- the content of the titanium oxide particles is preferably 1 to 95% by mass, more preferably 20 to 90% by mass, more preferably 40 to 85% by mass, relative to the total mass of the refractive index adjusting layer. % is more preferred.
- the refractive index of the refractive index adjusting layer is preferably higher than that of the photosensitive composition layer.
- the refractive index of the refractive index adjusting layer is preferably 1.50 or higher, more preferably 1.55 or higher, even more preferably 1.60 or higher, and particularly preferably 1.65 or higher.
- the upper limit of the refractive index of the refractive index adjusting layer is preferably 2.10 or less, more preferably 1.85 or less, and even more preferably 1.78 or less.
- the thickness of the refractive index adjusting layer is preferably 50 to 500 nm, more preferably 55 to 110 nm, even more preferably 60 to 100 nm.
- the thickness of the refractive index adjusting layer is calculated as an average value of arbitrary five points measured by cross-sectional observation with a scanning electron microscope (SEM).
- a method for manufacturing the transfer film of the first embodiment is not particularly limited, and a known method can be used.
- a method for producing the transfer film 10 for example, a photosensitive composition is applied to the surface of the temporary support 1 to form a coating film, and the coating film is dried to form the photosensitive composition layer 3.
- the transfer film 10 including the temporary support 1, the photosensitive composition layer 3, the refractive index adjusting layer 5, and the protective film 7 can be manufactured.
- the transfer film 10 may be wound up to produce and store a roll-shaped transfer film.
- the roll-shaped transfer film can be provided as it is to the lamination step with the substrate by the roll-to-roll method, which will be described later.
- the photosensitive resin layer 3 may be formed on the surface of the refractive index adjusting layer 5. good. Further, as a method for producing the above-described transfer film 10, the photosensitive composition layer 3 is formed on the temporary support 1, and the refractive index adjustment layer 5 is separately formed on the protective film 7, and the photosensitive composition layer 3 may be formed by adhering the refractive index adjusting layer 5 together.
- the photosensitive composition layer in the transfer film contains components constituting the above-described photosensitive composition layer (e.g., binder polymer, It is preferably formed by a coating method using a photosensitive composition containing a polymerizable compound, a polymerization initiator, etc.) and a solvent.
- the method for producing the transfer film of the first embodiment includes coating a photosensitive composition on a temporary support to form a coating film, and drying the coating film at a predetermined temperature. It is preferably a method of forming a photosensitive composition layer.
- organic solvent is preferable as a solvent that can be contained in the photosensitive composition.
- organic solvents include methyl ethyl ketone, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate (also known as 1-methoxy-2-propyl acetate), diethylene glycol ethyl methyl ether, cyclohexanone, methyl isobutyl ketone, ethyl lactate, methyl lactate, and caprolactam. , n-propanol, and 2-propanol.
- an organic solvent having a boiling point of 180 to 250° C. can be used as necessary.
- a solvent may be used individually by 1 type, and can also use 2 or more types.
- the total solid content of the photosensitive composition is preferably 5 to 80% by mass, more preferably 5 to 40% by mass, even more preferably 5 to 30% by mass, based on the total mass of the photosensitive composition. That is, the content of the solvent in the photosensitive composition is preferably 20 to 95% by mass, more preferably 60 to 95% by mass, and further 70 to 95% by mass, based on the total mass of the photosensitive composition. preferable.
- the viscosity of the photosensitive composition at 25° C. is, for example, preferably 1 to 50 mPa ⁇ s, more preferably 2 to 40 mPa ⁇ s, and even more preferably 3 to 30 mPa ⁇ s, from the viewpoint of coating properties. Viscosity is measured using a viscometer.
- a viscometer for example, a viscometer manufactured by Toki Sangyo Co., Ltd. (trade name: VISCOMETER TV-22) can be preferably used.
- the viscometer is not limited to the viscometers described above.
- the surface tension of the photosensitive composition at 25°C is, for example, preferably from 5 to 100 mN/m, more preferably from 10 to 80 mN/m, even more preferably from 15 to 40 mN/m, from the viewpoint of coating properties.
- Surface tension is measured using a surface tensiometer.
- a surface tensiometer manufactured by Kyowa Interface Science Co., Ltd. (trade name: Automatic Surface Tensiometer CBVP-Z) can be preferably used.
- the surface tension meter is not limited to the surface tension meter described above.
- Examples of methods for applying the photosensitive composition include printing, spraying, roll coating, bar coating, curtain coating, spin coating, and die coating (that is, slit coating).
- Heat drying and reduced pressure drying are preferable as a method for drying the coating film of the photosensitive composition.
- drying means removing at least part of the solvent contained in the composition. Drying methods include, for example, natural drying, heat drying, and vacuum drying. The methods described above can be applied singly or in combination.
- the drying temperature is preferably 80° C. or higher, more preferably 90° C. or higher. Further, the upper limit thereof is preferably 130° C. or lower, more preferably 120° C. or lower. Drying can also be performed by changing the temperature continuously.
- the drying time is preferably 20 seconds or longer, more preferably 40 seconds or longer, and even more preferably 60 seconds or longer. Although the upper limit is not particularly limited, it is preferably 600 seconds or less, more preferably 300 seconds or less.
- the composition for forming the refractive index adjustment layer preferably contains the above-described various components for forming the refractive index adjustment layer and a solvent.
- the preferred range of the content of each component with respect to the total solid content of the composition is the same as the preferred range of the content of each component with respect to the total mass of the refractive index adjustment layer.
- the solvent is not particularly limited as long as it can dissolve or disperse the components contained in the refractive index adjustment layer, and is preferably at least one selected from the group consisting of water and water-miscible organic solvents. Mixed solvents with water-miscible organic solvents are more preferred.
- water-miscible organic solvents include alcohols having 1 to 3 carbon atoms, acetone, ethylene glycol, and glycerin, with alcohols having 1 to 3 carbon atoms being preferred, and methanol or ethanol being more preferred.
- a solvent may be used individually by 1 type, and may be used 2 or more types.
- the content of the solvent is preferably 50 to 2,500 parts by mass, more preferably 50 to 1,900 parts by mass, and even more preferably 100 to 900 parts by mass, based on 100 parts by mass of the total solid content of the composition.
- the method for forming the refractive index adjusting layer is not particularly limited as long as it is a method capable of forming a layer containing the above components.
- known coating methods slit coating, spin coating, curtain coating, inkjet coating, etc. mentioned.
- the transfer film of the first embodiment can be manufactured by bonding the protective film to the refractive index adjusting layer.
- the method of bonding the protective film to the refractive index adjusting layer is not particularly limited, and includes known methods.
- Examples of the device for bonding the protective film to the refractive index adjusting layer include known laminators such as a vacuum laminator and an autocut laminator.
- the laminator is equipped with any heatable roller, such as a rubber roller, and preferably can be pressurized and heated.
- the arithmetic mean roughness Ra1 of the surface of the photosensitive composition layer side described above is smaller than the arithmetic mean roughness Ra2 of the surface opposite to the photosensitive composition layer side, manufactured by a known method.
- the manufacturing method is not particularly limited.
- methods for controlling the arithmetic mean roughness Ra1 and Ra2 include a method using physical action and a method using chemical action. More specifically, a method of contacting the surface of a member having a desired surface roughness with the surface of the protective film, a method of cutting or polishing the surface of the protective film, and a method of irradiating the surface of the protective film with actinic rays or plasma.
- a method of heat treatment a method of utilizing the temperature difference between the crystal transformation temperature and the melting point of polypropylene, a method of mixing polypropylene with a low melting point resin such as an olefin to cause segregation, and a combination of the above methods.
- a protective film in which the arithmetic mean roughness Ra1 is less than the arithmetic mean roughness Ra2 is obtained. can be manufactured.
- the transfer film 20 shown in FIG. 2 has a temporary support 11, a composition layer 12 including a thermoplastic resin layer 13, an intermediate layer 15 and a photosensitive composition layer 17, and a protective film 19 in this order. Further, the transfer film 20 shown in FIG. 2 has a form in which the thermoplastic resin layer 13 and the intermediate layer 15 are arranged, but the thermoplastic resin layer 13 and the intermediate layer 15 may not be arranged.
- the temporary support 11 and the protective film 17 are the same as the temporary support 1 and the protective film 9 of the first embodiment described above, and the preferred aspects are also the same. The explanation is omitted.
- the transfer film has a photosensitive composition layer.
- a display device with a touch panel such as a capacitive input device (organic electroluminescence (EL) display device, liquid crystal display device, etc.)
- the electrode pattern corresponding to the sensor in the visible part the wiring of the peripheral wiring part and the lead-out wiring part
- a conductive layer pattern such as is provided inside the touch panel.
- a negative photosensitive composition layer photosensitive layer
- the photosensitive composition layer is preferably a negative photosensitive composition layer.
- the photosensitive composition layer is a negative photosensitive composition layer, the formed pattern corresponds to the cured layer.
- the photosensitive composition layer When the photosensitive composition layer is a negative photosensitive composition layer, the negative photosensitive composition layer preferably contains a resin, a polymerizable compound, and a polymerization initiator. Further, when the photosensitive composition layer is a negative photosensitive composition layer, as described later, it is also preferable that an alkali-soluble resin (Polymer A, which is an alkali-soluble resin, etc.) is contained as part or all of the resin. . That is, in one aspect, the photosensitive composition layer preferably contains a resin containing an alkali-soluble resin, a polymerizable compound, and a polymerization initiator.
- Polymer A which is an alkali-soluble resin, etc.
- Such a photosensitive composition layer (negative photosensitive composition layer) is based on the total weight of the photosensitive composition layer, resin: 10 to 90% by weight; polymerizable compound: 5 to 70% by weight; polymerization Initiator: preferably contains 0.01 to 20% by mass. Below, each component is demonstrated in order.
- Polymer A (resin)>
- the resin contained in the photosensitive composition layer is also referred to as polymer A.
- Resin A is not particularly limited. Acid-modified epoxy acrylate resins obtained by reaction with anhydrides can be mentioned.
- the (meth)acrylic resin means a resin having a structural unit derived from a (meth)acrylic compound.
- the content of structural units derived from the (meth)acrylic compound is preferably 30% by mass or more, more preferably 50% by mass or more, based on the total structural units of the (meth)acrylic resin. 60% by mass or more is more preferable.
- a polymer having a structural unit derived from a (meth)acrylic compound and a structural unit derived from a styrene compound is also preferable.
- Polymer A is preferably an alkali-soluble resin.
- the acid value of the polymer A is preferably 220 mgKOH/g or less, more preferably less than 200 mgKOH/g, from the viewpoint of better resolution by suppressing swelling of the negative photosensitive composition layer due to the developer. More preferably less than 190 mg KOH/g.
- the lower limit of the acid value of polymer A is not particularly limited, but from the viewpoint of better developability, it is preferably 60 mgKOH/g or more, more preferably 120 mgKOH/g or more, still more preferably 150 mgKOH/g or more, and 170 mgKOH/g or more. Especially preferred.
- the acid value (mgKOH/g) is the mass [mg] of potassium hydroxide required to neutralize 1 g of the sample.
- the acid value can be calculated, for example, from the average content of acid groups in the compound.
- the acid value of the polymer A may be adjusted according to the type of structural units constituting the polymer A and the content of structural units containing an acid group.
- the weight average molecular weight of polymer A is preferably 5,000 to 500,000.
- a weight-average molecular weight of 500,000 or less is preferable from the viewpoint of improving resolution and developability.
- the weight average molecular weight is more preferably 100,000 or less, even more preferably 60,000 or less.
- the weight-average molecular weight is 5,000 or more, from the viewpoint of controlling the properties of development aggregates and the properties of unexposed films such as edge fuse properties and cut chip properties in the case of negative photosensitive resin laminates.
- the weight average molecular weight is more preferably 10,000 or more, still more preferably 20,000 or more, and particularly preferably 30,000 or more.
- Edge fuseability refers to the extent to which the negative photosensitive composition layer tends to protrude from the end face of the roll when the negative photosensitive resin laminate is wound into a roll.
- the cut chip property refers to the degree of easiness of chip flying when the unexposed film is cut with a cutter. If this chip adheres to the upper surface of the negative photosensitive resin laminate, etc., it will be transferred to the mask in the subsequent exposure process or the like, resulting in defective products.
- the degree of dispersion of polymer A is preferably 1.0 to 6.0, more preferably 1.0 to 5.0, even more preferably 1.0 to 4.0, and particularly preferably 1.0 to 3.0. .
- dispersity is the ratio of weight average molecular weight to number average molecular weight (weight average molecular weight/number average molecular weight).
- weight average molecular weight and number average molecular weight are values measured using gel permeation chromatography.
- the polymer A is a composition based on a monomer having an aromatic hydrocarbon group. It preferably contains units. Examples of such aromatic hydrocarbon groups include substituted or unsubstituted phenyl groups and substituted or unsubstituted aralkyl groups.
- the content of structural units based on the monomer having an aromatic hydrocarbon group in the polymer A is preferably 20% by mass or more, more preferably 30% by mass or more, relative to the total mass of the polymer A.
- the upper limit is not particularly limited, it is preferably 95% by mass or less, more preferably 85% by mass or less.
- the average value of the content of the constituent units based on the monomer having an aromatic hydrocarbon group is within the above range.
- monomers having an aromatic hydrocarbon group examples include monomers having an aralkyl group, styrene, and polymerizable styrene derivatives (e.g., methylstyrene, vinyltoluene, tert-butoxystyrene, acetoxystyrene, 4-vinylbenzoyl acids, styrene dimers, styrene trimers, etc.).
- a monomer having an aralkyl group or styrene is preferred.
- the content of structural units based on styrene is 20 to 70% by mass with respect to the total mass of the polymer A. is preferred, 25 to 65% by weight is more preferred, 30 to 60% by weight is even more preferred, and 30 to 55% by weight is particularly preferred.
- the photosensitive resin layer contains a plurality of types of polymer A, the content of structural units derived from monomers having aromatic hydrocarbon groups is obtained as a weight average value.
- Aralkyl groups include substituted or unsubstituted phenylalkyl groups (excluding benzyl groups), substituted or unsubstituted benzyl groups, and the like, with substituted or unsubstituted benzyl groups being preferred.
- Examples of monomers having a phenylalkyl group include phenylethyl (meth)acrylate.
- Examples of monomers having a benzyl group include (meth)acrylates having a benzyl group, such as benzyl (meth)acrylate and chlorobenzyl (meth)acrylate; vinyl monomers having a benzyl group, such as vinylbenzyl chloride, and vinyl benzyl alcohol and the like. Among them, benzyl (meth)acrylate is preferred.
- the content of structural units based on benzyl (meth) acrylate is the total mass of the polymer A
- 50 to 95% by mass is preferable, 60 to 90% by mass is more preferable, 70 to 90% by mass is still more preferable, and 75 to 90% by mass is particularly preferable.
- Polymer A containing a structural unit based on a monomer having an aromatic hydrocarbon group is a monomer having an aromatic hydrocarbon group and at least one of the first monomers described later and / or It is preferably obtained by polymerizing at least one of the second monomers.
- the polymer A that does not contain a structural unit based on a monomer having an aromatic hydrocarbon group is preferably obtained by polymerizing at least one of the first monomers described later, and the first monomer It is more preferably obtained by copolymerizing at least one of the monomers and at least one of the second monomers described below.
- a 1st monomer is a monomer which has a carboxyl group in a molecule
- the first monomer include (meth)acrylic acid, fumaric acid, cinnamic acid, crotonic acid, itaconic acid, 4-vinylbenzoic acid, maleic anhydride, and maleic acid half ester. .
- (meth)acrylic acid is preferred.
- the content of the structural unit based on the first monomer in the polymer A is preferably 5 to 50% by mass, more preferably 10 to 40% by mass, more preferably 15 to 30% by mass, based on the total mass of the polymer A. % is more preferred.
- Setting the content to 5% by mass or more is preferable from the viewpoint of exhibiting good developability, controlling edge fuse properties, and the like.
- Setting the content to 50% by mass or less is preferable from the viewpoints of high resolution and groove shape of the resist pattern, and further from the viewpoint of chemical resistance of the resist pattern.
- the second monomer is a monomer that is non-acidic and has at least one polymerizable unsaturated group in the molecule.
- Examples of the second monomer include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, and isobutyl (meth) acrylate.
- tert-butyl (meth)acrylate 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, cyclohexyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate; acetic acid; esters of vinyl alcohol such as vinyl; and (meth)acrylonitrile.
- methyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, or n-butyl (meth)acrylate is preferred, and methyl (meth)acrylate is more preferred.
- the content of the structural unit based on the second monomer in the polymer A is preferably 5 to 60% by mass, more preferably 15 to 50% by mass, more preferably 17 to 45% by mass, based on the total mass of the polymer A. % is more preferred.
- the polymer A contains a structural unit based on a monomer having an aralkyl group and/or a structural unit based on a styrene monomer, thickening of the line width and deterioration of the resolution when the focal point shifts during exposure are suppressed.
- a copolymer containing a structural unit based on methacrylic acid, a structural unit based on benzyl methacrylate, and a structural unit based on styrene a structural unit based on methacrylic acid, a structural unit based on methyl methacrylate, a structural unit based on benzyl methacrylate, and a structural unit based on styrene.
- a copolymer or the like containing a structural unit based on is preferable.
- the polymer A contains 25 to 55% by mass of structural units based on a monomer having an aromatic hydrocarbon group, 20 to 35% by mass of structural units based on the first monomer, and the second A polymer containing 15 to 45% by mass of structural units based on a monomer is preferred.
- the polymer contains 70 to 90% by mass of structural units based on a monomer having an aromatic hydrocarbon group and 10 to 25% by mass of structural units based on the first monomer. is preferred.
- Polymer A may have any one of a linear structure, a branched structure, and an alicyclic structure in the side chain.
- a branched structure or an alicyclic structure can be introduced into the side chain of the polymer A by using a monomer containing a group having a branched structure in the side chain or a monomer containing a group having an alicyclic structure in the side chain. .
- the group having an alicyclic structure may be monocyclic or polycyclic
- Specific examples of the monomer containing a group having a branched structure in the side chain include isopropyl (meth)acrylate, isobutyl (meth)acrylate, (meth)acrylate ) sec-butyl acrylate, tert-butyl (meth)acrylate, isoamyl (meth)acrylate, tert-amyl (meth)acrylate, sec-amyl (meth)acrylate, 2-octyl (meth)acrylate, Examples include 3-octyl (meth)acrylate and tert-octyl (meth)acrylate.
- isopropyl (meth)acrylate, isobutyl (meth)acrylate, and tert-butyl methacrylate are preferred, and isopropyl methacrylate and tert-butyl methacrylate are more preferred.
- the monomer containing a group having an alicyclic structure in its side chain include a monomer having a monocyclic aliphatic hydrocarbon group and a monomer having a polycyclic aliphatic hydrocarbon group.
- (Meth)acrylates having an alicyclic hydrocarbon group with 5 to 20 carbon atoms are also included.
- More specific examples include (meth)acrylic acid (bicyclo[2.2.1]heptyl-2), (meth)acrylate-1-adamantyl, (meth)acrylate-2-adamantyl, (meth) 3-methyl-1-adamantyl acrylate, 3,5-dimethyl-1-adamantyl (meth)acrylate, 3-ethyladamantyl (meth)acrylate, 3-methyl-5-(meth)acrylate Ethyl-1-adamantyl, (meth)acrylate-3,5,8-triethyl-1-adamantyl, (meth)acrylate-3,5-dimethyl-8-ethyl-1-adamantyl, (meth)acrylic acid 2 -methyl-2-adamantyl, 2-ethyl-2-adamantyl (meth)acrylate, 3-hydroxy-1-adamantyl (meth)acrylate, octahydro-4,7-mentanoindene-5- (meth
- cyclohexyl (meth)acrylate, (nor)bornyl (meth)acrylate, isobornyl (meth)acrylate, 1-adamantyl (meth)acrylate, (meth)acrylic acid -2-adamantyl, fenchyl (meth)acrylate, -1-menthyl (meth)acrylate, or tricyclodecane (meth)acrylate is preferred, cyclohexyl (meth)acrylate, (nor)bornyl (meth)acrylate , isobornyl (meth)acrylate, 2-adamantyl (meth)acrylate, or tricyclodecane (meth)acrylate are more preferable.
- Polymer A may be used alone or in combination of two or more.
- a mixture of two types of polymer A containing a structural unit based on a monomer having an aromatic hydrocarbon group, or based on a monomer having an aromatic hydrocarbon group It is preferable to use a mixture of a polymer A containing structural units and a polymer A containing no structural units based on a monomer having an aromatic hydrocarbon group.
- the use ratio of the polymer A containing a structural unit based on a monomer having an aromatic hydrocarbon group is preferably 50% by mass or more, and preferably 70% by mass or more, relative to the total mass of the polymer A. It is more preferably 80% by mass or more, and more preferably 90% by mass or more.
- Polymer A is synthesized by adding a radical polymerization initiator such as benzoyl peroxide and azoisobutyronitrile to a solution of the above-described single or multiple monomers diluted with a solvent such as acetone, methyl ethyl ketone, and isopropanol. is preferably added in an appropriate amount and heated and stirred. In some cases, the synthesis is performed while part of the mixture is added dropwise to the reaction solution. After completion of the reaction, a solvent may be further added to adjust the desired concentration. As a means of synthesis, bulk polymerization, suspension polymerization, or emulsion polymerization may be used in addition to solution polymerization.
- a radical polymerization initiator such as benzoyl peroxide and azoisobutyronitrile
- the glass transition temperature Tg of polymer A is preferably 30 to 135°C.
- the Tg of the polymer A is more preferably 130° C. or lower, still more preferably 120° C. or lower, and particularly preferably 110° C. or lower.
- the polymer A having a Tg of 30° C. or more from the viewpoint of improving the edge fuse resistance. From this viewpoint, the Tg of the polymer A is more preferably 40°C or higher, still more preferably 50°C or higher, particularly preferably 60°C or higher, and most preferably 70°C or higher.
- the negative photosensitive composition layer may contain other resins as the polymer A than those described above.
- Other resins include acrylic resins, styrene-acrylic copolymers, polyurethane resins, polyvinyl alcohol, polyvinyl formal, polyamide resins, polyester resins, polyamide resins, epoxy resins, polyacetal resins, polyhydroxystyrene resins, polyimide resins, poly Benzoxazole resins, polysiloxane resins, polyethyleneimines, polyallylamines, and polyalkylene glycols.
- an alkali-soluble resin which will be described later in the description of the thermoplastic resin layer, may be used.
- the content of the polymer A is preferably 10 to 90% by mass, more preferably 20 to 80% by mass, still more preferably 30 to 70% by mass, based on the total mass of the negative photosensitive composition layer, and 40 to 60% by weight is particularly preferred. It is preferable from the viewpoint of controlling the developing time that the content of the polymer A is 90% by mass or less. On the other hand, setting the content of the polymer A to 10% by mass or more is preferable from the viewpoint of improving the edge fuse resistance.
- the photosensitive composition layer is a negative photosensitive composition layer
- the negative photosensitive composition layer preferably contains a polymerizable compound having a polymerizable group.
- the term "polymerizable compound” means a compound that polymerizes under the action of a polymerization initiator, which will be described later, and that is different from the polymer A described above.
- the polymerizable group possessed by the polymerizable compound is not particularly limited as long as it is a group involved in the polymerization reaction.
- it has an ethylenically unsaturated group such as a vinyl group, an acryloyl group, a methacryloyl group, a styryl group and a maleimide group. groups; and groups having cationic polymerizable groups such as epoxy groups and oxetane groups.
- a group having an ethylenically unsaturated group is preferable, and an acryloyl group or a methacryloyl group is more preferable.
- a compound having one or more ethylenically unsaturated groups is preferable in terms of better photosensitivity of the negative photosensitive composition layer, and two in one molecule.
- Compounds having the above ethylenically unsaturated groups are more preferred.
- the number of ethylenically unsaturated groups that the ethylenically unsaturated compound has in one molecule is preferably 6 or less, more preferably 3 or less, and 2 or less. More preferred.
- a bifunctional or trifunctional ethylenically unsaturated group having two or three ethylenically unsaturated groups in one molecule is considered to have a better balance between the photosensitivity, resolution, and releasability of the negative photosensitive composition layer. It preferably contains a saturated compound, and more preferably contains a bifunctional ethylenically unsaturated compound having two ethylenically unsaturated groups in one molecule.
- the content of the bifunctional ethylenically unsaturated compound with respect to the total weight of the polymerizable compound is preferably 20% by weight or more, preferably 40% by weight, from the viewpoint of excellent peelability with respect to the total weight of the negative photosensitive composition layer.
- the upper limit is not particularly limited, and may be 100% by mass. That is, all polymerizable compounds may be difunctional ethylenically unsaturated compounds. Moreover, as the ethylenically unsaturated compound, a (meth)acrylate compound having a (meth)acryloyl group as a polymerizable group is preferable.
- the negative photosensitive composition layer also preferably contains a polymerizable compound B1 having an aromatic ring and two ethylenically unsaturated groups.
- Polymerizable compound B1 is a bifunctional ethylenically unsaturated compound having one or more aromatic rings in one molecule among the polymerizable compounds B described above.
- the mass ratio of the content of the polymerizable compound B1 to the total mass of the polymerizable compounds is preferably 40% or more, more preferably 50% or more, from the viewpoint of better resolution. , more preferably 55% by mass or more, and particularly preferably 60% by mass or more.
- the upper limit is not particularly limited, from the viewpoint of peelability, it is, for example, 100% by mass or less, preferably 99% by mass or less, more preferably 95% by mass or less, further preferably 90% by mass or less, and particularly 85% by mass or less. preferable.
- aromatic ring of the polymerizable compound B1 examples include aromatic hydrocarbon rings such as benzene ring, naphthalene ring and anthracene ring; aromatic rings such as thiophene ring, furan ring, pyrrole ring, imidazole ring, triazole ring and pyridine ring; Heterocyclic rings and condensed rings thereof are included, with aromatic hydrocarbon rings being preferred, and benzene rings being more preferred.
- the said aromatic ring may have a substituent.
- Polymerizable compound B1 may have only one aromatic ring, or may have two or more aromatic rings.
- Polymerizable compound B1 preferably has a bisphenol structure from the viewpoint of improving resolution by suppressing swelling of the photosensitive composition layer due to a developer.
- the bisphenol structure includes, for example, a bisphenol A structure derived from bisphenol A (2,2-bis(4-hydroxyphenyl)propane) and a bisphenol derived from bisphenol F (2,2-bis(4-hydroxyphenyl)methane).
- the F structure and the bisphenol B structure derived from bisphenol B (2,2-bis(4-hydroxyphenyl)butane) are included, with the bisphenol A structure being preferred.
- Examples of the polymerizable compound B1 having a bisphenol structure include compounds having a bisphenol structure and two polymerizable groups (preferably (meth)acryloyl groups) bonded to both ends of the bisphenol structure. Both ends of the bisphenol structure and the two polymerizable groups may be directly bonded or bonded via one or more alkyleneoxy groups.
- the alkyleneoxy group added to both ends of the bisphenol structure is preferably an ethyleneoxy group or a propyleneoxy group, more preferably an ethyleneoxy group.
- the number of alkyleneoxy groups to be added to the bisphenol structure is not particularly limited, but is preferably 4 to 16, more preferably 6 to 14 per molecule.
- the polymerizable compound B1 having a bisphenol structure is described in paragraphs 0072 to 0080 of JP-A-2016-224162, and the contents described in this publication are incorporated herein.
- polymerizable compound B1 a bifunctional ethylenically unsaturated compound having a bisphenol A structure is preferable, and 2,2-bis(4-((meth)acryloxypolyalkoxy)phenyl)propane is more preferable.
- 2,2-bis(4-((meth)acryloxypolyalkoxy)phenyl)propane includes, for example, 2,2-bis(4-(methacryloxydiethoxy)phenyl)propane (FA-324M, Hitachi Chemical Co., Ltd.) ), 2,2-bis(4-(methacryloxyethoxypropoxy)phenyl)propane, 2,2-bis(4-(methacryloxypentaethoxy)phenyl)propane (BPE-500, manufactured by Shin-Nakamura Chemical Co., Ltd.) , 2,2-bis(4-(methacryloxydodecaethoxytetrapropoxy)phenyl)propane (FA-3200MY, manufactured by Hitachi Chemical Co., Ltd.), 2,2-bis(4-(methacryloxypentadecaethoxy)phenyl)propane ( BPE-1300, manufactured by Shin-Nakamura Chemical Co., Ltd.), 2,2-bis(4-(methacryloxydiethoxy
- a compound represented by the following general formula (B1) is also preferable as the polymerizable compound B1.
- R 1 and R 2 each independently represent a hydrogen atom or a methyl group.
- A represents C2H4 .
- B represents C3H6 .
- n1 and n3 are each independently an integer of 1-39, and n1+n3 is an integer of 2-40.
- n2 and n4 are each independently an integer of 0-29, and n2+n4 is an integer of 0-30.
- the arrangement of -(AO)- and -(B-O)- constitutional units may be random or block. In the case of a block, either -(AO)- or -(B-O)- may be on the side of the biphenyl group.
- n1+n2+n3+n4 is preferably 2 to 20, more preferably 2 to 16, and even more preferably 4 to 12. Also, n2+n4 is preferably 0 to 10, more preferably 0 to 4, still more preferably 0 to 2, and particularly preferably 0.
- the content of the polymerizable compound B1 is preferably 10% by mass or more, more preferably 20% by mass or more, relative to the total mass of the negative photosensitive composition layer, from the viewpoint of better resolution.
- the upper limit is not particularly limited, it is preferably 70% by mass or less, more preferably 60% by mass or less, from the viewpoint of transferability and edge fusion (a phenomenon in which the photosensitive resin oozes out from the end of the transfer member).
- the negative photosensitive composition layer may contain a polymerizable compound other than the polymerizable compound B1 described above.
- Polymerizable compounds other than polymerizable compound B1 are not particularly limited, and can be appropriately selected from known compounds. For example, a compound having one ethylenically unsaturated group in one molecule (monofunctional ethylenically unsaturated compound), a bifunctional ethylenically unsaturated compound having no aromatic ring, and a trifunctional or higher ethylenically unsaturated compound is mentioned.
- Examples of monofunctional ethylenically unsaturated compounds include ethyl (meth)acrylate, ethylhexyl (meth)acrylate, 2-(meth)acryloyloxyethyl succinate, polyethylene glycol mono(meth)acrylate, polypropylene glycol mono(meth)acrylate. , and phenoxyethyl (meth)acrylate.
- bifunctional ethylenically unsaturated compounds having no aromatic ring examples include alkylene glycol di(meth)acrylate, polyalkylene glycol di(meth)acrylate, urethane di(meth)acrylate, and trimethylolpropane diacrylate. .
- Alkylene glycol di(meth)acrylates include, for example, tricyclodecanedimethanol diacrylate (A-DCP, manufactured by Shin-Nakamura Chemical Co., Ltd.), tricyclodecanedimethanol dimethacrylate (DCP, manufactured by Shin-Nakamura Chemical Co., Ltd.), 1,9-nonanediol diacrylate (A-NOD-N, manufactured by Shin-Nakamura Chemical Co., Ltd.), 1,6-hexanediol diacrylate (A-HD-N, manufactured by Shin-Nakamura Chemical Co., Ltd.), ethylene glycol dimethacrylate , 1,10-decanediol diacrylate, and neopentyl glycol di(meth)acrylate.
- A-DCP tricyclodecanedimethanol diacrylate
- DCP tricyclodecanedimethanol dimethacrylate
- A-NOD-N 1,9-nonanediol
- Polyalkylene glycol di(meth)acrylates include, for example, polyethylene glycol di(meth)acrylate, dipropylene glycol diacrylate, tripropylene glycol diacrylate, and polypropylene glycol di(meth)acrylate.
- Urethane di(meth)acrylates include, for example, propylene oxide-modified urethane di(meth)acrylates, and ethylene oxide and propylene oxide-modified urethane di(meth)acrylates.
- trifunctional or higher ethylenically unsaturated compounds include dipentaerythritol (tri/tetra/penta/hexa) (meth) acrylate, pentaerythritol (tri/tetra) (meth) acrylate, trimethylolpropane tri(meth) Acrylate, ditrimethylolpropane tetra(meth)acrylate, trimethylolethane tri(meth)acrylate, isocyanurate tri(meth)acrylate, glycerin tri(meth)acrylate, and alkylene oxide-modified products thereof.
- (tri/tetra/penta/hexa) (meth)acrylate is a concept including tri(meth)acrylate, tetra(meth)acrylate, penta(meth)acrylate, and hexa(meth)acrylate.
- (tri/tetra)(meth)acrylate” is a concept including tri(meth)acrylate and tetra(meth)acrylate.
- the negative photosensitive composition layer preferably contains the above-described polymerizable compound B1 and a trifunctional or higher ethylenically unsaturated compound, and the above-described polymerizable compound B1 and two or more trifunctional or higher functional More preferably, it contains an ethylenically unsaturated compound.
- the negative photosensitive composition layer preferably contains the polymerizable compound B1 and two or more trifunctional ethylenically unsaturated compounds described above.
- alkylene oxide-modified trifunctional or higher ethylenically unsaturated compounds examples include caprolactone-modified (meth)acrylate compounds (KAYARAD (registered trademark) DPCA-20 manufactured by Nippon Kayaku Co., Ltd., A-9300-1CL manufactured by Shin-Nakamura Chemical Co., Ltd. etc.), alkylene oxide-modified (meth)acrylate compounds (KAYARAD RP-1040 manufactured by Nippon Kayaku, ATM-35E and A-9300 manufactured by Shin-Nakamura Chemical Co., Ltd., EBECRYL (registered trademark) 135 manufactured by Daicel Allnex, etc.), Ethoxylated glycerin triacrylate (A-GLY-9E, etc.
- the polymerizable compound which has an acid group may form an acid anhydride group.
- the polymerizable compound having an acid group examples include Aronix (registered trademark) TO-2349 (manufactured by Toagosei Co., Ltd.), Aronix (registered trademark) M-520 (manufactured by Toagosei Co., Ltd.), and Aronix (registered trademark) M-510 ( manufactured by Toagosei Co., Ltd.).
- the polymerizable compound having an acid group for example, polymerizable compounds having an acid group described in paragraphs 0025 to 0030 of JP-A-2004-239942 may be used.
- a polymerizable compound may be used individually by 1 type, and may be used 2 or more types.
- the content of the polymerizable compound is preferably 10 to 70% by mass, more preferably 15 to 70% by mass, even more preferably 20 to 70% by mass, based on the total mass of the negative photosensitive composition layer.
- the molecular weight (weight average molecular weight when having a molecular weight distribution) of the polymerizable compound (including the polymerizable compound B1) is preferably 200 to 3,000, more preferably 280 to 2,200, and 300 to 2,200. More preferred.
- the negative photosensitive composition layer also preferably contains a polymerization initiator.
- the polymerization initiator is selected according to the type of polymerization reaction, and examples thereof include thermal polymerization initiators and photopolymerization initiators.
- the polymerization initiator may be a radical polymerization initiator or a cationic polymerization initiator.
- the negative photosensitive composition layer preferably contains a photopolymerization initiator.
- a photopolymerization initiator is a compound that initiates polymerization of a polymerizable compound upon exposure to actinic rays such as ultraviolet rays, visible rays, and X-rays.
- the photopolymerization initiator is not particularly limited, and known photopolymerization initiators can be used. Examples of photopolymerization initiators include radical photopolymerization initiators and cationic photopolymerization initiators, and radical photopolymerization initiators are preferred.
- photoradical polymerization initiators examples include photopolymerization initiators having an oxime ester structure, photopolymerization initiators having an ⁇ -aminoalkylphenone structure, photopolymerization initiators having an ⁇ -hydroxyalkylphenone structure, and acylphosphine oxide. structure and a photopolymerization initiator having an N-phenylglycine structure.
- the negative photosensitive composition layer contains 2,4,5-triarylimidazole dimer as a photoradical polymerization initiator. It preferably contains at least one selected from the group consisting of derivatives thereof and derivatives thereof.
- the two 2,4,5-triarylimidazole structures in the 2,4,5-triarylimidazole dimer and its derivative may be the same or different.
- 2,4,5-triarylimidazole dimer examples include, for example, 2-(o-chlorophenyl)-4,5-diphenylimidazole dimer, 2-(o-chlorophenyl)-4,5-di (Methoxyphenyl)imidazole dimer, 2-(o-fluorophenyl)-4,5-diphenylimidazole dimer, 2-(o-methoxyphenyl)-4,5-diphenylimidazole dimer, and 2- (p-Methoxyphenyl)-4,5-diphenylimidazole dimer.
- radical photopolymerization initiator for example, polymerization initiators described in paragraphs 0031 to 0042 of JP-A-2011-95716 and paragraphs 0064-0081 of JP-A-2015-14783 may be used.
- photoradical polymerization initiators examples include ethyl dimethylaminobenzoate (DBE, CAS No. 10287-53-3), benzoin methyl ether, anisyl (p,p'-dimethoxybenzyl), TAZ-110 (trade name: Midori Chemical Co., Ltd.), benzophenone, 4,4′-bis(diethylamino)benzophenone, TAZ-111 (trade name: Midori Chemical Co., Ltd.), Irgacure OXE01, OXE02, OXE03, OXE04 (manufactured by BASF), Omnirad 651 and 369 (products Name: IGM Resins B.V.), and 2,2'-bis(2-chlorophenyl)-4,4',5,5'-tetraphenyl-1,2'-biimidazole (Tokyo Chemical Industry Co., Ltd. made).
- DBE ethyl dimethylaminobenzoate
- radical photopolymerization initiators examples include 1-[4-(phenylthio)]-1,2-octanedione-2-(O-benzoyloxime) (trade name: IRGACURE (registered trademark) OXE-01).
- a photocationic polymerization initiator is a compound that generates an acid upon receiving an actinic ray.
- the photocationic polymerization initiator is preferably a compound that responds to an actinic ray with a wavelength of 300 nm or more, preferably 300 to 450 nm, and generates an acid, but its chemical structure is not limited.
- the sensitizer can be used.
- the photocationic polymerization initiator is preferably a photocationic polymerization initiator that generates an acid with a pKa of 4 or less, more preferably a photocationic polymerization initiator that generates an acid with a pKa of 3 or less, and an acid with a pKa of 2 or less.
- Photocationic polymerization initiators generated are particularly preferred.
- the lower limit of pKa is not particularly defined, it is preferably -10.0 or more, for example.
- photocationic polymerization initiators examples include ionic photocationic polymerization initiators and nonionic photocationic polymerization initiators.
- Ionic photocationic polymerization initiators include, for example, onium salt compounds such as diaryliodonium salts and triarylsulfonium salts, and quaternary ammonium salts.
- the ionic photocationic polymerization initiator the ionic photocationic polymerization initiators described in paragraphs 0114 to 0133 of JP-A-2014-085643 may be used.
- nonionic photocationic polymerization initiators include trichloromethyl-s-triazines, diazomethane compounds, imidosulfonate compounds, and oximesulfonate compounds.
- trichloromethyl-s-triazines, diazomethane compounds and imidosulfonate compounds compounds described in paragraphs 0083 to 0088 of JP-A-2011-221494 may be used.
- oxime sulfonate compound compounds described in paragraphs 0084 to 0088 of WO 2018/179640 may be used.
- the negative photosensitive composition layer preferably contains a photoradical polymerization initiator, and more preferably contains at least one selected from the group consisting of 2,4,5-triarylimidazole dimers and derivatives thereof. preferable.
- a polymerization initiator may be used individually by 1 type, and may be used 2 or more types.
- the content of the polymerization initiator (preferably a photopolymerization initiator) is not particularly limited, but is preferably 0.1% by mass or more, and 0.5% by mass or more, based on the total mass of the negative photosensitive composition layer. More preferably, 1.0% by mass or more is even more preferable.
- the upper limit is not particularly limited, it is preferably 20% by mass or less, more preferably 15% by mass or less, and more preferably 10% by mass or less, relative to the total mass of the negative photosensitive composition layer.
- the photosensitive composition layer has a maximum absorption wavelength of 450 nm or more in a wavelength range of 400 to 780 nm during color development, from the viewpoints of visibility of exposed and unexposed areas, pattern visibility after development, and resolution.
- a dye also referred to as “dye N”
- the adhesion to the adjacent layer for example, the water-soluble resin layer
- the resolution is improved.
- a dye in a colored state is decolored by an acid, a base, or a radical
- a dye in a decolored state is It may mean any one of a mode in which a color is developed by an acid, a base, or a radical, and a mode in which a dye in a coloring state changes to a coloring state of another hue.
- the dye N may be a compound that changes from a decolored state to develop color upon exposure, or a compound that changes from a colored state to decolor upon exposure.
- it may be a dye that changes the state of coloring or decoloring due to the action of an acid, a base, or a radical generated in the photosensitive composition layer by exposure, and the photosensitive composition is affected by an acid, a base, or a radical. It may be a dye that changes its coloring or decoloring state by changing the state (for example, pH) in the layer. Moreover, it may be a dye that changes its coloring or decoloring state by being directly stimulated by an acid, a base, or a radical without being exposed to light.
- the dye N is preferably a dye whose maximum absorption wavelength is changed by acid or radicals, more preferably a dye whose maximum absorption wavelength is changed by radicals. .
- the photosensitive composition layer is a negative photosensitive composition layer
- the negative photosensitive composition layer from the viewpoint of the visibility and resolution of the exposed and unexposed areas, has a maximum It is preferable to contain both a dye whose absorption wavelength changes and a photoradical polymerization initiator.
- the dye N is preferably a dye that develops color with an acid, a base, or a radical.
- a photoradical polymerization initiator, a photocationic polymerization initiator (photoacid generator), or a photobase generator is added to the photosensitive composition layer, and photoradical polymerization is initiated after exposure.
- a radical-reactive dye, an acid-reactive dye, or a base-reactive dye develops color by radicals, acids, or bases generated from the agent, photocationic polymerization initiator, or photobase generator. be done.
- the dye N preferably has a maximum absorption wavelength of 550 nm or more in the wavelength range of 400 to 780 nm during color development, more preferably 550 to 700 nm. ⁇ 650 nm is more preferred. Further, the dye N may have only one maximum absorption wavelength in the wavelength range of 400 to 780 nm during color development, or may have two or more. When the dye N has two or more maximum absorption wavelengths in the wavelength range of 400 to 780 nm during color development, the maximum absorption wavelength with the highest absorbance among the two or more maximum absorption wavelengths may be 450 nm or more.
- the maximum absorption wavelength of Dye N was measured in the air atmosphere using a spectrophotometer: UV3100 (manufactured by Shimadzu Corporation) in the range of 400 to 780 nm. and detecting the wavelength (maximum absorption wavelength) at which the light intensity becomes minimum.
- Examples of dyes that develop or decolorize upon exposure include leuco compounds.
- Examples of dyes that are decolorized by exposure include leuco compounds, diarylmethane-based dyes, oxazine-based dyes, xanthene-based dyes, iminonaphthoquinone-based dyes, azomethine-based dyes, and anthraquinone-based dyes.
- As the dye N a leuco compound is preferable from the viewpoint of the visibility of the exposed area and the non-exposed area.
- leuco compounds examples include leuco compounds having a triarylmethane skeleton (triarylmethane dyes), leuco compounds having a spiropyran skeleton (spiropyran dyes), leuco compounds having a fluorane skeleton (fluoran dyes), and diarylmethane skeletons.
- Leuco compounds can be mentioned.
- triarylmethane-based dyes or fluoran-based dyes are preferable, and leuco compounds having a triphenylmethane skeleton (triphenylmethane-based dyes) or fluoran-based dyes are more preferable.
- the leuco compound preferably has a lactone ring, a sultine ring, or a sultone ring from the viewpoint of the visibility of the exposed area and the non-exposed area.
- the lactone ring, sultine ring, or sultone ring of the leuco compound is reacted with a radical generated from a radical photopolymerization initiator or an acid generated from a photocationic polymerization initiator to change the leuco compound into a ring-closed state.
- the color can be developed by changing the leuco compound into a ring-opened state.
- the leuco compound is preferably a compound that has a lactone ring, a sultine ring, or a sultone ring and develops a color due to the opening of the lactone ring, sultine ring, or sultone ring by a radical or an acid.
- a compound that develops color by opening the lactone ring with an acid is more preferable.
- dye N examples include the following dyes and leuco compounds. Specific examples of dyes among dyes N include brilliant green, ethyl violet, methyl green, crystal violet, basic fuchsine, methyl violet 2B, quinaldine red, rose bengal, methanil yellow, thymolsulfophtalein, xylenol blue, methyl Orange, Paramethyl Red, Congo Red, Benzopurpurin 4B, ⁇ -Naphthyl Red, Nile Blue 2B, Nile Blue A, Methyl Violet, Malachite Green, Parafuchsin, Victoria Pure Blue-Naphthalene Sulfonate, Victoria Pure Blue BOH (protective Tsuchiya Chemical Industry Co., Ltd.), Oil Blue #603 (Orient Chemical Industry Co., Ltd.), Oil Pink #312 (Orient Chemical Industry Co., Ltd.), Oil Red 5B (Orient Chemical Industry Co., Ltd.), Oil Scarlet #308 (Orient Chemical Industry Co., Ltd.) company), Oil Red OG (Orient Chemical
- leuco compound of the dye N include p,p′,p′′-hexamethyltriaminotriphenylmethane (leuco crystal violet), Pergascript Blue SRB (manufactured by Ciba-Geigy), crystal violet lactone, malachite green lactone, benzoyl leucomethylene blue, 2-(N-phenyl-N-methylamino)-6-(Np-tolyl-N-ethyl)aminofluorane, 2-anilino-3-methyl-6-(N-ethyl-p -toluidino)fluorane, 3,6-dimethoxyfluorane, 3-(N,N-diethylamino)-5-methyl-7-(N,N-dibenzylamino)fluorane, 3-(N-cyclohexyl-N-methyl amino)-6-methyl-7-anilinofluorane, 3-(N,N-diethylamino)-6-
- Dye N is preferably a dye whose maximum absorption wavelength is changed by radicals from the viewpoint of visibility of exposed and unexposed areas, pattern visibility after development, and resolution, and is a dye that develops color by radicals. It is more preferable to have Preferred dyes N are leuco crystal violet, crystal violet lactone, brilliant green, or victoria pure blue-naphthalene sulfonate.
- the pigment N may be used singly or in combination of two or more.
- the content of dye N is 0.1% by mass or more with respect to the total mass of the photosensitive composition layer, from the viewpoints of visibility of exposed and unexposed areas, pattern visibility after development, and resolution. is preferred, 0.1 to 10% by mass is more preferred, 0.1 to 5% by mass is even more preferred, and 0.1 to 1% by mass is particularly preferred.
- the content of the dye N means the content of the dye when all the dyes N contained in the total weight of the photosensitive composition layer are in a colored state.
- a method for quantifying the content of dye N will be described below using a dye that develops color by radicals as an example.
- a solution of 0.001 g and 0.01 g of dye in 100 mL of methyl ethyl ketone is prepared.
- a radical photopolymerization initiator Irgacure OXE01 (trade name, BASF Japan Co., Ltd.) is added to each of the obtained solutions, and radicals are generated by irradiation with light of 365 nm to make all the dyes develop colors. After that, the absorbance of each solution having a liquid temperature of 25° C.
- the absorbance of the solution in which all the dyes are developed is measured in the same manner as described above except that 3 g of the photosensitive composition layer is dissolved in methyl ethyl ketone instead of the dyes. From the absorbance of the obtained solution containing the photosensitive composition layer, the content of the dye contained in the photosensitive composition layer is calculated based on the calibration curve. 3 g of the photosensitive composition layer is the same as 3 g of the total solid content in the photosensitive resin composition.
- the photosensitive composition layer is a negative photosensitive composition layer, it preferably contains a thermally crosslinkable compound from the viewpoint of the strength of the resulting cured film and the adhesiveness of the resulting uncured film.
- a thermally crosslinkable compound having an ethylenically unsaturated group which will be described later, is not treated as a polymerizable compound, but as a thermally crosslinkable compound.
- Thermally crosslinkable compounds include methylol compounds and blocked isocyanate compounds. Among them, a blocked isocyanate compound is preferable from the viewpoint of the strength of the cured film to be obtained and the adhesiveness of the uncured film to be obtained.
- the blocked isocyanate compound reacts with the hydroxy group and the carboxy group, for example, when the resin and/or the polymerizable compound has at least one of the hydroxy group and the carboxy group, the hydrophilicity of the formed film is lowered. , the function tends to be enhanced when a film obtained by curing a negative photosensitive composition layer is used as a protective film.
- the blocked isocyanate compound refers to "a compound having a structure in which the isocyanate group of isocyanate is protected (so-called masked) with a blocking agent".
- the dissociation temperature of the blocked isocyanate compound is not particularly limited, it is preferably 100 to 160°C, more preferably 130 to 150°C.
- the dissociation temperature of the blocked isocyanate means "the temperature of the endothermic peak associated with the deprotection reaction of the blocked isocyanate as measured by DSC (Differential Scanning Calorimetry) analysis using a differential scanning calorimeter".
- DSC Different Scanning Calorimetry
- a differential scanning calorimeter for example, a differential scanning calorimeter (model: DSC6200) manufactured by Seiko Instruments Inc. can be preferably used. However, the differential scanning calorimeter is not limited to this.
- the blocking agent having a dissociation temperature of 100 to 160° C. is preferably at least one selected from oxime compounds from the viewpoint of storage stability.
- the blocked isocyanate compound preferably has an isocyanurate structure from the viewpoint of, for example, improving the brittleness of the film and improving the adhesion to the transferred material.
- a blocked isocyanate compound having an isocyanurate structure can be obtained, for example, by converting hexamethylene diisocyanate into an isocyanurate for protection.
- a compound having an oxime structure using an oxime compound as a blocking agent tends to have a dissociation temperature within a preferable range and produces less development residue than a compound having no oxime structure. It is preferable from the viewpoint that it is easy to
- the blocked isocyanate compound may have a polymerizable group.
- the polymerizable group is not particularly limited, and any known polymerizable group can be used, and a radically polymerizable group is preferred.
- Polymerizable groups include ethylenically unsaturated groups such as (meth)acryloxy groups, (meth)acrylamide groups, and styryl groups, and groups having epoxy groups such as glycidyl groups. Among them, the polymerizable group is preferably an ethylenically unsaturated group, more preferably a (meth)acryloxy group, and still more preferably an acryloxy group.
- a commercial item can be used as a block isocyanate compound.
- blocked isocyanate compounds include Karenz (registered trademark) AOI-BM, Karenz (registered trademark) MOI-BM, Karenz (registered trademark) MOI-BP, etc. (manufactured by Showa Denko KK), block type Duranate series (eg, Duranate (registered trademark) TPA-B80E, Duranate (registered trademark) WT32-B75P, etc., manufactured by Asahi Kasei Chemicals).
- the compound of the following structure can also be used as a blocked isocyanate compound.
- the thermally crosslinkable compounds may be used singly or in combination of two or more.
- the content of the heat-crosslinkable compound is preferably 1 to 50% by mass, more preferably 5 to 30% by mass, based on the total mass of the photosensitive composition layer. preferable.
- the photosensitive composition layer may contain known additives, if necessary, in addition to the above components.
- additives include radical polymerization inhibitors, sensitizers, plasticizers, heterocyclic compounds (triazole, etc.), benzotriazoles, carboxybenzotriazoles, pyridines (isonicotinamide, etc.), purine bases (adenine, etc.), ), and surfactants.
- Each additive may be used individually by 1 type, and may be used 2 or more types.
- the photosensitive composition layer may contain a radical polymerization inhibitor.
- radical polymerization inhibitors include thermal polymerization inhibitors described in paragraph 0018 of Japanese Patent No. 4502784. Among them, phenothiazine, phenoxazine and 4-methoxyphenol are preferred.
- Other radical polymerization inhibitors include naphthylamine, cuprous chloride, N-nitrosophenylhydroxyamine aluminum salt, and diphenylnitrosamine. In order not to impair the sensitivity of the photosensitive composition layer, it is preferred to use N-nitrosophenylhydroxyamine aluminum salt as a radical polymerization inhibitor.
- a preferred content of the radical polymerization inhibitor is the same as in the first embodiment.
- benzotriazoles include 1,2,3-benzotriazole, 1-chloro-1,2,3-benzotriazole, bis(N-2-ethylhexyl)aminomethylene-1,2,3-benzotriazole, bis(N-2-ethylhexyl)aminomethylene-1,2,3-tolyltriazole, bis(N-2-hydroxyethyl)aminomethylene-1,2,3-benzotriazole and the like.
- Carboxybenzotriazoles include, for example, 4-carboxy-1,2,3-benzotriazole, 5-carboxy-1,2,3-benzotriazole, N-(N,N-di-2-ethylhexyl)aminomethylene Carboxybenzotriazole, N-(N,N-di-2-hydroxyethyl)aminomethylene carboxybenzotriazole, N-(N,N-di-2-ethylhexyl)aminoethylene carboxybenzotriazole and the like.
- carboxybenzotriazoles commercially available products such as CBT-1 (manufactured by Johoku Kagaku Kogyo Co., Ltd., trade name) can be used.
- benzotriazoles include 1,2,3-benzotriazole, 1-chloro-1,2,3-benzotriazole, bis(N-2-ethylhexyl)aminomethylene-1,2,3-benzotriazole, bis(N-2-ethylhexyl)aminomethylene-1,2,3-tolyltriazole, bis(N-2-hydroxyethyl)aminomethylene-1,2,3-benzotriazole and the like.
- Carboxybenzotriazoles include, for example, 4-carboxy-1,2,3-benzotriazole, 5-carboxy-1,2,3-benzotriazole, N-(N,N-di-2-ethylhexyl)aminomethylene Carboxybenzotriazole, N-(N,N-di-2-hydroxyethyl)aminomethylene carboxybenzotriazole, N-(N,N-di-2-ethylhexyl)aminoethylene carboxybenzotriazole and the like.
- carboxybenzotriazoles commercially available products such as CBT-1 (manufactured by Johoku Kagaku Kogyo Co., Ltd., trade name) can be used.
- the total content of benzotriazoles and carboxybenzotriazoles is preferably 0.01 to 3% by mass, more preferably 0.05 to 1% by mass, based on the total mass of the photosensitive composition layer. preferable.
- the content is 0.01% by mass or more, the storage stability of the photosensitive composition layer is more excellent.
- the content is 3% by mass or less, the maintenance of sensitivity and suppression of decolorization of the dye are more excellent.
- the photosensitive composition layer may contain a sensitizer.
- the sensitizer is not particularly limited, and known sensitizers, dyes and pigments can be used.
- Sensitizers include, for example, dialkylaminobenzophenone compounds, pyrazoline compounds, anthracene compounds, coumarin compounds, xanthone compounds, thioxanthone compounds, acridone compounds, oxazole compounds, benzoxazole compounds, thiazole compounds, benzothiazole compounds, triazole compounds (e.g., 1,2,4-triazoles), stilbene compounds, triazine compounds, thiophene compounds, naphthalimide compounds, triarylamine compounds, and aminoacridine compounds.
- a sensitizer may be used alone or in combination of two or more.
- the content of the sensitizer can be appropriately selected depending on the purpose, but from the viewpoint of improving the sensitivity to the light source and improving the curing speed due to the balance between the polymerization speed and the chain transfer. , preferably 0.01 to 5% by mass, more preferably 0.05 to 1% by mass, based on the total mass of the photosensitive composition layer.
- the photosensitive composition layer may contain at least one selected from the group consisting of plasticizers and heterocyclic compounds.
- Plasticizers and heterocyclic compounds include compounds described in paragraphs 0097-0103 and 0111-0118 of WO2018/179640.
- the photosensitive composition layer preferably contains a surfactant.
- a surfactant the same surfactant as in the first embodiment can be used, and the preferred aspects are also the same.
- the photosensitive composition layer contains metal oxide particles, antioxidants, dispersants, acid multipliers, development accelerators, conductive fibers, ultraviolet absorbers, thickeners, cross-linking agents, and organic or inorganic precipitates. It may further contain known additives such as inhibitors. Additives contained in the photosensitive composition layer are described in paragraphs 0165 to 0184 of JP-A-2014-085643, and the contents of this publication are incorporated herein.
- the water content in the photosensitive composition layer is preferably 0.01 to 1.0% by mass, more preferably 0.05 to 0.5% by mass, from the viewpoint of improving reliability and lamination properties.
- the layer thickness (film thickness) of the photosensitive composition layer is generally 0.1 to 300 ⁇ m, preferably 0.2 to 100 ⁇ m, more preferably 0.5 to 50 ⁇ m, and further preferably 0.5 to 15 ⁇ m.
- 0.5 to 10 ⁇ m is particularly preferred, and 0.5 to 8 ⁇ m is most preferred.
- the thickness is preferably 0.5 to 5 ⁇ m, more preferably 0.5 to 4 ⁇ m, even more preferably 0.5 to 3 ⁇ m.
- the transmittance of the photosensitive composition layer for light with a wavelength of 365 nm is preferably 10% or more, more preferably 30% or more, and even more preferably 50% or more.
- the upper limit is not particularly limited, 99.9% or less is preferable.
- the photosensitive composition layer may contain a certain amount of impurities.
- impurities include sodium, potassium, magnesium, calcium, iron, manganese, copper, aluminum, titanium, chromium, cobalt, nickel, zinc, tin, halogens and ions thereof.
- halide ions, sodium ions, and potassium ions are likely to be mixed as impurities, so the following contents are preferable.
- the content of impurities in the photosensitive composition layer is preferably 80 ppm or less, more preferably 10 ppm or less, and even more preferably 2 ppm or less on a mass basis.
- the content of impurities can be 1 ppb or more, and may be 0.1 ppm or more, on a mass basis.
- the amount of impurities can be made within the above range.
- Impurities can be quantified by known methods such as ICP (Inductively Coupled Plasma) emission spectroscopy, atomic absorption spectroscopy, and ion chromatography.
- ICP Inductively Coupled Plasma
- the content of compounds such as benzene, formaldehyde, trichlorethylene, 1,3-butadiene, carbon tetrachloride, chloroform, N,N-dimethylformamide, N,N-dimethylacetamide, and hexane in the photosensitive composition layer is small. is preferred.
- the content of these compounds with respect to the total mass of the photosensitive composition layer is preferably 100 ppm or less, more preferably 20 ppm or less, and even more preferably 4 ppm or less, based on mass.
- the lower limit can be 10 ppb or more, and can be 100 ppb or more based on the total weight of the photosensitive composition layer.
- the content of these compounds can be suppressed in the same manner as the metal impurities described above. Moreover, it can quantify by a well-known measuring method.
- the water content in the photosensitive composition layer is preferably 0.01 to 1.0% by mass, more preferably 0.05 to 0.5% by mass, from the viewpoint of improving reliability and lamination properties.
- the photosensitive composition layer may be a colored resin layer containing a pigment.
- a cover glass with a black frame-shaped light-shielding layer formed on the periphery of the back surface of a transparent glass substrate or the like is attached to the liquid crystal display window.
- a colored resin layer may be used to form such a light shielding layer.
- the pigment may be appropriately selected according to the desired hue, and may be selected from black pigments, white pigments, and chromatic pigments other than black and white. Among them, when forming a black pattern, a black pigment is preferably selected as the pigment.
- black pigment a known black pigment (organic pigment, inorganic pigment, etc.) can be appropriately selected as long as it does not impair the effects of the present invention.
- black pigments include, for example, carbon black, titanium oxide, titanium carbide, iron oxide, and graphite, and carbon black is particularly preferred.
- carbon black from the viewpoint of surface resistance, carbon black having at least a part of the surface coated with a resin is preferable.
- the number average particle diameter of the black pigment is preferably 0.001 to 0.1 ⁇ m, more preferably 0.01 to 0.08 ⁇ m.
- the particle size refers to the diameter of a circle obtained by determining the area of a pigment particle from a photographic image of the pigment particle taken with an electron microscope and considering a circle having the same area as the area of the pigment particle. is an average value obtained by obtaining the above particle size for 100 arbitrary particles and averaging the obtained 100 particle sizes.
- White pigments described in paragraphs 0015 and 0114 of JP-A-2005-007765 can be used as pigments other than black pigments.
- inorganic pigments are preferably titanium oxide, zinc oxide, lithopone, light calcium carbonate, white carbon, aluminum oxide, aluminum hydroxide, or barium sulfate, and more preferably titanium oxide or zinc oxide. Preferred, and more preferred is titanium oxide.
- titanium oxide rutile-type or anatase-type titanium oxide is more preferable, and rutile-type titanium oxide is particularly preferable.
- the surface of titanium oxide may be subjected to silica treatment, alumina treatment, titania treatment, zirconia treatment, or organic substance treatment, or may be subjected to two or more treatments.
- the catalytic activity of titanium oxide is suppressed, and heat resistance, fade resistance, and the like are improved.
- the surface treatment of the titanium oxide surface is preferably at least one of alumina treatment and zirconia treatment, and particularly preferably both alumina treatment and zirconia treatment.
- the photosensitive composition layer when the photosensitive composition layer is a colored resin layer, from the viewpoint of transferability, the photosensitive composition layer preferably further contains a chromatic pigment other than the black pigment and the white pigment.
- a chromatic pigment when a chromatic pigment is included, the particle size of the chromatic pigment is preferably 0.1 ⁇ m or less, more preferably 0.08 ⁇ m or less, from the viewpoint of better dispersibility.
- chromatic pigments include Victoria Pure Blue BO (Color Index (hereinafter C.I.) 42595), Auramine (C.I. 41000), Fat Black HB (C.I. 26150), and Monolite. ⁇ Yellow GT (C.I. Pigment Yellow 12), Permanent Yellow GR (C.I. Pigment Yellow 17), Permanent Yellow HR (C.I.
- Pigment Yellow 83 Permanent Carmine FBB (C) Pigment Red 146), Hoster Balm Red ESB (C.I. Pigment Violet 19), Permanent Ruby FBH (C.I. Pigment Red 11), Fastel Pink B Spra (C.I. Pigment Red 81), Monastral Fast Blue (C.I. Pigment Blue 15), Monolite Fast Black B (C.I. Pigment Black 1) and Carbon, C.I. I. Pigment Red 97, C.I. I. Pigment Red 122, C.I. I. Pigment Red 149, C.I. I. Pigment Red 168, C.I. I. Pigment Red 177, C.I. I. Pigment Red 180, C.I. I. Pigment Red 192, C.I. I.
- C.I. I. Pigment Red 177 is preferred.
- the content of the pigment is preferably more than 3% by mass and 40% by mass or less, and more than 3% by mass and 35% by mass or less with respect to the total mass of the photosensitive composition layer. More preferably, it is more than 5% by mass and 35% by mass or less, and particularly preferably 10% by mass or more and 35% by mass or less.
- the content of pigments other than black pigments is preferably 30% by mass or less with respect to black pigments, and 1 to 20 % by mass is more preferred, and 3 to 15% by mass is even more preferred.
- the black pigment preferably carbon black
- the dispersion liquid may be prepared by adding a mixture obtained by previously mixing a black pigment and a pigment dispersant to an organic solvent (or vehicle) and dispersing the mixture with a dispersing machine.
- the pigment dispersant may be selected according to the pigment and solvent, and commercially available dispersants can be used, for example.
- the vehicle refers to the part of the medium in which the pigment is dispersed when it is made into a pigment dispersion, and is a liquid binder component that holds the black pigment in a dispersed state, and a solvent component that dissolves and dilutes the binder component. (organic solvent) and
- dispersants include urethane-based dispersants such as polyurethane, polycarboxylic acid esters such as polyacrylate, unsaturated polyamide, polycarboxylic acid, polycarboxylic acid (partial) amine salt, polycarboxylic acid ammonium salt, polycarboxylic acid Alkylamine salts, polysiloxanes, long-chain polyaminoamide phosphates, hydroxyl group-containing polycarboxylic acid esters, modified products thereof, amides formed by the reaction of poly(lower alkyleneimine) with polyesters having free carboxyl groups, and Oily dispersants such as salts thereof, (meth)acrylic acid-styrene copolymer, (meth)acrylic acid-(meth)acrylic acid ester copolymer, styrene-maleic acid copolymer, polyvinyl alcohol, polyvinylpyrrolidone water-soluble resins such as water-soluble polymer compounds, polyester-based compounds,
- Preferred dispersants include, for example, basic polymer-type dispersants.
- Basic polymeric dispersants include, for example, polymers containing nitrogen atoms. The nitrogen atom may be contained in the main chain of the polymer, may be contained in the side chain of the polymer, or may be contained in the main chain and side chains of the polymer.
- the basic polymer-type dispersant is preferably a polymer containing a nitrogen atom in its side chain. Since the surface of carbon black is generally acidic, a basic polymer-type dispersant is particularly preferable as the dispersant when carbon black is used as the pigment.
- Polymers containing nitrogen atoms include, for example, primary amino groups, secondary amino groups, tertiary amino groups, quaternary ammonium bases and nitrogen-containing Examples include polymers containing at least one atomic group selected from the group consisting of heterocyclic groups. For example, polymers containing quaternary ammonium bases are preferred.
- the atomic group is preferably introduced into the side chain of the polymer. For example, a polymer containing at least one atomic group selected from the group consisting of a primary amino group, a secondary amino group, a tertiary amino group, a quaternary ammonium base and a nitrogen-containing heterocyclic group in the side chain.
- Counter ions for the quaternary ammonium cation in the quaternary ammonium base include, for example, carboxylate ions.
- Carboxylate ions include, for example, aliphatic carboxylate ions and aromatic carboxylate ions.
- a polymer containing a nitrogen atom is preferably a polymer containing structural units derived from styrene and structural units derived from a maleimide derivative. is more preferred.
- a maleimide derivative has a structure in which at least one hydrogen atom of maleimide is substituted with a substituent.
- the maleimide derivative includes, for example, at least one atomic group selected from the group consisting of primary amino groups, secondary amino groups, tertiary amino groups, quaternary ammonium bases and nitrogen-containing heterocyclic groups. and maleimide derivatives containing The maleimide derivative is preferably a maleimide derivative containing a quaternary ammonium base.
- the dispersant may be a commercially available dispersant, such as BYK-2012 (BYK-Chemie Japan Co., Ltd.).
- the composition may contain a dispersing aid (also referred to as a pigment dispersing aid) in addition to the pigment.
- Dispersing aids may be selected from known dispersing aids.
- Dispersing aids include, for example, compounds having organic dye residues. Examples of organic dyes include phthalocyanine-based pigments, diketopyrrolopyrrole-based pigments, anthraquinone-based pigments, quinacridone-based pigments, dioxazine-based pigments, perinone-based pigments, perylene-based pigments, thiazineindigo-based pigments, triazine-based pigments, benzimidazo Ron-based pigments, indole-based pigments such as benzoisoindole, isoindoline-based pigments, isoindolinone-based pigments, quinophthalone-based pigments, naphthol-based pigments, threne-based pigments, metal complex-based pigments,
- a compound having an organic dye residue may have an acidic substituent, a basic substituent or a neutral substituent.
- Acidic substituents include, for example, sulfo groups, carboxy groups and phosphate groups.
- Basic substituents include, for example, sulfonamide groups and amino groups.
- Neutral substituents include, for example, phenyl groups and phthalimidoalkyl groups. Aspects of the dispersing aid may be selected from items described in paragraphs [0067] to [0084] of JP-A-2021-012355.
- Preferred dispersing aids include, for example, compounds having phthalocyanine residues.
- the dispersing aid is preferably a phthalocyanine pigment derivative or a salt thereof having an acidic substituent, and at least one acidic substituent selected from the group consisting of a sulfo group, a carboxyl group and a phosphoric acid group. or a salt thereof, and more preferably a phthalocyanine pigment derivative having a sulfo group or a salt thereof.
- Phthalocyanine pigment derivatives are described, for example, in JP-A-2007-226161, WO-A-2016/163351, JP-A-2017-165820 and JP-A-5753266. These publications are incorporated herein by reference.
- the disperser is not particularly limited, and includes known dispersers such as kneaders, roll mills, attritors, super mills, dissolvers, homomixers, and sand mills. Furthermore, it may be finely pulverized using frictional force by mechanical grinding. Regarding the dispersing machine and the fine pulverization, reference can be made to the description in "Encyclopedia of Pigment” (Kunizo Asakura, 1st edition, Asakura Shoten, 2000, pp. 438, 310).
- the transfer film may have a thermoplastic resin layer.
- the thermoplastic resin layer is usually arranged between the temporary support and the photosensitive composition layer.
- the thermoplastic resin layer contains resin.
- the resin includes a thermoplastic resin in part or in whole. That is, in one aspect, it is also preferable that the resin of the thermoplastic resin layer is a thermoplastic resin.
- the thermoplastic resin is preferably an alkali-soluble resin.
- alkali-soluble resins include acrylic resins, polystyrene resins, styrene-acrylic copolymers, polyurethane resins, polyvinyl alcohol, polyvinyl formal, polyamide resins, polyester resins, polyamide resins, epoxy resins, polyacetal resins, and polyhydroxystyrene resins. , polyimide resins, polybenzoxazole resins, polysiloxane resins, polyethyleneimines, polyallylamines, and polyalkylene glycols.
- an acrylic resin is preferable from the viewpoint of developability and adhesion to adjacent layers.
- the acrylic resin is at least selected from the group consisting of structural units derived from (meth)acrylic acid, structural units derived from (meth)acrylic acid esters, and structural units derived from (meth)acrylic acid amide. It means a resin having one kind of constitutional unit.
- the acrylic resin the total content of structural units derived from (meth)acrylic acid, structural units derived from (meth)acrylic acid ester, and structural units derived from (meth)acrylic acid amide is the total content of the acrylic resin. It is preferably 50% by mass or more based on the mass. Among them, the total content of structural units derived from (meth) acrylic acid and structural units derived from (meth) acrylic acid ester is preferably 30 to 100% by mass, based on the total mass of the acrylic resin, and 50 to 100% by mass is more preferred.
- the alkali-soluble resin is preferably a polymer having an acid group.
- the acid group includes a carboxy group, a sulfo group, a phosphoric acid group, and a phosphonic acid group, with the carboxy group being preferred.
- the alkali-soluble resin is more preferably an alkali-soluble resin having an acid value of 60 mgKOH/g or more, and more preferably a carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more.
- the upper limit of the acid value of the alkali-soluble resin is not particularly limited, it is preferably 300 mgKOH/g or less, more preferably 250 mgKOH/g or less, still more preferably 200 mgKOH/g or less, and particularly preferably 150 mgKOH/g or less.
- the carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more is not particularly limited, and can be appropriately selected from known resins and used.
- an alkali-soluble resin that is a carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more, described in paragraphs 0033 to 0052 of JP-A-2010-237589 A carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more among the polymers, and a carboxy group-containing acrylic resin having an acid value of 60 mgKOH/g or more among the binder polymers described in paragraphs 0053 to 0068 of JP-A-2016-224162.
- the copolymerization ratio of the structural unit having a carboxy group in the carboxy group-containing acrylic resin is preferably 5 to 50% by mass, more preferably 10 to 40% by mass, and 12 to 30% by mass with respect to the total mass of the acrylic resin. is more preferred.
- an acrylic resin having a structural unit derived from (meth)acrylic acid is particularly preferable from the viewpoint of developability and adhesion to an adjacent layer.
- the alkali-soluble resin may have a reactive group.
- the reactive group may be any group capable of addition polymerization, and includes an ethylenically unsaturated group; a polycondensable group such as a hydroxy group and a carboxyl group; a polyaddition reactive group such as an epoxy group and a (blocked) isocyanate group. mentioned.
- the weight average molecular weight (Mw) of the alkali-soluble resin is preferably 1,000 or more, more preferably 10,000 to 100,000, and even more preferably 20,000 to 50,000.
- Alkali-soluble resin may be used individually by 1 type, and may be used 2 or more types.
- the content of the alkali-soluble resin is preferably 10 to 99% by mass, more preferably 20 to 90% by mass, based on the total mass of the thermoplastic resin layer, from the viewpoint of developability and adhesion to adjacent layers. 40 to 80 mass % is more preferred, and 50 to 75 mass % is particularly preferred.
- thermoplastic resin layer has a maximum absorption wavelength of 450 nm or more in a wavelength range of 400 to 780 nm during color development, and contains a dye whose maximum absorption wavelength is changed by an acid, a base, or a radical (also simply referred to as "dye B"). is preferred.
- Preferred embodiments of the dye B are the same as preferred embodiments of the dye N described above, except for the points described later.
- Dye B is preferably a dye whose maximum absorption wavelength changes with acid or radicals, more preferably a dye whose maximum absorption wavelength changes with acid, from the viewpoint of visibility and resolution of exposed and unexposed areas.
- the thermoplastic resin layer contains both a dye whose maximum absorption wavelength is changed by an acid as the dye B and a compound that generates an acid by light, which will be described later. preferably included.
- the dye B may be used alone or in combination of two or more.
- the content of the dye B is preferably 0.2% by mass or more, more preferably 0.2 to 6% by mass, based on the total mass of the thermoplastic resin layer, from the viewpoint of visibility of the exposed and unexposed areas. , more preferably 0.2 to 5% by mass, particularly preferably 0.25 to 3.0% by mass.
- the content of the dye B means the content of the dye when all of the dye B contained in the thermoplastic resin layer is in a colored state.
- a method for quantifying the content of the dye B will be described below using a dye that develops color by radicals as an example.
- a solution of 0.001 g and 0.01 g of dye in 100 mL of methyl ethyl ketone is prepared.
- a radical photopolymerization initiator Irgacure OXE01 (trade name, BASF Japan Co., Ltd.) is added to each of the solutions obtained, and radicals are generated by irradiation with light of 365 nm to bring all the dyes into a colored state. After that, the absorbance of each solution having a liquid temperature of 25° C.
- thermoplastic resin layer is measured using a spectrophotometer (UV3100, manufactured by Shimadzu Corporation) in an air atmosphere to create a calibration curve.
- UV3100 UV3100, manufactured by Shimadzu Corporation
- the absorbance of the solution in which all the dyes are developed is measured in the same manner as described above except that 0.1 g of the thermoplastic resin layer is dissolved in methyl ethyl ketone instead of the dyes. From the absorbance of the obtained solution containing the thermoplastic resin layer, the amount of dye contained in the thermoplastic resin layer is calculated based on the calibration curve. 3 g of the thermoplastic resin layer is the same as 3 g of the solid content of the composition.
- the thermoplastic resin layer may contain a compound that generates an acid, a base, or a radical (simply referred to as “compound C”) upon exposure to light.
- Compound C is preferably a compound that generates an acid, a base, or a radical upon receiving actinic rays such as ultraviolet rays and visible rays.
- known photoacid generators, photobase generators, and photoradical polymerization initiators photoradical generators
- thermoplastic resin layer may contain a photoacid generator from the viewpoint of resolution.
- photoacid generator include photocationic polymerization initiators that may be included in the negative photosensitive composition layer described above, and preferred embodiments are the same except for the points described later.
- the photoacid generator preferably contains at least one compound selected from the group consisting of onium salt compounds and oxime sulfonate compounds. From the viewpoint of compatibility, it is more preferable to contain an oxime sulfonate compound. Moreover, as a photo-acid generator, the photo-acid generator which has the following structures is also preferable.
- thermoplastic resin layer may contain a radical photopolymerization initiator.
- photoradical polymerization initiator include photoradical polymerization initiators that may be included in the negative photosensitive composition layer described above, and preferred embodiments are also the same.
- the thermoplastic resin composition may contain a photobase generator.
- the photobase generator is not particularly limited as long as it is a known photobase generator. Examples include 2-nitrobenzylcyclohexylcarbamate, triphenylmethanol, O-carbamoylhydroxylamide, O-carbamoyloxime, [[(2, 6-dinitrobenzyl)oxy]carbonyl]cyclohexylamine, bis[[(2-nitrobenzyl)oxy]carbonyl]hexane 1,6-diamine, 4-(methylthiobenzoyl)-1-methyl-1-morpholinoethane, (4 -morpholinobenzoyl)-1-benzyl-1-dimethylaminopropane, N-(2-nitrobenzyloxycarbonyl)pyrrolidine, hexaamminecobalt (III) tris(triphenylmethylborate), 2-benzyl-2-dimethylamino- 1-(4-morpholinophenyl)-butanone
- Compound C may be used alone or in combination of two or more.
- the content of compound C is preferably 0.1 to 10% by mass, preferably 0.5 to 5%, based on the total mass of the thermoplastic resin layer, from the viewpoint of visibility and resolution of exposed and unexposed areas. % by mass is more preferred.
- the thermoplastic resin layer preferably contains a plasticizer from the viewpoints of resolution, adhesion to adjacent layers, and developability.
- the plasticizer preferably has a smaller molecular weight (weight average molecular weight if it is an oligomer or polymer and has a molecular weight distribution) than the alkali-soluble resin.
- the molecular weight (weight average molecular weight) of the plasticizer is preferably 200 to 2,000.
- the plasticizer is not particularly limited as long as it is a compound that exhibits plasticity by being compatible with the alkali-soluble resin, but from the viewpoint of imparting plasticity, the plasticizer preferably has an alkyleneoxy group in the molecule, such as polyalkylene glycol. Compounds are more preferred.
- the alkyleneoxy group contained in the plasticizer more preferably has a polyethyleneoxy structure or a polypropyleneoxy structure.
- the plasticizer preferably contains a (meth)acrylate compound from the viewpoint of resolution and storage stability.
- the alkali-soluble resin is an acrylic resin and the plasticizer contains a (meth)acrylate compound.
- the (meth)acrylate compound used as the plasticizer include the (meth)acrylate compounds described above as the polymerizable compound contained in the negative photosensitive composition layer.
- both the thermoplastic resin layer and the negative photosensitive composition layer contain the same (meth)acrylate compound. is preferred. This is because when the same (meth)acrylate compound is included in the thermoplastic resin layer and the negative photosensitive composition layer, the diffusion of components between layers is suppressed and the storage stability is improved.
- the thermoplastic resin layer contains a (meth)acrylate compound as a plasticizer
- the (meth)acrylate compound should not be polymerized even in the exposed areas after exposure.
- the (meth)acrylate compound used as a plasticizer has two or more (meth) Polyfunctional (meth)acrylate compounds having acryloyl groups are preferred.
- a (meth)acrylate compound or a urethane (meth)acrylate compound having an acid group is also preferable.
- a plasticizer may be used individually by 1 type, and may be used 2 or more types.
- the content of the plasticizer is preferably 1 to 70% by mass based on the total mass of the thermoplastic resin layer from the viewpoints of the resolution of the thermoplastic resin layer, the adhesion to adjacent layers, and the developability. 10 to 60% by mass is more preferable, and 20 to 50% by mass is even more preferable.
- the thermoplastic resin layer may contain a sensitizer.
- the sensitizer is not particularly limited, and includes sensitizers that may be included in the negative photosensitive composition layer described above.
- a sensitizer may be used alone or in combination of two or more.
- the content of the sensitizer can be appropriately selected depending on the purpose, but from the viewpoint of improving the sensitivity to the light source and visibility of the exposed area and the non-exposed area, it is 0.01 with respect to the total mass of the thermoplastic resin layer. ⁇ 5% by mass is preferable, and 0.05 to 1% by mass is more preferable.
- thermoplastic resin layer may contain known additives such as surfactants, if necessary, in addition to the above components. Further, the thermoplastic resin layer is described in paragraphs 0189 to 0193 of JP-A-2014-085643, and the contents described in this publication are incorporated herein.
- the layer thickness of the thermoplastic resin layer is not particularly limited, it is preferably 1 ⁇ m or more, more preferably 2 ⁇ m or more, from the viewpoint of adhesion to adjacent layers.
- the upper limit is not particularly limited, it is preferably 20 ⁇ m or less, more preferably 10 ⁇ m or less, and even more preferably 8 ⁇ m or less from the viewpoint of developability and resolution.
- the transfer film may have an intermediate layer.
- the intermediate layer 5 is present between the thermoplastic resin layer 3 and the photosensitive composition layer 7 , so that the thermoplastic resin layer 3 and the photosensitive composition layer 7 are formed and coated. Mixing of components that may occur during storage after formation can be suppressed.
- a water-soluble resin layer containing a water-soluble resin can be used as the intermediate layer.
- an oxygen-blocking layer having an oxygen-blocking function which is described as a "separation layer" in JP-A-5-072724, can also be used. It is preferable that the intermediate layer is an oxygen-blocking layer because the sensitivity during exposure is improved, the time load of the exposure machine is reduced, and the productivity is improved.
- the oxygen blocking layer used as the intermediate layer may be appropriately selected from known layers described in the above publications. Among them, an oxygen-blocking layer that exhibits low oxygen permeability and is dispersed or dissolved in water or an alkaline aqueous solution (a 1% by mass aqueous solution of sodium carbonate at 22° C.) is preferred. Each component that can be included in the water-soluble resin layer (intermediate layer) is described below.
- the water-soluble resin layer contains a resin.
- the resin includes a water-soluble resin as part or all of it.
- resins that can be used as water-soluble resins include polyvinyl alcohol-based resins, polyvinylpyrrolidone-based resins, cellulose-based resins, acrylamide-based resins, polyethylene oxide-based resins, gelatin, vinyl ether-based resins, polyamide resins, and copolymers thereof. Examples include resins such as coalescence.
- a (meth)acrylic acid/vinyl compound copolymer or the like can also be used as the water-soluble resin.
- the (meth)acrylic acid/vinyl compound copolymer As the (meth)acrylic acid/vinyl compound copolymer, a (meth)acrylic acid/allyl (meth)acrylate copolymer is preferable, and a methacrylic acid/allyl methacrylate copolymer is more preferable.
- the water-soluble resin is a (meth)acrylic acid/vinyl compound copolymer
- the composition ratio (mol%) is preferably 90/10 to 20/80, and preferably 80/20 to 30/70. more preferred.
- the lower limit of the weight average molecular weight of the water-soluble resin is preferably 5,000 or more, more preferably 7,000 or more, and even more preferably 10,000 or more. Moreover, the upper limit thereof is preferably 200,000 or less, more preferably 100,000 or less, and even more preferably 50,000 or less.
- the dispersity (Mw/Mn) of the water-soluble resin is preferably 1-10, more preferably 1-5.
- the resin in the water-soluble resin layer (intermediate layer) is arranged on one side of the water-soluble resin layer (intermediate layer). It is preferable that the resin contained in the layer on which the second surface is arranged is different from the resin contained in the layer arranged on the other surface side.
- the resin of the water-soluble resin layer (intermediate layer) 15 is It is preferably a resin different from the polymer A and the thermoplastic resin (alkali-soluble resin).
- the water-soluble resin preferably contains polyvinyl alcohol, and more preferably contains both polyvinyl alcohol and polyvinylpyrrolidone, from the viewpoint of further improving the oxygen-blocking property and the ability to suppress interlayer mixing.
- One type of water-soluble resin may be used alone, or two or more types may be used.
- the content of the water-soluble resin is not particularly limited, it is preferably 50% by mass or more with respect to the total mass of the water-soluble resin layer (intermediate layer) in order to further improve the oxygen barrier property and the ability to suppress interlayer mixing. , more preferably 70% by mass or more, still more preferably 80% by mass or more, and particularly preferably 90% by mass or more.
- the upper limit is not particularly limited, for example, 99.9% by mass or less is preferable, and 99.8% by mass or less is more preferable.
- the intermediate layer may contain known additives such as surfactants, if necessary.
- the layer thickness of the water-soluble resin layer (intermediate layer) is not particularly limited, it is preferably 0.1 to 5 ⁇ m, more preferably 0.5 to 3 ⁇ m.
- the inter-layer mixing suppression ability is excellent without lowering the oxygen barrier properties. Further, it is possible to suppress an increase in the removal time of the water-soluble resin layer (intermediate layer) during development.
- the adhesion between the layers satisfies the following relationship.
- Adhesion relationship 1 The adhesion between the intermediate layer and the photosensitive composition layer is greater than the adhesion between the photosensitive composition layer and the protective film.
- Adhesion relationship 2 The adhesion between the temporary support and the intermediate layer is greater than the adhesion between the photosensitive composition layer and the protective film.
- the adhesion strength of the intermediate layer satisfies the following relationship.
- Adhesion relationship 3 The adhesion between the intermediate layer and the photosensitive composition layer is greater than the adhesion between the temporary support and the intermediate layer.
- a method for manufacturing the transfer film of the second embodiment is not particularly limited, and a known method can be used.
- a method for producing the transfer film 20 for example, a thermoplastic resin composition is applied to the surface of the temporary support 11 to form a coating film, and the coating film is dried to form the thermoplastic resin layer 13.
- the transfer film 20 including the temporary support 11, the thermoplastic resin layer 13, the intermediate layer 15, the photosensitive composition layer 17, and the protective film 19 can be manufactured by the manufacturing method described above. After manufacturing the transfer film 20 by the manufacturing method described above, the transfer film 20 may be wound up to produce and store a roll-shaped transfer film.
- the roll-shaped transfer film can be provided as it is to the lamination step with the substrate by the roll-to-roll method, which will be described later.
- the method of manufacturing the transfer film 20 is a method of forming the photosensitive resin layer 17 and the intermediate layer 15 on the protective film 19, and then forming the thermoplastic resin layer 3 on the surface of the intermediate layer 15.
- the method for forming the thermoplastic resin layer on the temporary support is not particularly limited, and known methods can be used. For example, it can be formed by applying a composition for forming a thermoplastic resin layer onto a temporary support and drying it if necessary.
- the composition for forming a thermoplastic resin layer preferably contains the above-described various components for forming the thermoplastic resin layer and a solvent.
- the preferred range of the content of each component with respect to the total solid content of the composition is the same as the preferred range of the content of each component with respect to the total mass of the thermoplastic resin layer. be.
- the solvent is not particularly limited as long as it can dissolve or disperse each component other than the solvent, and known solvents can be used.
- Examples of the solvent include those similar to the solvent contained in the photosensitive composition described later, and the preferred embodiments are also the same.
- the content of the solvent is preferably 50 to 1,900 parts by mass, more preferably 100 to 900 parts by mass, based on 100 parts by mass of the total solid content of the composition.
- the method for forming the thermoplastic resin layer is not particularly limited as long as it is a method capable of forming a layer containing the above components.
- known coating methods slit coating, spin coating, curtain coating, inkjet coating, etc. mentioned.
- the water-soluble resin composition preferably contains various components and a solvent for forming the intermediate layer (water-soluble resin layer) described above.
- the preferred range of the content of each component with respect to the total solid content of the composition is the same as the preferred range of the content of each component with respect to the total mass of the water-soluble resin layer described above.
- the solvent is not particularly limited as long as it can dissolve or disperse the water-soluble resin, preferably at least one selected from the group consisting of water and water-miscible organic solvents, water or water and water-miscible organic solvents A mixed solvent with a solvent is more preferable.
- water-miscible organic solvents include alcohols having 1 to 3 carbon atoms, acetone, ethylene glycol, and glycerin, with alcohols having 1 to 3 carbon atoms being preferred, and methanol or ethanol being more preferred.
- a solvent may be used individually by 1 type, and may be used 2 or more types.
- the content of the solvent is preferably 50 to 2,500 parts by mass, more preferably 50 to 1,900 parts by mass, and even more preferably 100 to 900 parts by mass, based on 100 parts by mass of the total solid content of the composition.
- the method for forming the water-soluble resin layer is not particularly limited as long as it is a method capable of forming a layer containing the above components.
- known coating methods slit coating, spin coating, curtain coating, inkjet coating, etc. mentioned.
- Photosensitive composition and method for forming photosensitive composition layer In terms of excellent productivity and easy formation of the above-described photosensitive composition layer, components constituting the above-described photosensitive composition layer (e.g., binder polymer, polymerizable compound, and polymerization initiator, etc.) , and a solvent-containing photosensitive composition, and is preferably formed by a coating method.
- the method for producing the transfer film of the second embodiment includes coating a photosensitive composition on the intermediate layer to form a coating film, and subjecting the coating film to a drying treatment at a predetermined temperature to expose the film.
- the method is a method of forming a liquid composition layer.
- the photosensitive composition preferably contains various components and a solvent for forming the photosensitive composition layer described above.
- the preferred range of the content of each component with respect to the total solid content of the composition is the same as the preferred range of the content of each component with respect to the total mass of the photosensitive composition layer described above.
- the solvent is not particularly limited as long as it can dissolve or disperse each component other than the solvent, and known solvents can be used.
- alkylene glycol ether solvents for example, alkylene glycol ether solvents, alkylene glycol ether acetate solvents, alcohol solvents (methanol, ethanol, etc.), ketone solvents (acetone, methyl ethyl ketone, etc.), aromatic hydrocarbon solvents (toluene, etc.), aprotic polar Solvents (N,N-dimethylformamide, etc.), cyclic ether solvents (tetrahydrofuran, etc.), ester solvents (n-propyl acetate, etc.), amide solvents, lactone solvents, and mixed solvents containing two or more of these can be mentioned.
- alcohol solvents methanol, ethanol, etc.
- ketone solvents acetone, methyl ethyl ketone, etc.
- aromatic hydrocarbon solvents toluene, etc.
- aprotic polar Solvents N,N-dimethylformamide, etc.
- the solvent preferably contains at least one selected from the group consisting of alkylene glycol ether solvents and alkylene glycol ether acetate solvents.
- a mixed solvent containing at least one selected from the group consisting of alkylene glycol ether solvents and alkylene glycol ether acetate solvents and at least one selected from the group consisting of ketone solvents and cyclic ether solvents is more preferable.
- a mixed solvent containing at least one selected from the group consisting of an alkylene glycol ether solvent and an alkylene glycol ether acetate solvent, a ketone solvent, and a cyclic ether solvent is more preferable.
- alkylene glycol ether solvents include ethylene glycol monoalkyl ether, ethylene glycol dialkyl ether, propylene glycol monoalkyl ether (propylene glycol monomethyl ether acetate, etc.), propylene glycol dialkyl ether, diethylene glycol dialkyl ether, dipropylene glycol monoalkyl ether, and dipropylene glycol dialkyl ethers.
- Alkylene glycol ether acetate solvents include, for example, ethylene glycol monoalkyl ether acetate, propylene glycol monoalkyl ether acetate, diethylene glycol monoalkyl ether acetate, and dipropylene glycol monoalkyl ether acetate.
- the solvent described in paragraphs 0092 to 0094 of WO 2018/179640, and the solvent described in paragraph 0014 of JP 2018-177889 may be used, the contents of which are herein. incorporated into.
- a solvent may be used individually by 1 type, and may be used 2 or more types.
- the content of the solvent is preferably 50 to 1,900 parts by mass, more preferably 100 to 1,200 parts by mass, even more preferably 100 to 900 parts by mass, based on 100 parts by mass of the total solid content of the composition.
- Examples of methods for applying the photosensitive composition include printing, spraying, roll coating, bar coating, curtain coating, spin coating, and die coating (that is, slit coating).
- Heat drying and reduced pressure drying are preferable as a method for drying the coating film of the photosensitive composition.
- the drying temperature is preferably 80° C. or higher, more preferably 90° C. or higher.
- the upper limit thereof is preferably 130° C. or lower, more preferably 120° C. or lower. Drying can also be performed by changing the temperature continuously.
- the drying time is preferably 20 seconds or longer, more preferably 40 seconds or longer, and even more preferably 60 seconds or longer.
- the upper limit is not particularly limited, it is preferably 600 seconds or less, more preferably 300 seconds or less.
- the transfer film of the second embodiment can be produced by laminating the protective film to the photosensitive composition layer.
- a method for laminating the protective film to the photosensitive composition layer is not particularly limited, and includes known methods.
- Apparatuses for bonding the protective film to the photosensitive composition layer include known laminators such as a vacuum laminator and an autocut laminator.
- the laminator is equipped with any heatable roller, such as a rubber roller, and preferably can be pressurized and heated.
- the arithmetic mean roughness Ra1 of the surface of the photosensitive composition layer side described above is smaller than the arithmetic mean roughness Ra2 of the surface opposite to the photosensitive composition layer side, manufactured by a known method.
- the manufacturing method is not particularly limited. The method is as described for the transfer film of the first embodiment.
- the transfer film of the present invention can be applied to various uses. For example, it can be applied to electrode protective films, insulating films, planarizing films, overcoat films, hard coat films, passivation films, barrier ribs, spacers, microlenses, optical filters, antireflection films, etching resists, plating members, and the like. More specific examples include protective films or insulating films for touch panel electrodes, protective films or insulating films for printed wiring boards, protective films or insulating films for TFT substrates, color filters, overcoat films for color filters, and An etching resist etc. can be mentioned.
- a laminate having a conductor pattern can be produced using the transfer film described above.
- the method for producing a laminate having a conductor pattern is not particularly limited as long as it is a method using the transfer film described above, but the method for producing a laminate having a conductor pattern of the present invention is preferably the following production method.
- a method for manufacturing a laminate having a conductor pattern comprising a removal step of removing the conductive layer exposed by the resist pattern stripping step and forming a conductor pattern on the substrate,
- a peeling process is a process of peeling a protective film from a transfer film. When the peeling step is carried out, the surface of the photosensitive composition layer of the transfer film is exposed.
- the peeling method of the protective film is not particularly limited, and a known method can be used.
- the protective film can be peeled off while being wound into a roll.
- the lamination step is a step of laminating the transfer film and the substrate having the conductive layer such that the exposed surface of the photosensitive composition layer is in contact with the conductive layer of the substrate having the conductive layer on the surface.
- a laminate substrate with a photosensitive composition layer having the substrate, the conductive layer, the photosensitive composition layer, and the temporary support in this order is obtained.
- a substrate having a conductive layer has a conductive layer on the substrate, and any layer may be formed as necessary. That is, a substrate having a conductive layer is a conductive substrate having at least a substrate and a conductive layer disposed on the substrate.
- substrates include resin substrates, glass substrates, and semiconductor substrates. Preferred aspects of the substrate are described, for example, in paragraph [0140] of WO2018/155193, the content of which is incorporated herein. Preferred materials for the resin substrate are cycloolefin polymer and polyimide.
- the thickness of the resin substrate is preferably 5-200 ⁇ m, more preferably 10-100 ⁇ m.
- the conductive layer is at least one layer selected from the group consisting of a metal layer, a conductive metal oxide layer, a graphene layer, a carbon nanotube layer, and a conductive polymer layer, from the viewpoint of conductivity and fine line formation. It is preferable to have Also, one conductive layer may be arranged on the substrate, or two or more layers may be arranged. When two or more conductive layers are arranged, the conductive layers are preferably made of different materials. Preferred embodiments of the conductive layer are described, for example, in paragraph [0141] of WO2018/155193, the content of which is incorporated herein.
- the conductive layer may be a transparent conductive layer capable of forming a transparent electrode through the steps described below.
- the transparent conductive layer is preferably composed of metal oxide films such as ITO (indium tin oxide) and IZO (indium zinc oxide), metal mesh, and metal fine wires such as metal nanowires.
- Fine metal wires include fine wires of silver, copper, and the like. Among them, silver conductive materials such as silver mesh and silver nanowire are preferable.
- the thickness of the conductive layer is not particularly limited, preferably 50 nm or more, more preferably 100 nm or more.
- the upper limit is preferably 10 ⁇ m or less, more preferably 2 ⁇ m or less.
- the conductive layer and the surface of the photosensitive composition layer are pressure-bonded so that they are in contact with each other.
- the method of pressure bonding is not particularly limited, and known transfer methods and lamination methods can be used. Among others, it is preferable that the surface of the photosensitive composition layer is placed on a substrate having a conductive portion, and pressure and heat are applied using rolls or the like.
- a known laminator such as a vacuum laminator and an autocut laminator can be used for bonding.
- the lamination temperature is not particularly limited, it is preferably 70 to 130° C., for example.
- the exposure step is a step of patternwise exposing the photosensitive composition layer.
- a resist pattern that protects at least part of the conductive layer is formed on the conductive layer on the substrate by performing the exposure process and the development process described later.
- patterned exposure refers to exposure in a form of exposure in a pattern, that is, exposure in which an exposed portion and a non-exposed portion are present.
- the positional relationship between the exposed area and the unexposed area in pattern exposure is not particularly limited, and is adjusted as appropriate.
- the photosensitive composition layer may be exposed from the side opposite to the substrate, or the photosensitive composition layer may be exposed from the substrate side.
- the light source for pattern exposure can be appropriately selected and used as long as it can irradiate at least light in a wavelength range capable of curing the photosensitive composition layer (for example, 365 nm or 405 nm).
- the dominant wavelength of the exposure light for pattern exposure is preferably 365 nm. Note that the dominant wavelength is the wavelength with the highest intensity.
- Examples of light sources include various lasers, light emitting diodes (LEDs), ultrahigh pressure mercury lamps, high pressure mercury lamps, and metal halide lamps.
- the exposure dose is preferably 5-200 mJ/cm 2 , more preferably 10-200 mJ/cm 2 .
- the temporary support peeling step is a step of peeling the temporary support from the substrate with the photosensitive composition layer between the bonding step and the exposure step, or between the exposure step and the development step described below.
- the peeling method is not particularly limited, and a mechanism similar to the cover film peeling mechanism described in paragraphs [0161] to [0162] of JP-A-2010-072589 can be used.
- the development step is a step of developing the exposed photosensitive composition layer to form a resist pattern.
- Development of the photosensitive composition layer can be performed using a developer.
- a developer an alkaline aqueous solution is preferred.
- Alkaline compounds that can be contained in the alkaline aqueous solution include, for example, sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium hydrogen carbonate, potassium hydrogen carbonate, tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide, and choline (2-hydroxyethyltrimethylammonium hydroxide).
- Development methods include, for example, puddle development, shower development, spin development, and dip development.
- Examples of the developer suitably used in the present specification include the developer described in paragraph [0194] of International Publication No. 2015/093271. Examples include the development method described in paragraph [0195] of 2015/093271.
- a rinse treatment for removing the developer remaining on the substrate with the conductive layer before proceeding to the next step.
- Water or the like can be used for the rinse treatment.
- a drying treatment for removing excess liquid from the substrate with the conductive layer may be performed.
- an acidic or alkaline etchant may be appropriately selected according to the object to be etched.
- acidic etching solutions include aqueous solutions of acidic components alone selected from hydrochloric acid, sulfuric acid, nitric acid, acetic acid, hydrofluoric acid, oxalic acid and phosphoric acid, and acidic components, ferric chloride, ammonium fluoride and A mixed aqueous solution with a salt selected from potassium permanganate can be mentioned.
- the acidic component may be a combination of multiple acidic components.
- Alkaline etchants include aqueous solutions of alkali components alone selected from sodium hydroxide, potassium hydroxide, ammonia, organic amines, and salts of organic amines (tetramethylammonium hydroxide, etc.), and alkali components and salts. (potassium permanganate, etc.).
- the alkaline component may be a component obtained by combining a plurality of alkaline components.
- the plating step is a step of plating the conductive layer in the region where the resist pattern is not arranged.
- Examples of plating methods include electroplating and electroless plating, with electroplating being preferred from the standpoint of productivity.
- a plated layer having a pattern shape similar to that of the area where the resist pattern is not arranged (the opening of the resist pattern) is obtained on the substrate with the conductive layer.
- the conductive layer is preferably a metal layer.
- the metal contained in the plating layer examples include known metals. Specific examples include metals such as copper, chromium, lead, nickel, gold, silver, tin, and zinc, and alloys of these metals. Above all, the plated layer preferably contains copper or its alloy from the viewpoint of better conductivity of the conductive pattern. In addition, the plating layer preferably contains copper as a main component in order to improve the conductivity of the conductor pattern.
- the thickness of the plating layer is preferably 0.1 ⁇ m or more, more preferably 1 ⁇ m or more.
- the upper limit is preferably 20 ⁇ m or less.
- the resist pattern stripping step is a step of stripping the remaining resist pattern.
- a method for removing the remaining resin pattern is not particularly limited, but a method of removing by chemical treatment is mentioned, and a method of removing using a removing liquid is preferable.
- the substrate having the remaining resin pattern is immersed for 1 to 30 minutes in a stirring removal liquid having a liquid temperature of preferably 30 to 80° C., more preferably 50 to 80° C. method.
- the remover include a remover obtained by dissolving an inorganic alkaline component or an organic alkaline component in water, dimethylsulfoxide, N-methylpyrrolidone, or a mixed solution thereof.
- inorganic alkaline components include sodium hydroxide and potassium hydroxide.
- Organic alkali components include primary amine compounds, secondary amine compounds, tertiary amine compounds and quaternary ammonium salt compounds. Alternatively, it may be removed by a known method such as a spray method, a shower method, or a paddle method using a remover.
- the removing step is a step of removing the conductive layer exposed by the resist pattern stripping step to form a conductive pattern on the substrate.
- the plating layer formed by the plating step is used as an etching resist to etch the conductive layer located in the non-pattern forming region (in other words, the region not protected by the plating layer).
- the method for removing part of the conductive layer is not particularly limited, it is preferable to use a known etchant.
- known etching solutions include ferric chloride solution, cupric chloride solution, ammonia alkali solution, sulfuric acid-hydrogen peroxide mixed solution, and phosphoric acid-hydrogen peroxide mixed solution. .
- the removal step When the removal step is performed, the conductive layer exposed to the surface from the substrate is removed, and the plated layer (conductor pattern) having a pattern shape remains to obtain a laminate having the conductor pattern.
- the upper limit of the line width of the formed conductor pattern is preferably 8 ⁇ m or less, more preferably 6 ⁇ m or less. Although the lower limit is not particularly limited, it is often 1 ⁇ m or more.
- a method for manufacturing a laminate having a conductor pattern may include arbitrary steps (other steps) other than the steps described above.
- steps other steps
- the step of reducing the visible light reflectance described in paragraph [0172] of WO2019/022089, a new conductive layer on the insulating film described in paragraph [0172] of WO2019/022089 Examples include a forming step and the like, but are not limited to these steps.
- a method for producing a laminate having a conductor pattern may include a step of performing a process for reducing the visible light reflectance of some or all of the plurality of conductive layers of the substrate.
- the treatment for reducing the visible light reflectance includes oxidation treatment.
- the visible light reflectance of the conductive layer can be reduced by oxidizing the copper to form copper oxide and blackening the conductive layer.
- the treatment for reducing the visible light reflectance is described in paragraphs 0017 to 0025 of JP-A-2014-150118, and paragraphs 0041, 0042, 0048 and 0058 of JP-A-2013-206315. , the contents of which are incorporated herein.
- the method of manufacturing a laminate having a conductor pattern includes the steps of forming an insulating film on the surface of the conductor pattern and forming a new conductive layer on the surface of the insulating film.
- a second electrode pattern insulated from the first electrode pattern can be formed.
- the process of forming the insulating film is not particularly limited, and a known method of forming a permanent film can be used.
- an insulating film having a desired pattern may be formed by photolithography using an insulating photosensitive material.
- the step of forming a new conductive layer on the insulating film is not particularly limited.
- a conductive photosensitive material may be used to form a new conductive layer in a desired pattern by photolithography.
- a method for producing a laminate having a conductor pattern uses a substrate having a plurality of conductive layers on both surfaces of the base material, and sequentially or simultaneously forms circuits on the conductive layers formed on both surfaces of the base material. is also preferred. With such a configuration, it is possible to form a laminate having a conductor pattern for a touch panel in which the first conductor pattern is formed on one surface of the substrate and the second conductor pattern is formed on the other surface of the substrate. Moreover, it is also preferable to form the laminated body which has the conductor pattern for touch panels of such a structure from the both surfaces of a base material by roll-to-roll.
- a laminate having a conductor pattern manufactured by the above manufacturing method can be applied to various devices.
- the device including a laminate having a conductor pattern manufactured by the above manufacturing method include a display device, a printed wiring board, a semiconductor package, and an input device.
- a touch panel is preferable, and a capacitive touch panel is more preferable. preferable.
- the input device can be applied to display devices such as an organic EL display device and a liquid crystal display device.
- the photosensitive composition layer can be transferred to a transfer target.
- the transfer film of the present invention is preferably used for manufacturing a touch panel.
- the method for producing a laminate of the present invention includes: A peeling step of peeling the protective film from the transfer film to expose the surface of the photosensitive composition layer; A photosensitive composition comprising a substrate, a conductive layer, a photosensitive composition layer, and a temporary support in this order, wherein the surface of the transfer film opposite to the temporary support is brought into contact with and bonded to a substrate having a conductive portion.
- a lamination step of obtaining a substrate with a material layer An exposure step of pattern-exposing the photosensitive composition layer; a developing step of developing the exposed photosensitive composition layer to form a protective film pattern that protects the conductive layer; Furthermore, between the bonding step and the exposure step, or between the exposure step and the development step, a temporary support peeling step of peeling the temporary support from the substrate with the photosensitive composition layer.
- a temporary support peeling step of peeling the temporary support from the substrate with the photosensitive composition layer is preferably a manufacturing method of The procedure of the above steps will be described in detail below.
- the peeling step, the developing step, and the temporary support peeling step in the method for producing the laminate are the same as the peeling step, the developing step, and the temporary support peeling step in the method for producing the laminate described above, and the preferred embodiment is also the same. is.
- the lamination step the surface of the transfer film on the side opposite to the temporary support is brought into contact with a substrate having a conductive portion and laminated, and the substrate, the conductive layer, the photosensitive composition layer, and the temporary support are bonded to this. It is a step of obtaining a substrate having a photosensitive composition layer in order.
- the lamination method is the same as the lamination method in the above-described method for manufacturing a laminate having a conductor pattern, and the preferred mode thereof is also the same.
- a substrate having a conductive layer has a conductive layer on the substrate, and any layer may be formed as necessary. That is, a substrate having a conductive layer is a conductive substrate having at least a substrate and a conductive layer disposed on the substrate.
- Examples of the substrate include substrates similar to those in the laminate having the conductor pattern described above, and preferred embodiments thereof are also the same.
- Examples of the conductive layer include the same conductive layer as the substrate in the laminate having the conductor pattern, and the preferred embodiments thereof are also the same.
- a substrate having at least one of a transparent electrode and lead wiring is also preferable.
- the substrate as described above can be suitably used as a touch panel substrate.
- a transparent electrode can function suitably as an electrode for touch panels.
- the transparent electrode is preferably composed of metal oxide films such as ITO (indium tin oxide) and IZO (indium zinc oxide), metal meshes, and thin metal wires such as metal nanowires.
- Fine metal wires include fine wires of silver, copper, and the like. Among them, silver conductive materials such as silver mesh and silver nanowire are preferable.
- a metal is preferable as the material of the routing wiring.
- metals for the routing wiring include gold, silver, copper, molybdenum, aluminum, titanium, chromium, zinc, manganese, and alloys composed of two or more of these metal elements. Copper, molybdenum, aluminum, or titanium is preferable as the material of the routing wiring, and copper is particularly preferable.
- the touch panel electrode protective film formed using the photosensitive composition layer in the transfer film of the present invention is used for the purpose of protecting the electrodes and the like (that is, at least one of the touch panel electrodes and the touch panel wiring). It is preferably provided so as to cover directly or via another layer.
- the exposure step is a step of patternwise exposing the photosensitive composition layer.
- a protective film pattern that protects at least part of the conductive layer is formed on the conductive layer on the substrate by performing the exposure process and the development process described later.
- patterned exposure refers to exposure in a form of exposure in a pattern, that is, exposure in which an exposed portion and a non-exposed portion are present.
- the method of the exposure step the same method as that for the laminate having the conductor pattern can be mentioned, and the preferred embodiments thereof are also the same.
- the method for manufacturing the laminate may include a step of exposing the pattern obtained by the developing step (post-exposure step) and/or a step of heating (post-baking step).
- post-exposure step a step of exposing the pattern obtained by the developing step
- post-baking step a step of heating
- post-baking step is preferably performed after post-exposure.
- the exposure amount of post-exposure is preferably 100 to 5000 mJ/cm 2 , more preferably 200 to 3000 mJ/cm 2 .
- the post-baking temperature is preferably 80°C to 250°C, more preferably 90°C to 160°C.
- the post-baking time is preferably 1 minute to 180 minutes, more preferably 10 minutes to 60 minutes.
- a laminate manufactured by the method for manufacturing a laminate of the present invention can be applied to various apparatuses.
- the device including the laminate include a display device, a printed wiring board, a semiconductor package, an input device, and the like, preferably a touch panel, and more preferably a capacitive touch panel.
- the input device can be applied to display devices such as an organic electroluminescence display device and a liquid crystal display device.
- the pattern formed from the photosensitive composition layer is preferably used as a protective film for touch panel electrodes or touch panel wiring. That is, the photosensitive composition layer contained in the transfer film is preferably used for forming a touch panel electrode protective film or a touch panel wiring.
- Transfer films used in Examples and Comparative Examples were produced in the following procedure. First, the compositions and the like used to prepare the transfer films of Examples and Comparative Examples will be described.
- Temporary support The following temporary support A was used as the temporary support.
- Temporary support A PET film with a thickness of 16 ⁇ m (16QS62, manufactured by Toray Industries, Inc.)
- composition A The following intermediate layer forming composition A was prepared.
- ⁇ Polyvinylpyrrolidone manufactured by ISP Japan, K-30
- ⁇ Distilled water 524 parts by mass
- Methanol 429 parts by mass
- composition for forming a photosensitive composition layer The following composition A for forming a photosensitive resin was prepared.
- ⁇ Styrene / methacrylic acid / methyl methacrylate 52/29/19 (mass%) copolymer propylene glycol monomethyl ether acetate solution (solid content concentration 30.0%, weight average molecular weight: 70000): 25 parts by mass ⁇ NK Ester BPE-500 (manufactured by Shin-Nakamura Chemical Co., Ltd.): 3 parts by mass NK Ester HD-N (manufactured by Shin-Nakamura Chemical Co., Ltd.): 2 parts by mass B-CIM (manufactured by Kurogane Kasei): 1 part by mass SB- PI 701 (manufactured by Sanyo Trading Co., Ltd.): 0.1 parts by mass Leuco Crystal Violet (manufactured by Tokyo Chemical Industry Co., Ltd.): 0.05 parts by mass Methyl ethyl ket
- Protective films having thicknesses and arithmetic mean roughnesses Ra1 and Ra2 shown in Table 1 below were prepared as protective films.
- the arithmetic mean roughness Ra1 and Ra2 as described above, was measured using a fine shape measuring instrument (ET-350K, manufactured by Kosaka Laboratory Co., Ltd.), three-dimensional analysis software (TDA-22, (manufactured by Kosaka Laboratory Co., Ltd.) to obtain arithmetic mean roughness Ra1 and Ra2.
- the measurement conditions by the fine shape measuring instrument were as follows.
- Example 4 before forming the photosensitive composition layer, the intermediate layer-forming composition A was applied to one surface of the temporary support A so that the film thickness after drying was 2 ⁇ m. An intermediate layer A was formed by coating and drying at 100° C. for 2 minutes. Thereafter, a transfer film was produced in the same manner as in Example 1, except that the photosensitive composition layer A was formed on the surface of the intermediate layer A. Transfer films used in other examples and comparative examples were produced in the same manner as in Example 1, except that the type of protective film was changed as shown in Table 1 below.
- Defect inspectability Each of the produced transfer films was visually observed under a fluorescent lamp from the protective film side, and defects in the transfer film were inspected from reflection of light from the fluorescent lamp. When a defect was visually recognized, the part was marked. The presence or absence of foreign matter on the marked portion was observed using an optical microscope. Defect detection rate (%) is calculated by calculating the ratio of the number of parts where the presence of foreign matter is actually confirmed with an optical microscope to the number of parts where defects are visually observed, and the defect inspection is performed according to the following criteria. evaluated the sex. Practically, the defect inspectability is preferably evaluated as C or higher. It should be noted that the higher the evaluation below, the easier the defect inspection can be performed visually. ⁇ A: Defect detection rate is more than 90% and 100% or less ⁇ B: Defect detection rate is more than 80% and 90% or less ⁇ C: Defect detection rate is more than 70% and 80% or less ⁇ D: Defect detection rate is 70% or less
- the transfer film was peeled off from the roll-shaped transfer film while winding the protective film.
- the conditions for winding were room temperature, a winding speed of 4 m/min, and a plastic winding core of 3 inches in diameter.
- the take-up property of the protective film was evaluated according to the following criteria from the positional deviation of the winding end face when the film was continuously wound for 100 m under the above conditions.
- the winding end face refers to the end face of the roll formed by the end of the protective film along the longitudinal direction of the protective film wound roll, and the misalignment of the winding end face refers to the roll at the start of winding.
- Positional deviation of the winding end face is less than 3 mm
- a glass substrate having a thickness of 0.5 mm and a copper layer having a thickness of 0.5 ⁇ m formed thereon (a substrate having a conductive layer on the surface) was prepared.
- the protective film of the transfer film was peeled off to expose the photosensitive composition layer, and the substrate and the transfer film were laminated such that the copper layer of the substrate and the photosensitive composition layer were in close contact with each other.
- Lamination was performed at a temperature of 100° C., a speed of 1 m/min and a pressure of 1 MPa. Then, using a mask having a line-and-space pattern with lines and spaces of 10 ⁇ m, exposure was performed with a high-pressure mercury lamp.
- the amount of exposure was such that the resist pattern after development reproduces the line-and-space pattern.
- a flat nozzle was used as the shower nozzle, and the shower pressure was 1 MPa.
- a line-and-space resist pattern with lines and spaces of 10 ⁇ m was formed by the development treatment.
- the resist pattern formed by the above procedure was observed with an SEM from a direction perpendicular to the substrate to confirm the presence or absence of pattern defects (for example, partial loss of the pattern). The observation magnification was set at 500 times. Based on the number of pattern defects confirmed by the above observation, pattern defect suppressing properties were evaluated according to the following criteria.
- ⁇ A The number of pattern defects is 0 to 4
- ⁇ B The number of pattern defects is 5 to 9
- ⁇ C The number of pattern defects is 10 to 19
- ⁇ D The number of pattern defects is 20 or more
- Table 1 shows each configuration of the transfer film produced above and the evaluation results thereof.
- “Peeling temporary support during exposure” “A” represents that the temporary support was peeled off before exposure and then exposure was performed, and “B” represents temporary support during exposure. This means that the body was exposed without peeling.
- the transfer film of the present invention that is, the arithmetic average roughness Ra1 of the surface of the protective film on the side of the photosensitive composition layer is the opposite side of the photosensitive composition layer of the protective film It has been confirmed that a transfer film having a surface having an arithmetic mean roughness Ra2 of . From the comparison between Example 3 and other examples, it was confirmed that when the arithmetic mean roughness Ra1 is 0.050 ⁇ m or less, the pattern defect suppressing property is more excellent. From the comparison between Example 5 and other examples, it was confirmed that when the arithmetic mean roughness Ra2 is less than 0.150 ⁇ m, the defect inspectability is superior. From the comparison between Example 6 and other examples, it was confirmed that when the thickness of the protective film is 10 to 30 ⁇ m, the transfer film is more excellent in inhibiting air bubbles and pattern defects.
- Reference Signs List 10 20 transfer film 1, 11 temporary support 2, 12 composition layer 3, 17 photosensitive composition layer 5 refractive index adjusting layer 7, 19 protective film 13 thermoplastic resin layer 15 intermediate layer
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Abstract
Description
一般的にパターン化した層の形成には、必要とするパターン形状を得るための工程数が少ないといったことから、転写フィルムを用いて任意の基板上に感光性組成物層を配置して、この感光性組成物層に対してマスクを介して露光した後に現像する方法が広く使用されている。
また、転写フィルムを用いてパターンを形成する際に、パターン欠陥の発生が抑制されることが求められる。
本発明者が、特許文献1に開示された転写フィルムについて検討したところ、保護フィルムの巻き取りのしやすさと、パターン欠陥の発生の抑制との両立について、改善の余地があることを見出した。
また、本発明は、導体パターンを有する積層体、導体パターンを有する積層体の製造方法、及び、転写フィルムの製造方法の提供も課題とする。
上記保護フィルムが、ポリプロピレンを含み、
上記保護フィルムの上記感光性組成物層側の表面の算術平均粗さRa1が、上記保護フィルムの上記感光性組成物層とは反対側の表面の算術平均粗さRa2よりも小さい、転写フィルム。
〔2〕 上記算術平均粗さRa1が、0.050μm以下である、〔1〕に記載の転写フィルム。
〔3〕 上記算術平均粗さRa2が、0.050μm超である、〔1〕又は〔2〕に記載の転写フィルム。
〔4〕 上記算術平均粗さRa2が、0.150μm未満である、〔1〕~〔3〕のいずれか1つに記載の転写フィルム。
〔5〕 上記保護フィルムの厚さが、10~30μmである、〔1〕~〔4〕のいずれか1つに記載の転写フィルム。
〔6〕 〔1〕~〔5〕のいずれか1つに記載の転写フィルムを用いて形成した、導体パターンを有する積層体。
〔7〕 〔1〕~〔5〕のいずれか1つに記載の転写フィルムから、上記保護フィルムを剥離して上記感光性組成物層の表面を露出させる剥離工程と、
上記感光性組成物層の露出した表面が、表面に導電層を有する基板の上記導電層と接するように、上記転写フィルムと上記導電層を有する基板とを貼合する貼合工程と、
上記感光性組成物層を露光する露光工程と、
露光された上記感光性組成物層に対して現像処理を実施してレジストパターンを形成する現像工程と、
上記レジストパターンが配置されていない領域にある上記導電層に、エッチング処理を行うエッチング工程、及び、めっき処理を行うめっき処理工程のいずれか1つと、
上記レジストパターンを剥離するレジストパターン剥離工程と、
更に、上記めっき処理工程を有する場合は、上記レジストパターン剥離工程によって露出した上記導電層を除去し、上記基板上に導体パターンを形成する除去工程と、を有する、導体パターンを有する積層体の製造方法であって、
上記貼合工程と上記露光工程との間、又は、上記露光工程と上記現像工程との間に、更に、上記仮支持体を剥離する仮支持体剥離工程を有する、導体パターンを有する積層体の製造方法。
〔8〕 仮支持体上に感光性組成物層を形成する工程と、
上記感光性組成物層の上記仮支持体とは反対側の面に保護フィルムを貼合する工程とを含む転写フィルムの製造方法であって、
上記保護フィルムが、ポリプロピレンを含み、
上記保護フィルムの上記感光性組成物層側の表面の算術平均粗さRa1が、上記保護フィルムの上記感光性組成物層とは反対側の表面の算術平均粗さRa2よりも小さい、転写フィルムの製造方法。
また、本発明によれば、導体パターンを有する積層体、導体パターンを有する積層体の製造方法、及び、転写フィルムの製造方法も提供できる。
以下に記載する構成要件の説明は、本発明の代表的な実施態様に基づいてなされる場合があるが、本発明はそのような実施態様に制限されない。
本明細書において、「~」を用いて表される数値範囲は、「~」の前後に記載される数値を下限値及び上限値として含む範囲を意味する。
本明細書において、段階的に記載されている数値範囲において、ある数値範囲で記載された上限値又は下限値は、他の段階的な記載の数値範囲の上限値又は下限値に置き換えてもよい。また、本明細書に記載されている数値範囲において、ある数値範囲で記載された上限値又は下限値は、実施例に示されている値に置き換えてもよい。
本明細書において、透過率は、分光光度計を用いて測定される値であり、例えば、日立製作所株式会社製の分光光度計U-3310を用いて測定できる。
本明細書において、特段の断りがない限り、高分子の構成単位の比は質量比である。
本明細書において、特段の断りがない限り、分子量分布がある化合物の分子量は、重量平均分子量(Mw)である。
本明細書において、特段の断りがない限り、金属元素の含有量は、誘導結合プラズマ(ICP:Inductively Coupled Plasma)分光分析装置を用いて測定した値である。
本明細書において、特段の断りがない限り、屈折率は、波長550nmでエリプソメーターを用いて測定した値である。
本明細書において、特段の断りがない限り、色相は、色差計(CR-221、ミノルタ株式会社製)を用いて測定した値である。
本発明の転写フィルムは、仮支持体と、感光性組成物層と、保護フィルムとをこの順に有する。本発明の転写フィルムの特徴点としては、保護フィルムがポリプロピレンを含み、保護フィルムの感光性組成物層側の表面の算術平均粗さRa1が、保護フィルムの感光性組成物層側とは反対側の表面の算術平均粗さRa2よりも小さい点が挙げられる。
本発明の転写フィルムが、保護フィルムを剥離して巻き取る際に保護フィルムの巻き取りがしやすく、パターン形成時にパターン欠陥の発生が抑制される機序は必ずしも明らかではないが、本発明者は以下のように推測している。
本発明の転写フィルムは、上記特徴点を備えることにより、保護フィルムを剥離して巻き取る際に、保護フィルムをロール状にして巻き取ってもブロッキングが生じにくく、巻取り不良が生じにくいと考えられる。
また、転写フィルムが上記特徴点を備えることにより、上記巻き取り不良の発生を生じにくくしつつ、上記算術平均粗さRa1に由来する保護フィルム側の感光性組成物層の表面の凹凸が小さくなる。結果として、他の部材に対して転写フィルムを用いて感光性組成物層を転写した際に、他の部材と感光性組成物層との界面で気泡等が生じにくく、パターン欠陥が生じにくいと考えられる。
本発明の転写フィルムは、仮支持体と、仮支持体上に配置された組成物層と、保護フィルムとをこの順に有する。
上記組成物層は、感光性組成物層を含めば特に制限されない。
上記感光性組成物層は、ネガ型感光性組成物層であってもよいし、化学増幅型感光性組成物層であってもよいが、ネガ型感光性組成物層であることが好ましい。
また、上記組成物層は、単層構成であってもよいし、2層以上の構成であってもよい。上記組成物層が感光性組成物層以外の他の組成物層を含む場合、他の組成物層としては、熱可塑性樹脂層、中間層、及び、屈折率調整層等が挙げられる。
(1)「仮支持体/感光性組成物層/屈折率調整層/保護フィルム」
(2)「仮支持体/感光性組成物層/保護フィルム」
(3)「仮支持体/中間層/感光性組成物層/保護フィルム」
(4)「仮支持体/熱可塑性樹脂層/中間層/感光性組成物層/保護フィルム」
なお、上記各構成において、感光性組成物層は、ネガ型感光性組成物層であることが好ましい。また、感光性組成物層が着色樹脂層であることも好ましい。
本発明の転写フィルムは、後述するように配線保護膜用の転写フィルムとして使用されてもよいし、エッチングレジスト用の転写フィルムとして使用されてもよい。
配線保護膜用の転写フィルムとする場合、転写フィルムの構成としては、例えば、上述した(1)又は(2)の構成であるのが好ましい。また、エッチングレジスト用の転写フィルムとする場合、転写フィルムの構成としては、例えば、上述した(2)~(4)の構成であるのが好ましい。
転写フィルムのうねりの最大幅は、以下の手順により測定される値である。
まず、転写フィルムを縦20cm×横20cmのサイズとなるように主面に垂直な方向に裁断し、保護フィルムを剥離して試験サンプルを作製する。次いで、表面が平滑で且つ水平なステージ上に、上記試験サンプルを仮支持体の表面がステージに対向するように静置する。静置後、試験サンプルの中心10cm角の範囲について、試料サンプルの表面をレーザー顕微鏡(例えば、(株)キーエンス社製 VK-9700SP)で走査して3次元表面画像を取得し、得られた3次元表面画像で観察される最大凸高さから最低凹高さを引き算する。上記操作を10個の試験サンプルについて行い、その算術平均値を「転写フィルムのうねり最大幅」とする。
以下、保護フィルムを剥離して巻き取る際に保護フィルムの巻き取り不良が生じにくいことを、「保護フィルムの巻き取り性に優れる」ともいい、パターン形成時にパターン欠陥の発生が抑制されることを、「パターン欠陥抑制性に優れる」ともいう。
以下において、第1実施形態の転写フィルムの実施形態の一例について説明する。
図1に示す転写フィルム10は、仮支持体1と、感光性組成物層3及び屈折率調整層5を含む組成物層2と、保護フィルム7とを、この順に有する。
なお、図1で示す転写フィルム10は屈折率調整層5を配置した形態であるが、屈折率調整層5は、配置されなくてもよい。
以下において、転写フィルムを構成する各要素について説明する。
転写フィルムは、仮支持体を有する。
仮支持体は、組成物層を支持する部材であり、最終的には剥離処理により除去される。
仮支持体は、フィルムであることが好ましく、樹脂フィルムであることがより好ましい。仮支持体としては、可撓性を有し、かつ、加圧下、又は、加圧及び加熱下において、著しい変形、収縮、又は、伸びを生じないフィルムが好ましい。
上記フィルムとしては、例えば、ポリエチレンテレフタレートフィルム(例えば、2軸延伸ポリエチレンテレフタレートフィルム)、ポリメチルメタクリレートフィルム、トリ酢酸セルロースフィルム、ポリスチレンフィルム、ポリイミドフィルム、及び、ポリカーボネートフィルムが挙げられる。
なかでも、仮支持体としては、ポリエチレンテレフタレートフィルムが好ましい。
また、仮支持体として使用するフィルムには、シワ等の変形、及び、傷等がないことが好ましい。
仮支持体を介するパターン露光時のパターン形成性、及び、仮支持体の透明性の点から、仮支持体のヘイズは小さい方が好ましい。具体的には、仮支持体のヘイズ値が、2%以下が好ましく、0.5%以下がより好ましく、0.4%以下が更に好ましく、0.1%以下が特に好ましい。但し、後段で説明する露光時に、仮支持体を剥離して露光を行う場合は、仮支持体のヘイズはこの限りではない。
また、仮支持体のヘイズは、仮支持体製造時の搬送性の点で、0.05%以上が好ましく、0.1%以上がより好ましい。
なお、上記ヘイズは、JIS K 7136:2000に準拠した全光線ヘーズ(%)であり、ヘイズメーター(装置名:HZ-2、スガ試験機(株)製)を用いて全光ヘイズとして測定できる。
後述するように仮支持体に対して表面処理又は下塗り処理を行う場合、ヘイズの測定は、上記処理後の仮支持体を測定して得られる値とする。
仮支持体の厚みは、SEM(走査型電子顕微鏡:Scanning Electron Microscope)による断面観察により測定した任意の5点の平均値として算出する。
UV照射により表面改質される場合、露光量は10~2000mJ/cm2が好ましく、50~1000mJ/cm2がより好ましい。
UV照射のための光源としては、150~450nm波長帯域の光を発する低圧水銀ランプ、高圧水銀ランプ、超高圧水銀灯、カーボンアーク灯、メタルハライドランプ、キセノンランプ、ケミカルランプ、無電極放電ランプ、及び、発光ダイオード(LED)等を挙げることができる。光照射量がこの範囲にできる限り、ランプ出力や照度は特に制限はない。
また、仮支持体に対して、組成物層等との密着性の点で、ポリ塩化ビニリデン樹脂、スチレンブタジエンゴム、または、ゼラチンなどを含む下塗り層を形成する下塗り処理を施してもよい。
また、滑剤層の膜厚は、0.05~1.0μmが好ましい。仮支持体の市販品としては、ルミラー16KS40、ルミラー16FB40(以上、東レ株式会社製)、コスモシャインA4100、コスモシャインA4160、コスモシャインA4300、コスモシャインA8300(以上、東洋紡株式会社製)を挙げることができる。
転写フィルムは、感光性組成物層を有する。
感光性組成物層を被転写体上に転写した後、露光及び現像を行うことにより、被転写体上にパターンを形成できる。
感光性組成物層としては、ネガ型が好ましい。なお、ネガ型感光性組成物層とは、露光により露光部が現像液に対する溶解性が低下する感光性組成物層である。感光性組成物層がネガ型感光性組成物層である場合、形成されるパターンは硬化層に該当する。
感光性組成物層は、バインダーポリマーを含んでいてもよい。
バインダーポリマーとしては、例えば、(メタ)アクリル樹脂、スチレン樹脂、エポキシ樹脂、アミド樹脂、アミドエポキシ樹脂、アルキド樹脂、フェノール樹脂、エステル樹脂、ウレタン樹脂、エポキシ樹脂と(メタ)アクリル酸との反応で得られるエポキシアクリレート樹脂、及び、エポキシアクリレート樹脂と酸無水物との反応で得られる酸変性エポキシアクリレート樹脂が挙げられる。
なお、本明細書において、(メタ)アクリル樹脂とは、(メタ)アクリル化合物に由来する構成単位を有する樹脂を意味する。(メタ)アクリル化合物に由来する構成単位の含有量は、(メタ)アクリル樹脂の全構成単位に対して、50質量%以上が好ましく、70質量%以上がより好ましく、90質量%以上が更に好ましい。
(メタ)アクリル樹脂は、(メタ)アクリル化合物に由来する構成単位のみで構成されていてもよく、(メタ)アクリル化合物以外の重合性単量体に由来する構成単位を有していてもよい。すなわち、(メタ)アクリル化合物に由来する構成単位の含有量の上限は、(メタ)アクリル樹脂の全構成単位に対して、100質量%以下である。
(メタ)アクリル酸エステルとしては、例えば、(メタ)アクリル酸アルキルエステル、(メタ)アクリル酸テトラヒドロフルフリルエステル、(メタ)アクリル酸ジメチルアミノエチルエステル、(メタ)アクリル酸ジエチルアミノエチルエステル、(メタ)アクリル酸グリシジルエステル、(メタ)アクリル酸ベンジルエステル、2,2,2-トリフルオロエチル(メタ)アクリレート、及び、2,2,3,3-テトラフルオロプロピル(メタ)アクリレートが挙げられ、(メタ)アクリル酸アルキルエステルが好ましい。
(メタ)アクリルアミドとしては、例えば、ジアセトンアクリルアミド等のアクリルアミドが挙げられる。
(メタ)アクリル酸エステルとしては、炭素数1~4のアルキル基を有する(メタ)アクリル酸アルキルエステルが好ましく、(メタ)アクリル酸メチル又は(メタ)アクリル酸エチルがより好ましい。
上記構成単位を形成する重合性単量体としては、(メタ)アクリル化合物と共重合可能な(メタ)アクリル化合物以外の化合物であれば特に制限されず、例えば、スチレン、ビニルトルエン、及び、α-メチルスチレン等のα位又は芳香族環に置換基を有してもよいスチレン化合物、アクリロニトリル及びビニル-n-ブチルエーテル等のビニルアルコールエステル、マレイン酸、マレイン酸無水物、マレイン酸モノメチル、マレイン酸モノエチル、及び、マレイン酸モノイソプロピル等のマレイン酸モノエステル、フマール酸、ケイ皮酸、α-シアノケイ皮酸、イタコン酸、並びに、クロトン酸が挙げられる。
これらの重合性単量体は、1種又は2種以上を組み合わせて用いてもよい。
なかでも、(メタ)アクリル樹脂は、カルボキシ基を有する構成単位を有することがより好ましく、上記の(メタ)アクリル酸に由来する構成単位を有することが更に好ましい。
(メタ)アクリル酸アルキルエステルに由来する構成単位を有する場合、(メタ)アクリル樹脂における(メタ)アクリル酸アルキルエステルに由来する構成単位の含有量は、(メタ)アクリル樹脂の全構成単位に対して、1~90質量%が好ましく、1~50質量%がより好ましく、1~30質量%が更に好ましい。
また、(メタ)アクリル樹脂としては、メタクリル酸に由来する構成単位、メタクリル酸メチルに由来する構成単位、及び、アクリル酸エチルに由来する構成単位を有するアクリル樹脂も好ましい。
(メタ)アクリル樹脂におけるメタクリル酸に由来する構成単位及びメタクリル酸アルキルエステルに由来する構成単位の合計含有量は、本発明の効果がより優れる点から、(メタ)アクリル樹脂の全構成単位に対して、40質量%以上が好ましく、60質量%以上がより好ましい。上限は特に制限されず、100質量%以下であってもよく、80質量%以下が好ましい。
本発明の効果がより優れる点から、メタクリル酸に由来する構成単位及びメタクリル酸アルキルエステルに由来する構成単位の合計含有量は、アクリル酸に由来する構成単位及びアクリル酸アルキルエステルに由来する構成単位の合計含有量に対して、質量比で60/40~80/20が好ましい。
なお、(メタ)アクリル樹脂の末端部は、合成に用いた重合開始剤に由来する部位により構成される。末端にエステル基を有する(メタ)アクリル樹脂は、エステル基を有するラジカルを発生する重合開始剤を用いることにより合成できる。
バインダーポリマーは、例えば、現像性の点から、酸価60mgKOH/g以上のバインダーポリマーであることが好ましい。
また、バインダーポリマーは、例えば、加熱により架橋成分と熱架橋し、強固な膜を形成しやすいという点から、酸価60mgKOH/g以上のカルボキシ基を有する樹脂(いわゆる、カルボキシ基含有樹脂)であることがより好ましく、酸価60mgKOH/g以上のカルボキシ基を有する(メタ)アクリル樹脂(いわゆる、カルボキシ基含有(メタ)アクリル樹脂)であることが更に好ましい。
バインダーポリマーがカルボキシ基を有する樹脂であると、例えば、ブロックイソシアネート化合物等の熱架橋性化合物を添加して熱架橋することで、3次元架橋密度を高めることができる。また、カルボキシ基を有する樹脂のカルボキシ基が無水化され、疎水化すると、湿熱耐性が改善し得る。
例えば、特開2011-095716号公報の段落[0025]に記載のポリマーのうち、酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂、特開2010-237589号公報の段落[0033]~[0052]に記載のポリマーのうち、酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂等を好ましく使用できる。
なお、本明細書において、スチレン-アクリル共重合体とは、スチレン化合物に由来する構成単位と、(メタ)アクリル化合物に由来する構成単位とを有する樹脂を指し、上記スチレン化合物に由来する構成単位、及び、上記(メタ)アクリル化合物に由来する構成単位の合計含有量は、上記共重合体の全構成単位に対して、30質量%以上が好ましく、50質量%以上がより好ましい。
また、スチレン化合物に由来する構成単位の含有量は、上記共重合体の全構成単位に対して、1質量%以上が好ましく、5質量%以上がより好ましく、5~80質量%が更に好ましい。
また、上記(メタ)アクリル化合物に由来する構成単位の含有量は、上記共重合体の全構成単位に対して、5質量%以上が好ましく、10質量%以上がより好ましく、20~95質量%が更に好ましい。
芳香環構造を有する構成単位を形成するモノマーとしては、アラルキル基を有するモノマー、スチレン、及び重合可能なスチレン誘導体(例えば、メチルスチレン、ビニルトルエン、tert-ブトキシスチレン、アセトキシスチレン、4-ビニル安息香酸、スチレンダイマー、及びスチレントリマー等)が挙げられる。なかでも、アラルキル基を有するモノマー、又はスチレンが好ましい。アラルキル基としては、置換又は非置換のフェニルアルキル基(ベンジル基を除く)、及び置換又は非置換のベンジル基等が挙げられ、置換又は非置換のベンジル基が好ましい。
また、バインダーポリマーにおける芳香環構造を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~60モル%がより好ましく、20~60モル%が更に好ましい。
更に、バインダーポリマーにおける上記式(S)で表される構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~60モル%がより好ましく、20~60モル%が更に好ましく、20~50モル%が特に好ましい。
なお、本明細書において、「構成単位」の含有量をモル比で規定する場合、上記「構成単位」は「モノマー単位」と同義であるものとする。また、本明細書において、上記「モノマー単位」は、高分子反応等により重合後に修飾されていてもよい。以下においても同様である。
なかでも、本発明の効果がより優れる点から、2環以上の脂肪族炭化水素環が縮環した環が好ましく、テトラヒドロジシクロペンタジエン環(トリシクロ[5.2.1.02,6]デカン環)がより好ましい。
脂肪族炭化水素環構造を有する構成単位を形成するモノマーとしては、ジシクロペンタニル(メタ)アクリレート、シクロヘキシル(メタ)アクリレート、及び、イソボルニル(メタ)アクリレートが挙げられる。
また、バインダーポリマーは、本発明の効果がより優れる点から、下記式(Cy)で表される構成単位を有することがより好ましく、上記式(S)で表される構成単位、及び、下記式(Cy)で表される構成単位を有することがより好ましい。
式(Cy)におけるRCyは、本発明の効果がより優れる点から、炭素数5~20の脂肪族炭化水素環構造を有する一価の基であることが好ましく、炭素数6~16の脂肪族炭化水素環構造を有する一価の基であることがより好ましく、炭素数8~14の脂肪族炭化水素環構造を有する一価の基であることが更に好ましい。
また、式(Cy)のRCyにおける脂肪族炭化水素環構造は、本発明の効果がより優れる点から、シクロペンタン環構造、シクロヘキサン環構造、テトラヒドロジシクロペンタジエン環構造、ノルボルナン環構造、又は、イソボロン環構造であることが好ましく、シクロヘキサン環構造、又は、テトラヒドロジシクロペンタジエン環構造であることがより好ましく、テトラヒドロジシクロペンタジエン環構造であることが更に好ましい。
更に、式(Cy)のRCyにおける脂肪族炭化水素環構造は、本発明の効果がより優れる点から、2環以上の脂肪族炭化水素環が縮環した環構造であることが好ましく、2~4環の脂肪族炭化水素環が縮環した環であることがより好ましい。
更に、式(Cy)におけるRCyは、本発明の効果がより優れる点から、式(Cy)における-C(=O)O-の酸素原子と脂肪族炭化水素環構造とが直接結合する基、すなわち、脂肪族炭化水素環基であることが好ましく、シクロヘキシル基、又は、ジシクロペンタニル基であることがより好ましく、ジシクロペンタニル基であることが更に好ましい。
バインダーポリマーが脂肪族炭化水素環構造を有する構成単位を有する場合、脂肪族炭化水素環構造を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~90質量%が好ましく、10~80質量%がより好ましく、20~70質量%が更に好ましい。
また、バインダーポリマーにおける脂肪族炭化水素環構造を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~60モル%がより好ましく、20~50モル%が更に好ましい。
更に、バインダーポリマーにおける上記式(Cy)で表される構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~60モル%がより好ましく、20~50モル%が更に好ましい。
また、バインダーポリマーにおける芳香環構造を有する構成単位及び脂肪族炭化水素環構造を有する構成単位の総含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、10~80モル%が好ましく、20~70モル%がより好ましく、40~60モル%が更に好ましい。
更に、バインダーポリマーにおける上記式(S)で表される構成単位及び上記式(Cy)で表される構成単位の総含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、10~80モル%が好ましく、20~70モル%がより好ましく、40~60モル%が更に好ましい。
また、バインダーポリマーにおける上記式(S)で表される構成単位のモル量nSと上記式(Cy)で表される構成単位のモル量nCyは、本発明の効果がより優れる点から、下記式(SCy)に示す関係を満たすことが好ましく、下記式(SCy-1)を満たすことがより好ましく、下記式(SCy-2)を満たすことが更に好ましい。
0.2≦nS/(nS+nCy)≦0.8 式(SCy)
0.30≦nS/(nS+nCy)≦0.75 式(SCy-1)
0.40≦nS/(nS+nCy)≦0.70 式(SCy-2)
上記酸基としては、カルボキシ基、スルホ基、ホスホン酸基、及び、リン酸基が挙げられ、カルボキシ基が好ましい。
上記酸基を有する構成単位としては、下記に示す、(メタ)アクリル酸由来の構成単位が好ましく、メタクリル酸由来の構成単位がより好ましい。
バインダーポリマーが酸基を有する構成単位を有する場合、酸基を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~50質量%が好ましく、5~40質量%がより好ましく、10~30質量%が更に好ましい。
また、バインダーポリマーにおける酸基を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~50モル%がより好ましく、20~40モル%が更に好ましい。
更に、バインダーポリマーにおける(メタ)アクリル酸由来の構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~50モル%がより好ましく、20~40モル%が更に好ましい。
反応性基としては、ラジカル重合性基が好ましく、エチレン性不飽和基がより好ましい。また、バインダーポリマーがエチレン性不飽和基を有している場合、バインダーポリマーは、側鎖にエチレン性不飽和基を有する構成単位を有することが好ましい。
本明細書において、「主鎖」とは、樹脂を構成する高分子化合物の分子中で相対的に最も長い結合鎖を表し、「側鎖」とは、主鎖から枝分かれしている原子団を表す。
エチレン性不飽和基としては、アリル基又は(メタ)アクリロキシ基がより好ましい。
反応性基を有する構成単位の一例としては、下記に示すものが挙げられるが、これらに限定されない。
バインダーポリマーが反応性基を有する構成単位を有する場合、反応性基を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70質量%が好ましく、10~50質量%がより好ましく、20~40質量%が更に好ましい。
また、バインダーポリマーにおける反応性基を有する構成単位の含有量は、本発明の効果がより優れる点から、バインダーポリマーの全構成単位に対して、5~70モル%が好ましく、10~60モル%がより好ましく、20~50モル%が更に好ましい。
反応性基をバインダーポリマーに導入する手段の好ましい例としては、カルボキシ基を有するポリマーを重合反応により合成した後、高分子反応により、得られたポリマーのカルボキシ基の一部にグリシジル(メタ)アクリレートを反応させて、(メタ)アクリロキシ基をポリマーに導入する手段が挙げられる。この手段により、側鎖に(メタ)アクリロキシ基を有するバインダーポリマーを得ることができる。
上記重合反応は、70~100℃の温度条件で行うことが好ましく、80~90℃の温度条件で行うことがより好ましい。上記重合反応に用いる重合開始剤としては、アゾ系開始剤が好ましく、例えば、富士フイルム和光純薬(株)製のV-601(商品名)又はV-65(商品名)がより好ましい。上記高分子反応は、80~110℃の温度条件で行うことが好ましい。上記高分子反応においては、アンモニウム塩等の触媒を用いることが好ましい。
カルボン酸無水物構造は、鎖状カルボン酸無水物構造、及び、環状カルボン酸無水物構造のいずれであってもよいが、環状カルボン酸無水物構造であることが好ましい。
環状カルボン酸無水物構造の環としては、5~7員環が好ましく、5員環又は6員環がより好ましく、5員環が更に好ましい。
Z1aとしては、炭素数2~4のアルキレン基が好ましく、炭素数2又は3のアルキレン基がより好ましく、炭素数2のアルキレン基が更に好ましい。
n1aは、0以上の整数を表す。Z1aが炭素数2~4のアルキレン基を表す場合、n1aは、0~4の整数であることが好ましく、0~2の整数であることがより好ましく、0であることが更に好ましい。
n1aが2以上の整数を表す場合、複数存在するRA1aは、同一でも異なっていてもよい。また、複数存在するRA1aは、互いに結合して環を形成してもよいが、互いに結合して環を形成していないことが好ましい。
感光性組成物層が重合体Xを含む場合、本発明の効果がより優れる点から、重合体Xの含有量は、感光性組成物層全質量に対して、0.1~30質量%が好ましく、0.2~20質量%がより好ましく、0.5~20質量%が更に好ましく、1~20質量%が更に好ましい。
なお、バインダーポリマーの酸価は、JIS K0070:1992に記載の方法に従って、測定される値である。バインダーポリマーの分散度は、現像性の観点から、1.0~6.0が好ましく、1.0~5.0がより好ましく、1.0~4.0が更に好ましく、1.0~3.0が特に好ましい。
バインダーポリマーの含有量は、本発明の効果がより優れる点から、感光性組成物層全質量に対して、10~90質量%が好ましく、20~80質量%がより好ましく、30~70質量%が更に好ましい。
感光性組成物層は、重合性化合物を含んでいてもよい。
重合性化合物は、重合性基を有する化合物である。重合性基としては、例えば、ラジカル重合性基、及び、カチオン重合性基が挙げられ、ラジカル重合性基が好ましい。
エチレン性不飽和基としては、(メタ)アクリロキシ基が好ましい。
なお、本明細書におけるエチレン性不飽和化合物は、上記バインダーポリマー以外の化合物であり、分子量5,000未満であることが好ましい。
Q2-R1-Q1 式(M)
式(M)中、Q1及びQ2はそれぞれ独立に、(メタ)アクリロイルオキシ基を表し、R1は鎖状構造を有する二価の連結基を表す。
また、式(M)におけるQ1及びQ2は、反応性の点から、アクリロイルオキシ基であることが好ましい。
式(M)におけるR1としては、本発明の効果がより優れる点から、アルキレン基、アルキレンオキシアルキレン基(-L1-O-L1-)、又は、ポリアルキレンオキシアルキレン基(-(L1-O)p-L1-)が好ましく、炭素数2~20の炭化水素基、又は、ポリアルキレンオキシアルキレン基がより好ましく、炭素数4~20のアルキレン基が更に好ましく、炭素数6~18の直鎖アルキレン基が特に好ましい。
上記炭化水素基は、少なくとも一部に鎖状構造を有していればよく、上記鎖状構造以外の部分としては、特に制限はなく、例えば、分岐鎖状、環状、又は、炭素数1~5の直鎖状アルキレン基、アリーレン基、エーテル結合、及び、それらの組み合わせのいずれであってもよく、アルキレン基、又は、2以上のアルキレン基と1以上のアリーレン基とを組み合わせた基が好ましく、アルキレン基がより好ましく、直鎖アルキレン基が更に好ましい。
なお、上記L1は、それぞれ独立に、アルキレン基を表し、エチレン基、プロピレン基、又は、ブチレン基が好ましく、エチレン基又は1,2-プロピレン基がより好ましい。pは2以上の整数を表し、2~10の整数であることが好ましい。
本明細書において、「Q1とQ2の間を連結する最短の連結鎖の原子数」とは、Q1に連結するR1における原子からQ2に連結するR1における原子までを連結する最短の原子数である。
上記化合物のなかでも、本発明の効果がより優れる点から、1,6-ヘキサンジオールジ(メタ)アクリレート、1,9-ノナンジオールジ(メタ)アクリレート、1,10-デカンジオールジ(メタ)アクリレート、及び、ネオペンチルグリコールジ(メタ)アクリレートからなる群から選ばれた少なくとも1種の化合物であることが好ましく、1,6-ヘキサンジオールジ(メタ)アクリレート、1,9-ノナンジオールジ(メタ)アクリレート、及び、1,10-デカンジオールジ(メタ)アクリレートからなる群から選ばれた少なくとも1種の化合物であることがより好ましく、1,9-ノナンジオールジ(メタ)アクリレート、及び、1,10-デカンジオールジ(メタ)アクリレートからなる群から選ばれた少なくとも1種の化合物であることが更に好ましい。
本明細書において、「2官能以上のエチレン性不飽和化合物」とは、一分子中にエチレン性不飽和基を2つ以上有する化合物を意味する。
エチレン性不飽和化合物におけるエチレン性不飽和基としては、(メタ)アクリロイル基が好ましい。
エチレン性不飽和化合物としては、(メタ)アクリレート化合物が好ましい。
上記化合物M以外の2官能のエチレン性不飽和化合物としては、トリシクロデカンジメタノールジ(メタ)アクリレート、ジオキサングリコールジ(メタ)アクリレート、及び、1,4-シクロヘキサンジオールジ(メタ)アクリレートが挙げられる。
3官能以上のエチレン性不飽和化合物としては、ジペンタエリスリトール(トリ/テトラ/ペンタ/ヘキサ)(メタ)アクリレート、ペンタエリスリトール(トリ/テトラ)(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、ジトリメチロールプロパンテトラ(メタ)アクリレート、イソシアヌル酸(メタ)アクリレート、及び、グリセリントリ(メタ)アクリレート骨格の(メタ)アクリレート化合物が挙げられる。
ウレタン(メタ)アクリレートとしては、ウレタンジ(メタ)アクリレートが挙げられ、例えば、プロピレンオキサイド変性ウレタンジ(メタ)アクリレート、並びに、エチレンオキサイド及びプロピレンオキサイド変性ウレタンジ(メタ)アクリレートが挙げられる。
また、ウレタン(メタ)アクリレートとしては、3官能以上のウレタン(メタ)アクリレートも挙げられる。官能基数の下限としては、6官能以上がより好ましく、8官能以上が更に好ましい。なお、官能基数の上限としては、20官能以下が好ましい。3官能以上のウレタン(メタ)アクリレートとしては、例えば、8UX-015A(大成ファインケミカル(株)製)、UA-32P(新中村化学工業(株)製)、U-15HA(新中村化学工業(株)製)、UA-1100H(新中村化学工業(株)製)、共栄社化学(株)製のAH-600(商品名)、並びに、UA-306H、UA-306T、UA-306I、UA-510H、及びUX-5000(いずれも日本化薬(株)製)等が挙げられる。
酸基としては、リン酸基、スルホ基、及び、カルボキシ基が挙げられる。
これらのなかでも、酸基としては、カルボキシ基が好ましい。
酸基を有するエチレン性不飽和化合物としては、酸基を有する3~4官能のエチレン性不飽和化合物〔ペンタエリスリトールトリ及びテトラアクリレート(PETA)骨格にカルボキシ基を導入したもの(酸価:80~120mgKOH/g)〕、酸基を有する5~6官能のエチレン性不飽和化合物(ジペンタエリスリトールペンタ及びヘキサアクリレート(DPHA)骨格にカルボキシ基を導入したもの〔酸価:25~70mgKOH/g)〕等が挙げられる。
これら酸基を有する3官能以上のエチレン性不飽和化合物は、必要に応じ、酸基を有する2官能のエチレン性不飽和化合物と併用してもよい。
酸基を有するエチレン性不飽和化合物が、カルボキシ基を有する2官能以上のエチレン性不飽和化合物及びそのカルボン酸無水物からなる群から選ばれる少なくとも1種であると、現像性及び膜強度がより高まる。
カルボキシ基を有する2官能以上のエチレン性不飽和化合物は、特に制限されず、公知の化合物の中から適宜選択できる。
カルボキシ基を有する2官能以上のエチレン性不飽和化合物としては、アロニックス(登録商標)TO-2349(東亞合成(株)製)、アロニックス(登録商標)M-520(東亞合成(株)製)、アロニックス(登録商標)M-510(東亞合成(株)製)が挙げられる。
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、テトラメチロールメタン構造又はトリメチロールプロパン構造を有するエチレン不飽和化合物が好ましく、テトラメチロールメタントリ(メタ)アクリレート、テトラメチロールメタンテトラ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、又は、ジ(トリメチロールプロパン)テトラアクリレートがより好ましい。
エステル結合を含むエチレン性不飽和化合物としては、分子内にエステル結合を含むものであれば特に制限されないが、本発明の効果が優れる点で、テトラメチロールメタン構造又はトリメチロールプロパン構造を有するエチレン不飽和化合物が好ましく、テトラメチロールメタントリ(メタ)アクリレート、テトラメチロールメタンテトラ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、又は、ジ(トリメチロールプロパン)テトラアクリレートがより好ましい。
信頼性付与の点からは、エチレン性不飽和化合物としては、炭素数6~20の脂肪族基を有するエチレン性不飽和化合物と、上記のテトラメチロールメタン構造又はトリメチロールプロパン構造を有するエチレン不飽和化合物と、を含むことが好ましい。
炭素数6以上の脂肪族構造を有するエチレン性不飽和化合物としては、1,9-ノナンジオールジ(メタ)アクリレート、1,10-デカンジオールジ(メタ)アクリレート、及び、トリシクロデカンジメタノールジ(メタ)アクリレートが挙げられる。
上記重合性化合物としては、2環以上の脂肪族炭化水素環が縮環した環構造(好ましくは、トリシクロデカン構造及びトリシクロデセン構造からなる群から選択される構造)を有する重合性化合物が好ましく、2環以上の脂肪族炭化水素環が縮環した環構造を有する2官能エチレン性不飽和化合物がより好ましく、トリシクロデカンジメタノールジ(メタ)アクリレートが更に好ましい。
上記脂肪族炭化水素環構造としては、本発明の効果がより優れる点から、シクロペンタン構造、シクロヘキサン構造、トリシクロデカン構造、トリシクロデセン構造、ノルボルナン構造、又は、イソボロン構造が好ましい。
感光性組成物層に含まれる重合性化合物のうち、分子量300以下の重合性化合物の含有量の割合は、感光性組成物層に含まれる全ての重合性化合物の含有量に対して、30質量%以下が好ましく、25質量%以下がより好ましく、20質量%以下が更に好ましい。
感光性組成物層において、2官能のエチレン性不飽和化合物の含有量と、3官能以上のエチレン性不飽和化合物の含有量との質量比は、10:90~90:10が好ましく、30:70~70:30がより好ましい。
全てのエチレン性不飽和化合物の合計量に対する、2官能のエチレン性不飽和化合物の含有量は、20~80質量%が好ましく、30~70質量%がより好ましい。
感光性組成物層における2官能のエチレン性不飽和化合物は、10~60質量%が好ましく、15~40質量%がより好ましい。
また、感光性組成物層の好適態様の一つとして、感光性組成物層は、基板密着性、現像残渣抑制性、及び、防錆性の点から、化合物M、及び、酸基を有するエチレン性不飽和化合物を含むことが好ましく、化合物M、脂肪族炭化水素環構造を有する2官能エチレン性不飽和化合物、及び、酸基を有するエチレン性不飽和化合物を含むことがより好ましく、化合物M、脂肪族炭化水素環構造を有する2官能エチレン性不飽和化合物、3官能以上のエチレン性不飽和化合物、及び、酸基を有するエチレン性不飽和化合物を含むことが更に好ましく、化合物M、脂肪族炭化水素環構造を有する2官能エチレン性不飽和化合物、3官能以上のエチレン性不飽和化合物、酸基を有するエチレン性不飽和化合物、及び、ウレタン(メタ)アクリレート化合物を含むことが特に好ましい。
また、感光性組成物層の好適態様の一つとして、感光性組成物層は、感光性組成物層は、基板密着性、現像残渣抑制性、及び、防錆性の点から、1,9-ノナンジオールジアクリレート、及び、カルボン酸基を有する多官能エチレン性不飽和化合物を含むことが好ましく、1,9-ノナンジオールジアクリレート、トリシクロデカンジメタノールジアクリレート、及び、カルボン酸基を有する多官能エチレン性不飽和化合物を含むことが好ましく、1,9-ノナンジオールジアクリレート、トリシクロデカンジメタノールジアクリレート、ジペンタエリスリトールヘキサアクリレート、及び、カルボン酸基を有するエチレン性不飽和化合物を含むことが更に好ましく、1,9-ノナンジオールジアクリレート、トリシクロデカンジメタノールジアクリレート、カルボン酸基を有するエチレン性不飽和化合物、及び、ウレタンアクリレート化合物を含むことが特に好ましい。
上記エチレン性不飽和化合物における2官能以上のエチレン性不飽和化合物の含有量は、感光性組成物層に含まれる全てのエチレン性不飽和化合物の総含有量に対し、60~100質量%が好ましく、80~100質量%がより好ましく、90~100質量%が更に好ましい。
感光性組成物層における重合性化合物(特に、エチレン性不飽和化合物)の含有量は、感光性組成物層全質量に対して、1~70質量%が好ましく、5~70質量%がより好ましく、5~60質量%が更に好ましく、5~50質量%が特に好ましい。
感光性組成物層は、重合開始剤を含んでいてもよい。
重合開始剤としては、光重合開始剤が好ましい。
光重合開始剤としては特に制限はなく、公知の光重合開始剤を使用できる。
光重合開始剤としては、オキシムエステル構造を有する光重合開始剤(以下、「オキシム系光重合開始剤」ともいう。)、α-アミノアルキルフェノン構造を有する光重合開始剤(以下、「α-アミノアルキルフェノン系光重合開始剤」ともいう。)、α-ヒドロキシアルキルフェノン構造を有する光重合開始剤(以下、「α-ヒドロキシアルキルフェノン系重合開始剤」ともいう。)、アシルフォスフィンオキサイド構造を有する光重合開始剤(以下、「アシルフォスフィンオキサイド系光重合開始剤」ともいう。)、及び、N-フェニルグリシン構造を有する光重合開始剤(以下、「N-フェニルグリシン系光重合開始剤」ともいう。)等が挙げられる。
感光性組成物層が光重合開始剤を含む場合、光重合開始剤の含有量は、感光性組成物層全質量に対して、0.1質量%以上であるのが好ましく、0.5質量%以上であるのがより好ましく、1.0質量%以上であるのが更に好ましい。また、その上限値としては、感光性組成物層全質量に対して、10質量%以下であるのが好ましく、5質量%以下であるのより好ましい。
感光性組成物層は、複素環化合物を含んでいてもよい。
複素環化合物が有する複素環は、単環及び多環のいずれの複素環でもよい。
複素環化合物が有するヘテロ原子としては、窒素原子、酸素原子、及び、硫黄原子が挙げられる。複素環化合物は、窒素原子、酸素原子、及び、硫黄原子からなる群より選ばれる少なくとも1種の原子を有することが好ましく、窒素原子を有することがより好ましい。
上記のなかでも、複素環化合物としては、トリアゾール化合物、ベンゾトリアゾール化合物、テトラゾール化合物、チアジアゾール化合物、トリアジン化合物、ローダニン化合物、チアゾール化合物、ベンゾイミダゾール化合物、及び、ベンゾオキサゾール化合物からなる群より選ばれる少なくとも1種の化合物が好ましく、トリアゾール化合物、ベンゾトリアゾール化合物、テトラゾール化合物、チアジアゾール化合物、チアゾール化合物、ベンゾチアゾール化合物、ベンゾイミダゾール化合物、及び、ベンゾオキサゾール化合物からなる群より選ばれる少なくとも1種の化合物がより好ましい。
感光性組成物層が複素環化合物を含む場合、複素環化合物の含有量は、感光性組成物層全質量に対して、0.01~20.0質量%が好ましく、0.10~10.0質量%がより好ましく、0.30~8.0質量%が更に好ましく、0.50~5.0質量%が特に好ましい。
感光性組成物層は、脂肪族チオール化合物を含んでいてもよい。
感光性組成物層が脂肪族チオール化合物を含むことで、脂肪族チオール化合物がエチレン性不飽和基を有するラジカル重合性化合物との間でエン-チオール反応することで、形成される膜の硬化収縮が抑えられ、応力が緩和される。
感光性組成物層は、得られる硬化膜の強度、及び、得られる未硬化膜の粘着性の点から、熱架橋性化合物を含むことが好ましい。なお、本明細書においては、後述するエチレン性不飽和基を有する熱架橋性化合物は、エチレン性不飽和化合物としては扱わず、熱架橋性化合物として扱うものとする。
熱架橋性化合物としては、エポキシ化合物、オキセタン化合物、メチロール化合物、及び、ブロックイソシアネート化合物が挙げられる。なかでも、得られる硬化膜の強度、及び、得られる未硬化膜の粘着性の点から、ブロックイソシアネート化合物が好ましい。
ブロックイソシアネート化合物は、ヒドロキシ基及びカルボキシ基と反応するため、例えば、バインダーポリマー及びエチレン性不飽和基を有するラジカル重合性化合物の少なくとも一方が、ヒドロキシ基及びカルボキシ基の少なくとも一方を有する場合には、形成される膜の親水性が下がり、保護膜としての機能が強化される傾向がある。
なお、ブロックイソシアネート化合物とは、「イソシアネートのイソシアネート基をブロック剤で保護(いわゆる、マスク)した構造を有する化合物」を指す。
ブロックイソシアネートの解離温度とは、「示差走査熱量計を用いて、DSC(Differential scanning calorimetry)分析にて測定した場合における、ブロックイソシアネートの脱保護反応に伴う吸熱ピークの温度」を意味する。
示差走査熱量計としては、例えば、セイコーインスツルメンツ(株)製の示差走査熱量計(型式:DSC6200)を好適に使用できる。但し、示差走査熱量計は、これに限定されない。
これらのなかでも、解離温度が90~160℃であるブロック剤としては、例えば、保存安定性の点から、オキシム化合物、ピラゾール化合物から選ばれる少なくとも1種が好ましい。
イソシアヌレート構造を有するブロックイソシアネート化合物は、例えば、ヘキサメチレンジイソシアネートをイソシアヌレート化して保護することにより得られる。
イソシアヌレート構造を有するブロックイソシアネート化合物のなかでも、オキシム化合物をブロック剤として用いたオキシム構造を有する化合物が、オキシム構造を有さない化合物よりも解離温度を好ましい範囲にしやすく、かつ、現像残渣を少なくしやすいという点から好ましい。
重合性基としては、特に制限はなく、公知の重合性基を用いることができ、ラジカル重合性基が好ましい。
重合性基としては、(メタ)アクリロキシ基、(メタ)アクリルアミド基、及び、スチリル基等のエチレン性不飽和基、並びに、グリシジル基等のエポキシ基を有する基が挙げられる。
なかでも、重合性基としては、エチレン性不飽和基が好ましく、(メタ)アクリロキシ基がより好ましく、アクリロキシ基が更に好ましい。
ブロックイソシアネート化合物の市販品の例としては、カレンズ(登録商標) AOI-BM、カレンズ(登録商標) MOI-BM、カレンズ(登録商標) MOI-BP等(以上、昭和電工(株)製)、ブロック型のデュラネートシリーズ(例えば、デュラネート(登録商標) TPA-B80E、デュラネート(登録商標)SBN-70D、デュラネート(登録商標) WT32-B75P等、旭化成ケミカルズ(株)製)が挙げられる。ブロックイソシアネート化合物としては、NCO価は、4.5mmol/g以上のブロックイソシアネート化合物を含有すること(以後、第1ブロックイソシアネート化合物ということがある)が、本発明の効果がより優れる点から好ましい。第1ブロックイソシアネート化合物NCO価は、5.0mmol/g以上が好ましく、5.3mmol/g以上がより好ましい。
第1ブロックイソシアネート化合物のNCO価の上限値は、本発明の効果がより優れる点から、8.0mmol/g以下が好ましく、6.0mmol/g以下がより好ましく、5.8mmol/g未満が更に好ましく、5.7mmol/g以下が特に好ましい。
本発明におけるブロックイソシアネート化合物のNCO価は、ブロックイソシアネート化合物1g当たりに含まれるイソシアネート基のモル数を意味し、ブロックイソシアネート化合物の構造式から計算される値である。
第1ブロックイソシアネート化合物は、本発明の効果がより優れる点から、環構造を有することが好ましい。環構造としては、脂肪族炭化水素環、芳香族炭化水素環及び複素環が挙げられ、本発明の効果がより優れる点から、脂肪族炭化水素環及び芳香族炭化水素環が好ましく、脂肪族炭化水素環がより好ましい。
脂肪族炭化水素環の具体例としては、シクロペンタン環、シクロヘキサン環が挙げられ、中でも、シクロヘキサン環が好ましい。
芳香族炭化水素環の具体例としては、ベンゼン環、ナフタレン環が挙げられ、中でも、ベンゼン環が好ましい。
複素環の具体例としては、イソシアヌレート環が挙げられる。
第1ブロックイソシアネート化合物が環構造を有する場合、環の個数は、本発明の効果がより優れる点から、1~2が好ましく、1がより好ましい。なお、第1ブロックイソシアネート化合物が縮合環を含む場合には、縮合環を構成する環の個数を数え、例えば、ナフタレン環における環の個数は2として数える。
B1-A1-L1-A2-B2 式Q
ブロックイソシアネート基としては、特に限定されないが、本発明の効果がより優れる点から、イソシアネート基がオキシム化合物でブロックされた基が好ましく、イソシアネート基がメチルエチルケトオキシムでブロックされた基(具体的には、*-NH-C(=O)-O-N=C(CH3)-C2H5で表される基。*は、A1又はA2との結合位置を表す。)がより好ましい。
B1及びB2は、同一の基であることが好ましい。
アルキレン基は、直鎖状、分岐状又は環状であってもよいが、直鎖状であることが好ましい。
アルキレン基の炭素数は、1~10であるが、本発明の効果がより優れる点から、1~5が好ましく、1~3がより好ましく、1が更に好ましい。
A1及びA2は、同一の基であることが好ましい。
2価の連結基の具体例としては、2価の炭化水素基が挙げられる。
2価の炭化水素基の具体例としては、2価の飽和炭化水素基、2価の芳香族炭化水素基、及び、これらの基が2つ以上連結されて形成される基が挙げられる。
2価の飽和炭化水素基としては、直鎖状、分岐状又は環状であってもよく、本発明の効果がより優れる点から、環状であることが好ましい。2価の飽和炭化水素基の炭素数は、本発明の効果がより優れる点から、4~15が好ましく、5~10がより好ましく、5~8が更に好ましい。
2価の芳香族炭化水素基としては、炭素数5~20であることが好ましく、例えば、フェニレン基が挙げられる。2価の芳香族炭化水素基は、置換基(例えば、アルキル基)を有していてもよい。
中でも、2価の連結基としては、炭素数5~10の直鎖状、分岐状若しくは環状の2価の飽和炭化水素基、炭素数5~10の環状の飽和炭化水素基と炭素数1~3の直鎖状のアルキレン基とが連結した基、置換基を有していてもよい2価の芳香族炭化水素基、又は、2価の芳香族炭化水素基と炭素数1~3の直鎖状のアルキレン基とが連結した基が好ましく、炭素数5~10の環状の2価の飽和炭化水素基、又は、置換基を有していてもよいフェニレン基がより好ましく、シクロヘキシレン基又は置換基を有していてもよいフェニレン基が更に好ましく、シクロヘキシレン基が特に好ましい。
B1a-A1a-L1a-A2a-B2a 式QA
L1aにおける環状の2価の飽和炭化水素基の炭素数は、5~10が好ましく、5~8がより好ましく、5~6が更に好ましく、6が特に好ましい。
L1aにおける2価の芳香族炭化水素基の好適態様は、式Q中のL1と同様である。
中でも、L1aは、環状の2価の飽和炭化水素基が好ましく、炭素数5~10の環状の2価の飽和炭化水素基がより好ましく、炭素数5~10の環状の2価の飽和炭化水素基が更に好ましく、炭素数5~6の環状の2価の飽和炭化水素基が特に好ましく、シクロへキシレン基が最も好ましい。
L1aがシクロへキシレン基である場合、式QAで表されるブロックイソシアネート化合物は、cis体とtrans体との異性体混合物(以下、「cis-trans異性体混合物」ともいう。)であってもよい。
cis体とtrans体との質量比は、cis体/trans体=10/90~90/10が好ましく、cis体/trans体=40/60~60/40がより好ましい。
感光性組成物層が熱架橋性化合物を含む場合、熱架橋性化合物の含有量は、感光性組成物層全質量に対して、1~50質量%が好ましく、5~30質量%がより好ましい。
感光性組成物層は、界面活性剤を含んでいてもよい。
界面活性剤としては、例えば、特許第4502784号公報の段落[0017]、及び、特開2009-237362号公報の段落[0060]~[0071]に記載の界面活性剤が挙げられる。
フッ素系界面活性剤の市販品としては、例えば、メガファック F-171、F-172、F-173、F-176、F-177、F-141、F-142、F-143、F-144、F-437、F-475、F-477、F-479、F-482、F-551-A、F-552、F-554、F-555-A、F-556、F-557、F-558、F-559、F-560、F-561、F-565、F-563、F-568、F-575、F-780、EXP.MFS-330、EXP.MFS-578、EXP.MFS-578-2、EXP.MFS-579、EXP.MFS-586、EXP.MFS-587、EXP.MFS-628、EXP.MFS-631、EXP.MFS-603、R-41、R-41-LM、R-01、R-40、R-40-LM、RS-43、TF-1956、RS-90、R-94、RS-72-K、DS-21(以上、DIC株式会社製)、フロラード FC430、FC431、FC171(以上、住友スリーエム(株)製)、サーフロンS-382、SC-101、SC-103、SC-104、SC-105、SC-1068、SC-381、SC-383、S-393、KH-40(以上、AGC(株)製)、PolyFox PF636、PF656、PF6320、PF6520、PF7002(以上、OMNOVA社製)、フタージェント 710FL、710FM、610FM、601AD、601ADH2、602A、215M、245F、251、212M、250、209F、222F、208G、710LA、710FS、730LM、650AC、681、683(以上、(株)NEOS製)、U-120E(ユニケム株式会社)等が挙げられる。
また、フッ素系界面活性剤としては、フッ素原子を含有する官能基を持つ分子構造を有し、熱を加えるとフッ素原子を含有する官能基の部分が切断されてフッ素原子が揮発するアクリル系化合物も好適に使用できる。このようなフッ素系界面活性剤としては、DIC(株)製のメガファック DSシリーズ(化学工業日報(2016年2月22日)、日経産業新聞(2016年2月23日))、例えばメガファック DS-21が挙げられる。
また、フッ素系界面活性剤としては、フッ素化アルキル基又はフッ素化アルキレンエーテル基を有するフッ素原子含有ビニルエーテル化合物と、親水性のビニルエーテル化合物との重合体を用いることも好ましい。
また、フッ素系界面活性剤としては、ブロックポリマーも使用できる。
また、フッ素系界面活性剤としては、フッ素原子を有する(メタ)アクリレート化合物に由来する構成単位と、アルキレンオキシ基(好ましくはエチレンオキシ基、プロピレンオキシ基)を2以上(好ましくは5以上)有する(メタ)アクリレート化合物に由来する構成単位と、を含む含フッ素高分子化合物も好ましく使用できる。
また、フッ素系界面活性剤としては、エチレン性不飽和結合含有基を側鎖に有する含フッ素重合体も使用できる。メガファック RS-101、RS-102、RS-718K、RS-72-K(以上、DIC株式会社製)等が挙げられる。
炭化水素系界面活性剤としては、グリセロール、トリメチロールプロパン、トリメチロールエタン並びにそれらのエトキシレート及びプロポキシレート(例えば、グリセロールプロポキシレート、グリセロールエトキシレート等)、ポリオキシエチレンラウリルエーテル、ポリオキシエチレンステアリルエーテル、ポリオキシエチレンオレイルエーテル、ポリオキシエチレンオクチルフェニルエーテル、ポリオキシエチレンノニルフェニルエーテル、ポリエチレングリコールジラウレート、ポリエチレングリコールジステアレート、ソルビタン脂肪酸エステル、等が挙げられる。具体例としては、プルロニック L10、L31、L61、L62、10R5、17R2、25R2、テトロニック 304、701、704、901、904、150R1、HYDROPALAT WE 3323(以上、BASF社製)、ソルスパース 20000(以上、日本ルーブリゾール(株)製)、NCW-101、NCW-1001、NCW-1002(以上、富士フイルム和光純薬(株)製)、パイオニン D-1105、D-6112、D-6112-W、D-6315(以上、竹本油脂(株)製)、オルフィンE1010、サーフィノール104、400、440(以上、日信化学工業(株)製)等が挙げられる。
EXP.S-309-2、EXP.S-315、EXP.S-503-2、EXP.S-505-2(以上、DIC株式会社製)、DOWSIL 8032 ADDITIVE、トーレシリコーンDC3PA、トーレシリコーンSH7PA、トーレシリコーンDC11PA、トーレシリコーンSH21PA、トーレシリコーンSH28PA、トーレシリコーンSH29PA、トーレシリコーンSH30PA、トーレシリコーンSH8400(以上、東レ・ダウコーニング(株)製)並びに、X-22-4952、X-22-4272、X-22-6266、KF-351A、K354L、KF-355A、KF-945、KF-640、KF-642、KF-643、X-22-6191、X-22-4515、KF-6004、KF-6001、KF-6002、KP-101、KP-103、KP-104、KP-105、KP-106、KP-109、KP-112、KP-120、KP-121、KP-124、KP-125、KP-301、KP-306、KP-310、KP-322、KP-323、KP-327、KP-341、KP-368、KP-369、KP-611、KP-620、KP-621、KP-626、KP-652(以上、信越シリコーン株式会社製)、F-4440、TSF-4300、TSF-4445、TSF-4460、TSF-4452(以上、モメンティブ・パフォーマンス・マテリアルズ社製)、BYK300、BYK306、BYK307、BYK310、BYK320、BYK323、BYK325、BYK330、BYK313、BYK315N、BYK331、BYK333、BYK345、BYK347、BYK348、BYK349、BYK370、BYK377、BYK378(以上、ビックケミー社製)等が挙げられる。
感光性組成物層が界面活性剤を含む場合、界面活性剤の含有量は、感光性組成物層全質量に対して、0.01~3.0質量%が好ましく、0.01~1.0質量%がより好ましく、0.05~0.80質量%が更に好ましい。
感光性組成物層は、重合禁止剤を含んでいてもよい。
重合禁止剤とは、重合反応を遅延又は禁止させる機能を有する化合物を意味する。重合禁止剤としては、例えば、重合禁止剤として用いられる公知の化合物を使用できる。
なかでも、本発明の効果がより優れる点で、重合禁止剤としては、フェノチアジン化合物、ニトロソ化合物又はその塩、及び、ヒンダードフェノール化合物からなる群より選ばれる少なくとも1種が好ましく、フェノチアジン、ビス[3-(3-tert-ブチル-4-ヒドロキシ-5-メチルフェニル)プロピオン酸]、[エチレンビス(オキシエチレン)]2,4-ビス〔(ラウリルチオ)メチル〕-o-クレゾール、1,3,5-トリス(3,5-ジ-t-ブチル-4-ヒドロキシベンジル)、p-メトキシフェノール、及び、N-ニトロソフェニルヒドロキシルアミンアルミニウム塩がより好ましい。
感光性組成物層が重合禁止剤を含む場合、重合禁止剤の含有量は、感光性組成物層全質量に対して、0.001~5.0質量%が好ましく、0.01~3.0質量%がより好ましく、0.02~2.0質量%が更に好ましい。重合禁止剤の含有量は、重合性化合物全質量に対しては、0.005~5.0質量%が好ましく、0.01~3.0質量%がより好ましく、0.01~1.0質量%が更に好ましい。
感光性組成物層は、水素供与性化合物を含んでいてもよい。
水素供与性化合物は、光重合開始剤の活性光線に対する感度を一層向上させる、及び、酸素による重合性化合物の重合阻害を抑制する等の作用を有する。
なかでも、本発明の効果がより優れる点で、アミン類としては、4,4’-ビス(ジエチルアミノ)ベンゾフェノン、及び、トリス(4-ジメチルアミノフェニル)メタンからなる群より選ばれる少なくとも1種が好ましい。
なかでも、本発明の効果がより優れる点で、アミノ酸化合物としては、N-フェニルグリシンが好ましい。
感光性組成物層が水素供与性化合物を含む場合、水素供与性化合物の含有量は、重合成長速度と連鎖移動のバランスとによる硬化速度の向上の点から、感光性組成物層全質量に対して、0.01~10.0質量%が好ましく、0.01~8.0質量%がより好ましく、0.03~5.0質量%が更に好ましい。
感光性組成物層は、所定量の不純物を含んでいてもよい。
不純物の具体例としては、ナトリウム、カリウム、マグネシウム、カルシウム、鉄、マンガン、銅、アルミニウム、チタン、クロム、コバルト、ニッケル、亜鉛、スズ、ハロゲン及びこれらのイオンが挙げられる。なかでも、ハロゲン化物イオン(塩化物イオン、臭化物イオン、ヨウ化物イオン)、ナトリウムイオン、及び、カリウムイオンは不純物として混入し易いため、下記の含有量にすることが好ましい。
感光性組成物層は、上述したアルカリ可溶性樹脂の各構成単位の残存モノマーを含む場合がある。
残存モノマーの含有量は、パターニング性、及び、信頼性の点から、アルカリ可溶性樹脂全質量に対して、5,000質量ppm以下が好ましく、2,000質量ppm以下がより好ましく、500質量ppm以下が更に好ましい。下限は特に制限されないが、1質量ppm以上が好ましく、10質量ppm以上がより好ましい。
アルカリ可溶性樹脂の各構成単位の残存モノマーは、パターニング性、及び、信頼性の点から、感光性組成物層全質量に対して、3,000質量ppm以下が好ましく、600質量ppm以下がより好ましく、100質量ppm以下が更に好ましい。下限は特に制限されないが、0.1質量ppm以上が好ましく、1質量ppm以上がより好ましい。
残存モノマーの量は、液体クロマトグラフィー、及び、ガスクロマトグラフィー等の公知の方法で測定できる。
感光性組成物層は、既述の成分以外の成分(以下、「他の成分」ともいう。)を含んでいてもよい。他の成分としては、例えば、着色剤、酸化防止剤、及び、粒子(例えば、金属酸化物粒子)が挙げられる。また、他の成分としては、特開2000-310706号公報の段落[0058]~[0071]に記載のその他の添加剤も挙げられる。
粒子としては、金属酸化物粒子が好ましい。
金属酸化物粒子における金属には、B、Si、Ge、As、Sb、及び、Te等の半金属も含まれる。
粒子の平均一次粒子径は、例えば、硬化膜の透明性の点から、1~200nmが好ましく、3~80nmがより好ましい。
粒子の平均一次粒子径は、電子顕微鏡を用いて任意の粒子200個の粒子径を測定し、測定結果を算術平均することにより算出される。なお、粒子の形状が球形でない場合には、最も長い辺を粒子径とする。
感光性組成物層は、粒子を含まないか、或いは、感光性組成物層が粒子を含む場合には、粒子の含有量が感光性組成物層全質量に対して、0質量%超35質量%以下が好ましく、粒子を含まないか、或いは、粒子の含有量が感光性組成物全質量に対して、0質量%超10質量%以下がより好ましく、粒子を含まないか、或いは、粒子の含有量が感光性組成物層全質量に対して0質量%超5質量%以下が更に好ましく、粒子を含まないか、或いは、粒子の含有量が感光性組成物層全質量に対して0質量%超1質量%以下が更に好ましく、粒子を含まないことが特に好ましい。
感光性組成物層は、微量の着色剤(顔料、染料等)を含んでいてもよいが、例えば、透明性の点からは、着色剤を実質的に含まないことが好ましい。
感光性組成物層が着色剤を含む場合、着色剤の含有量は、感光性組成物層全質量に対して、1質量%未満が好ましく、0.1質量%未満がより好ましい。
酸化防止剤としては、例えば、1-フェニル-3-ピラゾリドン(別名:フェニドン)、1-フェニル-4,4-ジメチル-3-ピラゾリドン、及び、1-フェニル-4-メチル-4-ヒドロキシメチル-3-ピラゾリドン等の3-ピラゾリドン類;ハイドロキノン、カテコール、ピロガロール、メチルハイドロキノン、及び、クロルハイドロキノン等のポリヒドロキシベンゼン類;パラメチルアミノフェノール、パラアミノフェノール、パラヒドロキシフェニルグリシン、及び、パラフェニレンジアミンが挙げられる。
なかでも、本発明の効果がより優れる点で、酸化防止剤としては、3-ピラゾリドン類が好ましく、1-フェニル-3-ピラゾリドンがより好ましい。
感光性組成物層の厚みは、特に制限されないが、30μm以下の場合が多く、本発明の効果がより優れる点で、20μm以下が好ましく、15μm以下がより好ましく、10μm以下が更に好ましく、5.0μm以下が特に好ましい。下限としては、感光性組成物層を硬化して得られる膜の強度が優れる点で、0.60μm以上が好ましく、1.5μm以上がより好ましい。
感光性組成物層の厚みは、例えば、走査型電子顕微鏡(SEM)による断面観察により測定した任意の5点の平均値として算出できる。
感光性組成物層の屈折率は、1.41~1.59が好ましく、1.47~1.56がより好ましい。
感光性組成物層は無彩色であることが好ましい。具体的には、全反射(入射角8°、光源:D-65(2°視野))が、CIE1976(L*,a*,b*)色空間において、L*値は10~90であることが好ましく、a*値は-1.0~1.0であることが好ましく、b*値は-1.0~1.0であることが好ましい。
具体的には、全反射(入射角8°、光源:D-65(2°視野))が、CIE1976(L*,a*,b*)色空間において、パターンのL*値は10~90であることが好ましく、パターンのa*値は-1.0~1.0であることが好ましく、パターンのb*値は-1.0~1.0であることが好ましい。
感光性組成物層の膜厚1.0μmあたりの可視光透過率は80%以上が好ましく、90%以上がより好ましく、95%以上が最も好ましい。可視光の透過率としては、波長400nm~800nmの平均透過率、波長400nm~800nmの透過率の最小値、波長400nmmの透過率、いずれもが上記を満たすことが好ましい。透過率の好ましい値としては、例えば、87%、92%、98%等を挙げることができる。感光性組成物層の硬化膜の膜厚1μmあたりの透過率も同様である。
感光性組成物層を硬化して得られるパターン(感光性組成物層の硬化膜)の膜厚40μmでの透湿度は、電極又は配線の防錆性の観点、及びデバイスの信頼性の観点から、500g/m2/24hr以下であることが好ましく、300g/m2/24hr以下であることがより好ましく、100g/m2/24hr以下であることが更に好ましい。
透湿度は、感光性組成物層を、i線によって露光量300mJ/cm2にて露光した後、145℃、30分間のポストベークを行うことにより、感光性組成物層を硬化させた硬化膜で測定する。透湿度の測定は、JIS Z0208のカップ法に準じて行う。温度40℃/湿度90%、温度65℃/湿度90%、及び温度80℃/湿度95%のいずれの試験条件においても、上記の透湿度であることが好ましい。具体的な好ましい数値としては、例えば、80g/m2/24hr、150g/m2/24hr、220g/m2/24hr、等を挙げることができる。
感光性組成物層の炭酸ナトリウム1.0%水溶液に対する溶解速度は、現像時の残渣抑制の観点から、0.01μm/秒以上が好ましく、0.10μm/秒以上がより好ましく、0.20μm/秒以上がより好ましい。パターンのエッジ形状の観点から、5.0μm/秒以下が好ましく、4.0μm/秒以下がより好ましく、3.0μm/秒以下が更に好ましい。具体的な好ましい数値としては、例えば、1.8μm/秒、1.0μm/秒、0.7μm/秒等を挙げることができる。1.0質量%炭酸ナトリウム水溶液に対する感光性組成物層の単位時間あたりの溶解速度は、以下のように測定するものとする。
ガラス基板に形成した、溶媒を十分に除去した感光性組成物層(膜厚1.0~10μmの範囲内)に対し、1.0質量%炭酸ナトリウム水溶液を用いて25℃で、感光性組成物層が溶け切るまでシャワー現像を行う(但し、最長で2分までとする)。 感光性組成物層の膜厚を、感光性組成物層が溶け切るまでに要した時間で割り算することで求める。なお、2分で溶け切らない場合は、それまでの膜厚変化量から同様に計算する。
感光性組成物層の硬化膜(膜厚1.0~10μmの範囲内)の炭酸ナトリウム1.0%水溶液に対する溶解速度は、3.0μm/秒以下が好ましく、2.0μm/秒以下がより好ましく、1.0μm/秒以下が更に好ましく、0.2μm/秒以下が最も好ましい。感光性組成物層の硬化膜は、感光性組成物層をi線によって露光量300mJ/cm2にて露光して得られる膜である。具体的な好ましい数値としては、例えば、0.8μm/秒、0.2μm/秒、0.001μm/秒等を挙げることができる。現像は、(株)いけうち製1/4MINJJX030PPのシャワーノズルを使用し、シャワーのスプレー圧は0.08MPaとする。上記条件の時、単位時間当たりのシャワー流量は1,800mL/minとする。
露光後の感光性組成物層の1.0質量%炭酸ナトリウム水溶液に対する膨潤率は、パターン形成性向上の観点から、100%以下が好ましく、50%以下がより好ましく、30%以下が更に好ましい。露光後の感光性樹脂層の1.0質量%炭酸ナトリウム水溶液に対する膨潤率は、以下のように測定するものとする。
ガラス基板に形成した、溶媒を十分に除去した感光性樹脂層(膜厚1.0~10μmの範囲内)に対し、超高圧水銀灯で500mj/cm2(i線測定)で露光する。25℃でガラス基板ごと、1.0質量%炭酸ナトリウム水溶液に浸漬し、30秒経過時点での膜厚を測定する。そして、浸漬後の膜厚が浸漬前の膜厚に対して増加した割合を計算する。具体的な好ましい数値としては、例えば、4%、13%、25%等を挙げることができる。
パターン形成性の観点から、感光性組成物層中の直径1.0μm以上の異物の数は、10個/mm2以下であることが好ましく、5個/mm2以下であることがより好ましい。異物個数は以下のように測定するものとする。感光性組成物層の表面の法線方向から、感光性組成物層の面上の任意の5か所の領域(1mm×1mm)を、光学顕微鏡を用いて目視にて観察して、各領域中の直径1.0μm以上の異物の数を測定して、それらを算術平均して異物の数として算出する。具体的な好ましい数値としては、例えば、0個/mm2、1個/mm2、4個/mm2、8個/mm2等を挙げることができる。
現像時での凝集物発生抑止の観点から、1.0質量%炭酸ナトリウムの30℃水溶液1.0リットルに1.0cm3の感光樹脂層を溶解させて得られる溶液のヘイズは60%以下であることが好ましく、30%以下であることがより好ましく、10%以下であることが更に好ましく、1%以下であることが最も好ましい。ヘイズは以下のように測定するものとする。まず、1.0質量%の炭酸ナトリウム水溶液を準備し、液温を30℃に調整する。炭酸ナトリウム水溶液1.0Lに1.0cm3の感光樹脂層を入れる。気泡を混入しないように注意しながら、30℃で4時間撹拌する。撹拌後、感光性樹脂層が溶解した溶液のヘイズを測定する。ヘイズは、ヘイズメーター(製品名「NDH4000」、日本電色工業社製)を用い、液体測定用ユニット及び光路長20mmの液体測定専用セルを用いて測定される。具体的な好ましい数値としては、例えば、0.4%、1.0%、9%、24%等を挙げることができる。
転写フィルムは、保護フィルムを有する。
保護フィルムは、ポリプロピレンを含む。
保護フィルムとしては、ポリプロピレンを含んでいれば特に制限されず、ポリプロピレン以外の他の樹脂を含んでいてもよい。他の樹脂としては、例えば、ポリエチレン等のポリオレフィン樹脂、ポリエチレンテレフタレート等のポリエステル樹脂、ポリカーボネート樹脂、及び、ポリスチレン樹脂が挙げられる。
なかでも、保護フィルムとしては、ポリプロピレンを含むポリオレフィンフィルムが好ましく、ポリプロピレンフィルム又はポリプロピレンを含むポリエチレンフィルムがより好ましく、ポリプロピレンフィルムが更に好ましい。
算術平均粗さRa1は、算術平均粗さRa2よりも小さければ特に制限されないが、パターン欠陥抑制性に優れる点で、算術平均粗さRa1は、0.090μm以下が好ましく、0.050μm以下がより好ましい。算術平均粗さRa1の下限は、0.000μm以上が挙げられ、0.005μm以上の場合が多い。
算術平均粗さRa2は、算術平均粗さRa1よりも大きければ特に制限されないが、保護フィルムの巻き取り性に優れる点で、0.050μm超が好ましく、0.060μm超がより好ましく、0.070μm超が更に好ましく、0.080μm超が特に好ましい。算術平均粗さRa2の上限は、転写フィルムにおける欠陥等を検査する際の検査性に優れる点で、0.200μm以下が好ましく、0.150μm未満がより好ましく、0.120μm以下が更に好ましく、0.100μm以下が特に好ましい。
また、算術平均粗さRa1に対する算術平均粗さRa2の比(算術平均粗さRa2/算術平均粗さRa1)は、1より大きく、1.3以上が好ましく、1.7以上がさらに好ましい。上記比の上限は特に設定されないが、5.0以下が好ましく、3.0以下がより好ましい。
本明細書においては、算術平均粗さRa2は、微細形状測定器(ET-350K、(株)小坂研究所製)で表面の凹凸を測定し、得られる輪郭曲線から、JIS B 0601:2001準拠して算術平均粗さRaを求めたものとする。なお、算術平均粗さRaの算出には、三次元解析ソフト(TDA-22、(株)小坂研究所製)を用いる。
また、保護フィルムの算術平均粗さRa1は、転写フィルムにおいて、保護フィルムと感光性組成物層との界面で保護フィルムを剥離し、感光性組成物層と接していた側の保護フィルムの表面について、上記算術平均粗さRa2と同様の方法で測定して得るものとする。
保護フィルムの厚みは、機械的強度に優れる点で、1μm以上が好ましく、10μm以上がより好ましい。また、比較的安価となる点、及び、後述する製造時に気泡を低減できる点で、100μm以下が好ましく、30μm以下がより好ましい。製造時の気泡を低減することで、パターン欠陥抑制性もより優れたものとすることができる。
なお、「フィッシュアイ」とは、材料を熱溶融し、混練、押し出し、2軸延伸及びキャスティング法等の方法によりフィルムを製造する際に、材料の異物、未溶解物、及び、酸化劣化物等がフィルム中に取り込まれたものである。
これにより、保護フィルムに含まれる粒子に起因する凹凸が感光性組成物層又は導電層に転写されることにより生じる欠陥を抑制することができる。
転写フィルムは、感光性組成物層を硬化した硬化膜の120℃における破断伸びが15%以上であり、仮支持体の感光性組成物層側の表面の算術平均粗さRaが50nm以下であり、保護フィルムの感光性組成物層側の表面の算術平均粗さRaが150nm以下であることも好ましい。
X×Y<1500 式(1)
ここで、式(1)中、Xは、感光性組成物層を硬化した硬化膜の120℃における破断伸びの値(%)を表し、Yは、仮支持体の感光性組成物層側の表面の算術平均粗さRaの値(nm)を表す。上記X×Yは、750以下がより好ましい。上記Xの具体的な数値としては、18%、25%、30%、35%等を挙げることが出来る。上記X×Yの具体的な数値としては、4nm、8nm、15nm、30nm等を挙げることが出来る。上記X×Yの具体的な数値としては、150、200、300、360、900等を挙げることが出来る。
Y≦Z 式(2)
ここで、式(2)中、Yは、仮支持体の感光性組成物層側の表面の算術平均粗さRaの値(nm)を表し、Zは、保護フィルムの感光性組成物層側の表面の算術平均粗さRaの値(nm)を表す。
転写フィルムは、屈折率調整層を有していてもよい。
屈折率調整層としては、公知の屈折率調整層を適用できる。屈折率調整層に含まれる材料としては、例えば、バインダーポリマー、重合性化合物、金属塩、及び、粒子が挙げられる。
屈折率調整層の屈折率を制御する方法は、特に制限されず、例えば、所定の屈折率の樹脂を単独で用いる方法、樹脂と粒子とを用いる方法、及び、金属塩と樹脂との複合体を用いる方法が挙げられる。
金属酸化物粒子の種類は特に制限はなく、公知の金属酸化物粒子が挙げられる。金属酸化物粒子における金属には、B、Si、Ge、As、Sb、及び、Te等の半金属も含まれる。
粒子の平均一次粒子径は、電子顕微鏡を用いて任意の粒子200個の粒子径を測定し、測定結果を算術平均することにより算出される。なお、粒子の形状が球形でない場合には、最も長い辺を粒子径とする。
これらのなかでも、金属酸化物粒子としては、例えば、屈折率を調整しやすいという点から、酸化ジルコニウム粒子及び酸化チタン粒子からなる群から選ばれる少なくとも1種がより好ましい。
屈折率調整層における粒子の含有量は、屈折率調整層全質量に対し、1~95質量%が好ましく、20~90質量%がより好ましく、40~85質量%が更に好ましい。
金属酸化物粒子として酸化チタンを用いる場合、酸化チタン粒子の含有量は、屈折率調整層全質量に対して、1~95質量%が好ましく、20~90質量%がより好ましく、40~85質量%が更に好ましい。
屈折率調整層の屈折率は、1.50以上が好ましく、1.55以上がより好ましく、1.60以上が更に好ましく、1.65以上が特に好ましい。屈折率調整層の屈折率の上限は、2.10以下が好ましく、1.85以下がより好ましく、1.78以下が更に好ましい。
屈折率調整層の厚みは、走査型電子顕微鏡(SEM)による断面観察により測定した任意の5点の平均値として算出する。
第1実施形態の転写フィルムの製造方法は特に制限されず、公知の方法を使用できる。
上記の転写フィルム10の製造方法としては、例えば、仮支持体1の表面に感光性組成物を塗布して塗膜を形成し、更にこの塗膜を乾燥して感光性組成物層3を形成する工程と、感光性組成物層3の表面に屈折率調整層形成用組成物を塗布して塗膜を形成し、更にこの塗膜を乾燥して屈折率調整層5を形成する工程と、屈折率調整層5上に、保護フィルム7を圧着する工程と、を含む方法が挙げられる。
上記工程により、仮支持体1、感光性組成物層3、屈折率調整層5、及び保護フィルム7を備える転写フィルム10を製造できる。
上記の製造方法により転写フィルム10を製造した後、転写フィルム10を巻き取ることにより、ロール形態の転写フィルムを作製及び保管してもよい。ロール形態の転写フィルムは、後述するロールツーロール方式での基板との貼合工程にそのままの形態で提供できる。
また、上記の転写フィルム10の製造方法としては、仮支持体1上に感光性組成物層3を形成し、別途、保護フィルム7上に屈折率調整層5を形成し、感光性組成物層3とに屈折率調整層5とを貼り合わせて形成する方法であってもよい。
生産性に優れる点、及び、上述した感光性組成物層が形成し易い点で、転写フィルム中の感光性組成物層は、上述した感光性組成物層を構成する成分(例えば、バインダーポリマー、重合性化合物、及び、重合開始剤等)、及び、溶剤を含む感光性組成物を使用して塗布法により形成されるのが望ましい。第1実施形態の転写フィルムの製造方法としては、具体的には、仮支持体上に感光性組成物を塗布して塗膜を形成し、この塗膜に所定温度にて乾燥処理を施して感光性組成物層を形成する方法であるのが好ましい。
感光性組成物の全固形分量は、感光性組成物の全質量に対して、5~80質量%が好ましく、5~40質量%がより好ましく、5~30質量%が更に好ましい。
つまり、感光性組成物中の溶剤の含有量としては、感光性組成物の全質量に対して、20~95質量%が好ましく、60~95質量%がより好ましく、70~95質量%が更に好ましい。
また、乾燥時間としては、20秒以上が好ましく、40秒以上がより好ましく、60秒以上が更に好ましい。また、その上限値としては特に制限されないが、600秒以下が好ましく、300秒以下がより好ましい。
屈折率調整層形成用組成物としては、上述した屈折率調整層を形成する各種成分と溶剤とを含むのが好ましい。なお、屈折率調整層形成用組成物において、組成物の全固形分に対する各成分の含有量の好適範囲は、上述した屈折率調整層の全質量に対する各成分の含有量の好適範囲と同じである。
溶剤としては、屈折率調整層に含まれる成分を溶解又は分散可能であれば特に制限されず、水及び水混和性の有機溶剤からなる群より選択される少なくとも1種が好ましく、水又は水と水混和性の有機溶剤との混合溶剤がより好ましい。
水混和性の有機溶剤としては、例えば、炭素数1~3のアルコール、アセトン、エチレングリコール、及びグリセリンが挙げられ、炭素数1~3のアルコールが好ましく、メタノール又はエタノールがより好ましい。
溶剤は、1種単独で使用してもよく、2種以上使用してもよい。
溶剤の含有量は、組成物の全固形分100質量部に対して、50~2,500質量部が好ましく、50~1,900質量部がより好ましく、100~900質量部が更に好ましい。
また、保護フィルムを屈折率調整層に貼り合わせることにより、第1実施形態の転写フィルムを製造できる。
保護フィルムを屈折率調整層に貼り合わせる方法は特に制限されず、公知の方法が挙げられる。
保護フィルムを屈折率調整層に貼り合わせる装置としては、真空ラミネーター、及び、オートカットラミネーター等の公知のラミネーターが挙げられる。
ラミネーターはゴムローラー等の任意の加熱可能なローラーを備え、加圧及び加熱ができるものが好ましい。
例えば、算術平均粗さRa1及びRa2を制御する方法として、物理的な作用を利用する方法、及び、化学的作用を利用する方法が挙げられる。より具体的には、所望の表面粗さを有する部材の表面と保護フィルムの表面とを接触させる方法、保護フィルムの表面を切削又は研磨する方法、保護フィルムの表面に活性光線またはプラズマを照射する方法、熱処理する方法、ポリプロピレンの結晶変態温度と融点との温度差を利用する方法、及び、ポリプロピレンに対してオレフィン系等の低融点樹脂を混合して偏析させる方法、並びに、上記方法を組み合わせた方法が挙げられる。上記方法を、保護フィルムの一方の面のみに適用するか、一方の面とは異なる度合いで作用するように適用すれば、上記算術平均粗さRa1が算術平均粗さRa2よりも小さい保護フィルムを製造できる。
以下において、第2実施形態の転写フィルムの実施形態の一例について説明する。
図2に示す転写フィルム20は、仮支持体11と、熱可塑性樹脂層13、中間層15、及び感光性組成物層17を含む組成物層12と、保護フィルム19とを、この順に有する。
また、図2で示す転写フィルム20は熱可塑性樹脂層13及び中間層15を配置した形態であるが、熱可塑性樹脂層13及び中間層15は、配置されなくてもよい。
以下において、転写フィルムを構成する各要素について説明する。
第2実施形態の転写フィルムにおいて、仮支持体11及び保護フィルム17としては、上述した第1実施形態の仮支持体1及び保護フィルム9と同じものが挙げられ、好適態様も同じであるため、その説明を省略する。
転写フィルムは、感光性組成物層を有する。
静電容量型入力装置等のタッチパネルを備えた表示装置(有機エレクトロルミネッセンス(EL)表示装置及び液晶表示装置等)では、視認部のセンサーに相当する電極パターン、周辺配線部分及び取り出し配線部分の配線等の導電層パターンがタッチパネル内部に設けられている。一般的にパターン化した層の形成には、転写フィルム等を用いて基板上にネガ型感光性組成物層(感光層)を設け、その感光層に対して所望のパターンを有するマスクを介して露光した後、現像する方法が広く採用されている。従って、感光性組成物層としては、ネガ型感光性組成物層であるのが好ましい。感光性組成物層がネガ型感光性組成物層である場合、形成されるパターンは硬化層に該当する。
このような感光性組成物層(ネガ型感光性組成物層)は、感光性組成物層の全質量を基準として、樹脂:10~90質量%;重合性化合物:5~70質量%;重合開始剤:0.01~20質量%を含むことが好ましい。
以下において、各成分を順に説明する。
感光性組成物層がネガ型感光性組成物層である場合に、感光性組成物層中に含まれる樹脂を、特に、重合体Aともいう。樹脂Aとしては、特に限定されないが、例えば、(メタ)アクリル樹脂、スチレン樹脂、エポキシ樹脂、アミド樹脂、アミドエポキシ樹脂、アルキド樹脂、フェノール樹脂、エステル樹脂、ウレタン樹脂、及び、エポキシアクリレート樹脂と酸無水物との反応で得られる酸変性エポキシアクリレート樹脂が挙げられる。
重合体Aは、アルカリ可溶性樹脂であることが好ましい。
重合体Aの酸価は、現像液によるネガ型感光性組成物層の膨潤を抑制することにより、解像性がより優れる観点から、220mgKOH/g以下が好ましく、200mgKOH/g未満がより好ましく、190mgKOH/g未満が更に好ましい。
重合体Aの酸価の下限は特に制限されないが、現像性がより優れる観点から、60mgKOH/g以上が好ましく、120mgKOH/g以上がより好ましく、150mgKOH/g以上が更に好ましく、170mgKOH/g以上が特に好ましい。
重合体Aの酸価は、重合体Aを構成する構成単位の種類及び酸基を含む構成単位の含有量により調整すればよい。
重合体Aにおける第一の単量体に基づく構成単位の含有量は、重合体Aの全質量に対して、5~50質量%が好ましく、10~40質量%がより好ましく、15~30質量%が更に好ましい。
上記含有量を5質量%以上にすることは、良好な現像性を発現させる観点、エッジフューズ性を制御する等の観点から好ましい。上記含有量を50質量%以下にすることは、レジストパターンの高解像性及びスソ形状の観点から、更にはレジストパターンの耐薬品性の観点から好ましい。
重合体Aにおける第二の単量体に基づく構成単位の含有量は、重合体Aの全質量に対して、5~60質量%が好ましく、15~50質量%がより好ましく、17~45質量%が更に好ましい。
一態様において、重合体Aは、芳香族炭化水素基を有する単量体に基づく構成単位を25~55質量%、第一の単量体に基づく構成単位を20~35質量%、第二の単量体に基づく構成単位を15~45質量%含む重合体であることが好ましい。また、別の態様において、芳香族炭化水素基を有する単量体に基づく構成単位を70~90質量%、第一の単量体に基づく構成単位を10~25質量%含む重合体であることが好ましい。
側鎖に分岐構造を有する基を含むモノマーの具体例としては、(メタ)アクリル酸イソプロピル、(メタ)アクリル酸イソブチル、(メタ)アクリル酸sec-ブチル、(メタ)アクリル酸tert-ブチル、(メタ)アクリル酸イソアミル、(メタ)アクリル酸tert-アミル、(メタ)アクリル酸sec-アミル、(メタ)アクリル酸2-オクチル、(メタ)アクリル酸3-オクチル及び(メタ)アクリル酸tert-オクチル等が挙げられる。これらのなかでも、(メタ)アクリル酸イソプロピル、(メタ)アクリル酸イソブチル、メタクリル酸tert-ブチルが好ましく、メタクリル酸イソプロピル又はメタクリル酸tert-ブチルがより好ましい。
側鎖に脂環構造を有する基を含むモノマーの具体例としては、単環の脂肪族炭化水素基を有するモノマー、及び、多環の脂肪族炭化水素基を有するモノマーが挙げられる。また、炭素原子数5~20個の脂環式炭化水素基を有する(メタ)アクリレートが挙げられる。より具体的な例としては、(メタ)アクリル酸(ビシクロ〔2.2.1〕ヘプチル-2)、(メタ)アクリル酸-1-アダマンチル、(メタ)アクリル酸-2-アダマンチル、(メタ)アクリル酸-3-メチル-1-アダマンチル、(メタ)アクリル酸-3,5-ジメチル-1-アダマンチル、(メタ)アクリル酸-3-エチルアダマンチル、(メタ)アクリル酸-3-メチル-5-エチル-1-アダマンチル、(メタ)アクリル酸-3,5,8-トリエチル-1-アダマンチル、(メタ)アクリル酸-3,5-ジメチル-8-エチル-1-アダマンチル、(メタ)アクリル酸2-メチル-2-アダマンチル、(メタ)アクリル酸2-エチル-2-アダマンチル、(メタ)アクリル酸3-ヒドロキシ-1-アダマンチル、(メタ)アクリル酸オクタヒドロ-4,7-メンタノインデン-5-イル、(メタ)アクリル酸オクタヒドロ-4,7-メンタノインデン-1-イルメチル、(メタ)アクリル酸-1-メンチル、(メタ)アクリル酸トリシクロデカン、(メタ)アクリル酸-3-ヒドロキシ-2,6,6-トリメチル-ビシクロ〔3.1.1〕ヘプチル、(メタ)アクリル酸-3,7,7-トリメチル-4-ヒドロキシ-ビシクロ〔4.1.0〕ヘプチル、(メタ)アクリル酸(ノル)ボルニル、(メタ)アクリル酸イソボルニル、(メタ)アクリル酸フェンチル、(メタ)アクリル酸-2,2,5-トリメチルシクロヘキシル、及び(メタ)アクリル酸シクロヘキシル等が挙げられる。これら(メタ)アクリル酸エステルのなかでも、(メタ)アクリル酸シクロヘキシル、(メタ)アクリル酸(ノル)ボルニル、(メタ)アクリル酸イソボルニル、(メタ)アクリル酸-1-アダマンチル、(メタ)アクリル酸-2-アダマンチル、(メタ)アクリル酸フェンチル、(メタ)アクリル酸-1-メンチル、又は(メタ)アクリル酸トリシクロデカンが好ましく、(メタ)アクリル酸シクロヘキシル、(メタ)アクリル酸(ノル)ボルニル、(メタ)アクリル酸イソボルニル、(メタ)アクリル酸-2-アダマンチル、又は(メタ)アクリル酸トリシクロデカンがより好ましい。
2種以上を使用する場合には、芳香族炭化水素基を有する単量体に基づく構成単位を含む重合体Aを2種類混合使用すること、又は芳香族炭化水素基を有する単量体に基づく構成単位を含む重合体Aと芳香族炭化水素基を有する単量体に基づく構成単位を含まない重合体Aとを混合使用することが好ましい。後者の場合、芳香族炭化水素基を有する単量体に基づく構成単位を含む重合体Aの使用割合は、重合体Aの全質量に対して、50質量%以上が好ましく、70質量%以上がより好ましく、80質量%以上が好ましく、90質量%以上がより好ましい。
その他の樹脂としては、アクリル樹脂、スチレン-アクリル系共重合体、ポリウレタン樹脂、ポリビニルアルコール、ポリビニルホルマール、ポリアミド樹脂、ポリエステル樹脂、ポリアミド樹脂、エポキシ樹脂、ポリアセタール樹脂、ポリヒドロキシスチレン樹脂、ポリイミド樹脂、ポリベンゾオキサゾール樹脂、ポリシロキサン樹脂、ポリエチレンイミン、ポリアリルアミン、及びポリアルキレングリコールが挙げられる。
感光性組成物層がネガ型感光性組成物層である場合、ネガ型感光性組成物層は、重合性基を有する重合性化合物を含むことが好ましい。なお、本明細書において「重合性化合物」とは、後述する重合開始剤の作用を受けて重合する化合物であって、上述した重合体Aとは異なる化合物を意味する。
重合性基としては、エチレン性不飽和基を有する基が好ましく、アクリロイル基又はメタアクリロイル基がより好ましい。
また、解像性及び剥離性により優れる点で、エチレン性不飽和化合物が一分子中に有するエチレン性不飽和基の数は、6つ以下が好ましく、3つ以下がより好ましく、2つ以下が更に好ましい。
重合性化合物の全質量に対する2官能エチレン性不飽和化合物の含有量は、ネガ型感光性組成物層の全質量に対して、剥離性に優れる観点から、20質量%以上が好ましく、40質量%超がより好ましく、55質量%以上が更に好ましい。上限は特に制限されず、100質量%であってもよい。即ち、重合性化合物が全て2官能エチレン性不飽和化合物であってもよい。
また、エチレン性不飽和化合物としては、重合性基として(メタ)アクリロイル基を有する(メタ)アクリレート化合物が好ましい。
ネガ型感光性組成物層は、芳香環及び2つのエチレン性不飽和基を有する重合性化合物B1を含むことも好ましい。重合性化合物B1は、上述した重合性化合物Bのうち、一分子中に1つ以上の芳香環を有する2官能エチレン性不飽和化合物である。
重合性化合物B1は、芳香環を1つのみ有してもよく、2つ以上の芳香環を有してもよい。
ビスフェノール構造としては、例えば、ビスフェノールA(2,2-ビス(4-ヒドロキシフェニル)プロパン)に由来するビスフェノールA構造、ビスフェノールF(2,2-ビス(4-ヒドロキシフェニル)メタン)に由来するビスフェノールF構造、及びビスフェノールB(2,2-ビス(4-ヒドロキシフェニル)ブタン)に由来するビスフェノールB構造が挙げられ、ビスフェノールA構造が好ましい。
ビスフェノール構造の両端と2つの重合性基とは、直接結合してもよく、1つ以上のアルキレンオキシ基を介して結合してもよい。ビスフェノール構造の両端に付加するアルキレンオキシ基としては、エチレンオキシ基又はプロピレンオキシ基が好ましく、エチレンオキシ基がより好ましい。ビスフェノール構造に付加するアルキレンオキシ基の付加数は特に制限されないが、1分子あたり4~16個が好ましく、6~14個がより好ましい。
ビスフェノール構造を有する重合性化合物B1については、特開2016-224162号公報の段落0072~0080に記載されており、この公報に記載の内容は本明細書に組み込まれる。
2,2-ビス(4-((メタ)アクリロキシポリアルコキシ)フェニル)プロパンとしては、例えば、2,2-ビス(4-(メタクリロキシジエトキシ)フェニル)プロパン(FA-324M、日立化成社製)、2,2-ビス(4-(メタクリロキシエトキシプロポキシ)フェニル)プロパン、2,2-ビス(4-(メタクリロキシペンタエトキシ)フェニル)プロパン(BPE-500、新中村化学工業社製)、2,2-ビス(4-(メタクリロキシドデカエトキシテトラプロポキシ)フェニル)プロパン(FA-3200MY、日立化成社製)、2,2-ビス(4-(メタクリロキシペンタデカエトキシ)フェニル)プロパン(BPE-1300、新中村化学工業社製)、2,2-ビス(4-(メタクリロキシジエトキシ)フェニル)プロパン(BPE-200、新中村化学工業社製)、及びエトキシ化(10)ビスフェノールAジアクリレート(NKエステルA-BPE-10、新中村化学工業社製)が挙げられる。
一態様において、n1+n2+n3+n4は、2~20が好ましく、2~16がより好ましく、4~12が更に好ましい。また、n2+n4は、0~10が好ましく、0~4がより好ましく、0~2が更に好ましく、0が特に好ましい。
重合性化合物B1の含有量は、解像性がより優れる観点から、ネガ型感光性組成物層の全質量に対して、10質量%以上が好ましく、20質量%以上がより好ましい。上限は特に制限されないが、転写性及びエッジフュージョン(転写部材の端部から感光性樹脂が滲み出す現象)の観点から、70質量%以下が好ましく、60質量%以下がより好ましい。
重合性化合物B1以外の重合性化合物は、特に制限されず、公知の化合物の中から適宜選択できる。例えば、一分子中に1つのエチレン性不飽和基を有する化合物(単官能エチレン性不飽和化合物)、芳香環を有さない2官能エチレン性不飽和化合物、及び3官能以上のエチレン性不飽和化合物が挙げられる。
アルキレングリコールジ(メタ)アクリレートとしては、例えば、トリシクロデカンジメタノールジアクリレート(A-DCP、新中村化学工業社製)、トリシクロデカンジメタノールジメタクリレート(DCP、新中村化学工業社製)、1,9-ノナンジオールジアクリレート(A-NOD-N、新中村化学工業社製)、1,6-ヘキサンジオールジアクリレート(A-HD-N、新中村化学工業社製)、エチレングリコールジメタクリレート、1,10-デカンジオールジアクリレート、及びネオペンチルグリコールジ(メタ)アクリレートが挙げられる。
ポリアルキレングリコールジ(メタ)アクリレートとしては、例えば、ポリエチレングリコールジ(メタ)アクリレート、ジプロピレングリコールジアクリレート、トリプロピレングリコールジアクリレート、及びポリプロピレングリコールジ(メタ)アクリレートが挙げられる。
ウレタンジ(メタ)アクリレートとしては、例えば、プロピレンオキサイド変性ウレタンジ(メタ)アクリレート、並びに、エチレンオキサイド及びプロピレンオキサイド変性ウレタンジ(メタ)アクリレートが挙げられる。の市販品としては、例えば、8UX-015A(大成ファインケミカル社製)、UA-32P(新中村化学工業社製)、及びUA-1100H(新中村化学工業社製)が挙げられる。
ここで、「(トリ/テトラ/ペンタ/ヘキサ)(メタ)アクリレート」は、トリ(メタ)アクリレート、テトラ(メタ)アクリレート、ペンタ(メタ)アクリレート、及びヘキサ(メタ)アクリレートを包含する概念であり、「(トリ/テトラ)(メタ)アクリレート」は、トリ(メタ)アクリレート及びテトラ(メタ)アクリレートを包含する概念である。
一態様において、ネガ型感光性組成物層は、上述した重合性化合物B1及び3官能以上のエチレン性不飽和化合物を含むことも好ましく、上述した重合性化合物B1及び2種以上の3官能以上のエチレン性不飽和化合物を含むことがより好ましい。この場合、重合性化合物B1と3官能以上のエチレン性不飽和化合物の質量比は、(重合性化合物B1の合計質量):(3官能以上のエチレン性不飽和化合物の合計質量)=1:1~5:1が好ましく、1.2:1~4:1がより好ましく、1.5:1~3:1が更に好ましい。
また、一態様において、ネガ型感光性組成物層は、上述した重合性化合物B1及び2種以上の3官能のエチレン性不飽和化合物を含むことが好ましい。
酸基を有する重合性化合物として、例えば、特開2004-239942号公報の段落0025~0030に記載の酸基を有する重合性化合物を用いてもよい。
重合性化合物の含有量は、ネガ型感光性組成物層の全質量に対し、10~70質量%が好ましく、15~70質量%がより好ましく、20~70質量%が更に好ましい。
感光性組成物層がネガ型感光性組成物層である場合、ネガ型感光性組成物層は、重合開始剤を含むことも好ましい。
重合開始剤は重合反応の形式に応じて選択され、例えば、熱重合開始剤、及び光重合開始剤が挙げられる。
重合開始剤は、ラジカル重合開始剤でもカチオン重合開始剤でもよい。
光重合開始剤は、紫外線、可視光線及びX線等の活性光線を受けて、重合性化合物の重合を開始する化合物である。光重合開始剤としては、特に制限されず、公知の光重合開始剤を使用できる。
光重合開始剤としては、例えば、光ラジカル重合開始剤及び光カチオン重合開始剤が挙げられ、光ラジカル重合開始剤が好ましい。
2,4,5-トリアリールイミダゾール二量体の誘導体としては、例えば、2-(o-クロロフェニル)-4,5-ジフェニルイミダゾール二量体、2-(o-クロロフェニル)-4,5-ジ(メトキシフェニル)イミダゾール二量体、2-(o-フルオロフェニル)-4,5-ジフェニルイミダゾール二量体、2-(o-メトキシフェニル)-4,5-ジフェニルイミダゾール二量体、及び2-(p-メトキシフェニル)-4,5-ジフェニルイミダゾール二量体が挙げられる。
127、IGM Resins B.V.製)、2-ベンジル-2-ジメチルアミノ-1-(4-モルフォリノフェニル)ブタノン-1(商品名:Omnirad 369、IGM Resins B.V.製)、2-ヒドロキシ-2-メチル-1-フェニルプロパン-1-オン(商品名:Omnirad 1173、IGM Resins B.V.製)、1-ヒドロキシシクロヘキシルフェニルケトン(商品名:Omnirad 184、IGM Resins B.V.製)、2,2-ジメトキシ-1,2-ジフェニルエタン-1-オン(商品名:Omnirad 651、IGM Resins B.V.製)、2,4,6-トリメチルベンゾイル-ジフェニルフォスフィンオキサイド(商品名:Omnirad TPO H、IGM Resins B.V.製)、ビス(2,4,6-トリメチルベンゾイル)フェニルフォスフィンオキサイド(商品名:Omnirad 819、IGM Resins B.V.製)、オキシムエステル系の光重合開始剤(商品名:Lunar 6、DKSHジャパン社製)、2,2’-ビス(2-クロロフェニル)-4,4’,5,5’-テトラフェニルビスイミダゾール(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)(商品名:B-CIM、Hampford社製)、及び2-(o-クロロフェニル)-4,5-ジフェニルイミダゾール二量体(商品名:BCTB、東京化成工業社製)、1-[4-(フェニルチオ)フェニル]-3-シクロペンチルプロパン-1,2-ジオン-2-(O-ベンゾイルオキシム)(商品名:TR-PBG-305、常州強力電子新材料有限公司社製)、1,2-プロパンジオン,3-シクロヘキシル-1-[9-エチル-6-(2-フラニルカルボニル)-9H-カルバゾール-3-イル]-,2-(O-アセチルオキシム)(商品名:TR-PBG-326、常州強力電子新材料有限公司社製)、及び3-シクロヘキシル-1-(6-(2-(ベンゾイルオキシイミノ)ヘキサノイル)-9-エチル-9H-カルバゾール-3-イル)-プロパン-1,2-ジオン-2-(O-ベンゾイルオキシム)(商品名:TR-PBG-391、常州強力電子新材料有限公司社製)が挙げられる。
光カチオン重合開始剤としては、pKaが4以下の酸を発生する光カチオン重合開始剤が好ましく、pKaが3以下の酸を発生する光カチオン重合開始剤がより好ましく、pKaが2以下の酸を発生する光カチオン重合開始剤が特に好ましい。pKaの下限値は特に定めないが、例えば、-10.0以上が好ましい。
イオン性光カチオン重合開始剤として、例えば、ジアリールヨードニウム塩類及びトリアリールスルホニウム塩類等のオニウム塩化合物、並びに、第4級アンモニウム塩類が挙げられる。
イオン性光カチオン重合開始剤としては、特開2014-085643号公報の段落0114~0133に記載のイオン性光カチオン重合開始剤を用いてもよい。
重合開始剤(好ましくは光重合開始剤)の含有量は、特に制限されないが、ネガ型感光性組成物層の全質量に対し、0.1質量%以上が好ましく、0.5質量%以上がより好ましく、1.0質量%以上が更に好ましい。上限は特に制限されないが、ネガ型感光性組成物層の全質量に対し、20質量%以下が好ましく、15質量%以下が更に好ましく、10質量%以下がより好ましい。
感光性組成物層は、露光部及び非露光部の視認性、現像後のパターン視認性、及び解像性の観点から、発色時の波長範囲400~780nmにおける最大吸収波長が450nm以上であり、且つ、酸、塩基、又はラジカルにより最大吸収波長が変化する色素(「色素N」ともいう)を含むことも好ましい。色素Nを含むと、詳細なメカニズムは不明であるが、隣接する層(例えば水溶性樹脂層)との密着性が向上し、解像性により優れる。
具体的には、色素Nは、露光により消色状態から変化して発色する化合物であってもよいし、露光により発色状態から変化して消色する化合物であってもよい。この場合、露光により酸、塩基、又はラジカルが感光性組成物層内において発生し作用することにより、発色又は消色の状態が変化する色素でもよく、酸、塩基、又はラジカルにより感光性組成物層内の状態(例えばpH)が変化することで発色又は消色の状態が変化する色素でもよい。また、露光を介さずに、酸、塩基、又はラジカルを刺激として直接受けて発色又は消色の状態が変化する色素でもよい。
感光性組成物層がネガ型感光性組成物層である場合は、ネガ型感光性組成物層は、露光部及び非露光部の視認性並びに解像性の観点から、色素Nとしてラジカルにより最大吸収波長が変化する色素、及び光ラジカル重合開始剤の両者を含むことが好ましい。
また、露光部及び非露光部の視認性の観点から、色素Nは、酸、塩基、又はラジカルにより発色する色素であることが好ましい。
また、色素Nは、発色時の波長範囲400~780nmにおける極大吸収波長を1つのみ有していてもよく、2つ以上有していてもよい。色素Nが発色時の波長範囲400~780nmにおける極大吸収波長を2つ以上有する場合は、2つ以上の極大吸収波長のうち吸光度が最も高い極大吸収波長が450nm以上であればよい。
露光により消色する色素としては、例えば、ロイコ化合物、ジアリールメタン系色素、オキザジン系色素、キサンテン系色素、イミノナフトキノン系色素、アゾメチン系色素、及びアントラキノン系色素が挙げられる。
色素Nとしては、露光部及び非露光部の視認性の観点から、ロイコ化合物が好ましい。
なかでも、トリアリールメタン系色素又はフルオラン系色素が好ましく、トリフェニルメタン骨格を有するロイコ化合物(トリフェニルメタン系色素)又はフルオラン系色素がより好ましい。
色素Nのうち染料の具体例としては、ブリリアントグリーン、エチルバイオレット、メチルグリーン、クリスタルバイオレット、ベイシックフクシン、メチルバイオレット2B、キナルジンレッド、ローズベンガル、メタニルイエロー、チモールスルホフタレイン、キシレノールブルー、メチルオレンジ、パラメチルレッド、コンゴーレッド、ベンゾプルプリン4B、α-ナフチルレッド、ナイルブルー2B、ナイルブルーA、メチルバイオレット、マラカイトグリーン、パラフクシン、ビクトリアピュアブルー-ナフタレンスルホン酸塩、ビクトリアピュアブルーBOH(保土谷化学工業社製)、オイルブルー#603(オリヱント化学工業社製)、オイルピンク#312(オリヱント化学工業社製)、オイルレッド5B(オリヱント化学工業社製)、オイルスカーレット#308(オリヱント化学工業社製)、オイルレッドOG(オリヱント化学工業社製)、オイルレッドRR(オリヱント化学工業社製)、オイルグリーン#502(オリヱント化学工業社製)、スピロンレッドBEHスペシャル(保土谷化学工業社製)、m-クレゾールパープル、クレゾールレッド、ローダミンB、ローダミン6G、スルホローダミンB、オーラミン、4-p-ジエチルアミノフェニルイミノナフトキノン、2-カルボキシアニリノ-4-p-ジエチルアミノフェニルイミノナフトキノン、2-カルボキシステアリルアミノ-4-p-N,N-ビス(ヒドロキシエチル)アミノ-フェニルイミノナフトキノン、1-フェニル-3-メチル-4-p-ジエチルアミノフェニルイミノ-5-ピラゾロン、及び1-β-ナフチル-4-p-ジエチルアミノフェニルイミノ-5-ピラゾロンが挙げられる。
色素Nとしては、ロイコクリスタルバイオレット、クリスタルバイオレットラクトン、ブリリアントグリーン、又はビクトリアピュアブルー-ナフタレンスルホン酸塩が好ましい。
色素Nの含有量は、露光部及び非露光部の視認性、現像後のパターン視認性、及び解像性の観点から、感光性組成物層の全質量に対して、0.1質量%以上が好ましく、0.1~10質量%がより好ましく、0.1~5質量%が更に好ましく、0.1~1質量%が特に好ましい。
メチルエチルケトン100mLに、色素0.001g及び0.01gを溶かした溶液を調製する。得られた各溶液に、光ラジカル重合開始剤Irgacure OXE01(商品名、BASFジャパン株式会社)を加え、365nmの光を照射することによりラジカルを発生させ、全ての色素を発色状態にする。その後、大気雰囲気下で、分光光度計(UV3100、(株)島津製作所製)を用いて、液温が25℃である各溶液の吸光度を測定し、検量線を作成する。
次に、色素に代えて感光性組成物層3gをメチルエチルケトンに溶かすこと以外は上記と同様の方法で、色素を全て発色させた溶液の吸光度を測定する。得られた感光性組成物層を含む溶液の吸光度から、検量線に基づいて感光性組成物層に含まれる色素の含有量を算出する。
なお、感光性組成物層3gとは、感光性樹脂組成物中の全固形分の3gと同様である。
感光性組成物層がネガ型感光性組成物層である場合、得られる硬化膜の強度、及び得られる未硬化膜の粘着性の観点から、熱架橋性化合物を含むことが好ましい。なお、本明細書においては、後述するエチレン性不飽和基を有する熱架橋性化合物は、重合性化合物としては扱わず、熱架橋性化合物として扱うものとする。
熱架橋性化合物としては、メチロール化合物、及びブロックイソシアネート化合物が挙げられる。なかでも、得られる硬化膜の強度、及び得られる未硬化膜の粘着性の観点から、ブロックイソシアネート化合物が好ましい。
ブロックイソシアネート化合物は、ヒドロキシ基及びカルボキシ基と反応するため、例えば、樹脂及び/又は重合性化合物等が、ヒドロキシ基及びカルボキシ基の少なくとも一方を有する場合には、形成される膜の親水性が下がり、ネガ型感光性組成物層を硬化した膜を保護膜として使用する場合の機能が強化される傾向がある。
なお、ブロックイソシアネート化合物とは、「イソシアネートのイソシアネート基をブロック剤で保護(いわゆる、マスク)した構造を有する化合物」を指す。
ブロックイソシアネートの解離温度とは、「示差走査熱量計を用いて、DSC(Differential scanning calorimetry)分析にて測定した場合における、ブロックイソシアネートの脱保護反応に伴う吸熱ピークの温度」を意味する。
示差走査熱量計としては、例えば、セイコーインスツルメンツ社製の示差走査熱量計(型式:DSC6200)を好適に使用できる。但し、示差走査熱量計は、これに限定されない。
これらのなかでも、解離温度が100~160℃であるブロック剤としては、例えば、保存安定性の観点から、オキシム化合物から選ばれる少なくとも1種が好ましい。
イソシアヌレート構造を有するブロックイソシアネート化合物は、例えば、ヘキサメチレンジイソシアネートをイソシアヌレート化して保護することにより得られる。
イソシアヌレート構造を有するブロックイソシアネート化合物のなかでも、オキシム化合物をブロック剤として用いたオキシム構造を有する化合物が、オキシム構造を有さない化合物よりも解離温度を好ましい範囲にしやすく、且つ、現像残渣を少なくしやすいという観点から好ましい。
重合性基としては、特に制限はなく、公知の重合性基を用いることができ、ラジカル重合性基が好ましい。
重合性基としては、(メタ)アクリロキシ基、(メタ)アクリルアミド基、及びスチリル基等のエチレン性不飽和基、並びに、グリシジル基等のエポキシ基を有する基が挙げられる。
なかでも、重合性基としては、エチレン性不飽和基が好ましく、(メタ)アクリロキシ基がより好ましく、アクリロキシ基が更に好ましい。
ブロックイソシアネート化合物の市販品の例としては、カレンズ(登録商標) AOI-BM、カレンズ(登録商標) MOI-BM、カレンズ(登録商標) MOI-BP等(以上、昭和電工社製)、ブロック型のデュラネートシリーズ(例えば、デュラネート(登録商標) TPA-B80E、デュラネート(登録商標) WT32-B75P等、旭化成ケミカルズ社製)が挙げられる。
また、ブロックイソシアネート化合物として、下記の構造の化合物を用いることもできる。
感光性組成物層が熱架橋性化合物を含む場合、熱架橋性化合物の含有量は、感光性組成物層の全質量に対して、1~50質量%が好ましく、5~30質量%がより好ましい。
感光性組成物層は、上記成分以外に、必要に応じて公知の添加剤を含んでもよい。
添加剤としては、例えば、ラジカル重合禁止剤、増感剤、可塑剤、ヘテロ環状化合物(トリアゾール等)、ベンゾトリアゾール類、カルボキシベンゾトリアゾール類、ピリジン類(イソニコチンアミド等)、プリン塩基(アデニン等)、及び界面活性剤が挙げられる。
各添加剤は、1種単独で使用してもよく、2種以上使用してもよい。
ラジカル重合禁止剤としては、例えば、特許第4502784号公報の段落0018に記載された熱重合防止剤が挙げられる。なかでも、フェノチアジン、フェノキサジン、又は4-メトキシフェノールが好ましい。その他のラジカル重合禁止剤としては、ナフチルアミン、塩化第一銅、N-ニトロソフェニルヒドロキシアミンアルミニウム塩、及びジフェニルニトロソアミン等が挙げられる。感光性組成物層の感度を損なわないために、N-ニトロソフェニルヒドロキシアミンアルミニウム塩をラジカル重合禁止剤として使用することが好ましい。
ラジカル重合禁止剤の好ましい含有量は、第1実施形態と同様である。
増感剤は、特に制限されず、公知の増感剤、染料及び顔料を使用できる。増感剤としては、例えば、ジアルキルアミノベンゾフェノン化合物、ピラゾリン化合物、アントラセン化合物、クマリン化合物、キサントン化合物、チオキサントン化合物、アクリドン化合物、オキサゾール化合物、ベンゾオキサゾール化合物、チアゾール化合物、ベンゾチアゾール化合物、トリアゾール化合物(例えば、1,2,4-トリアゾール)、スチルベン化合物、トリアジン化合物、チオフェン化合物、ナフタルイミド化合物、トリアリールアミン化合物、及びアミノアクリジン化合物が挙げられる。
感光性組成物層が増感剤を含む場合、増感剤の含有量は、目的により適宜選択できるが、光源に対する感度の向上、及び重合速度と連鎖移動のバランスによる硬化速度の向上の観点から、感光性組成物層の全質量に対して、0.01~5質量%が好ましく、0.05~1質量%がより好ましい。
可塑剤及びヘテロ環状化合物としては、国際公開第2018/179640号の段落0097~0103及び0111~0118に記載された化合物が挙げられる。
感光性組成物層に含まれる添加剤については特開2014-085643号公報の段落0165~0184に記載されており、この公報の内容は本明細書に組み込まれる。
また、一態様において、0.5~5μmが好ましく、0.5~4μmがより好ましく、0.5~3μmが更に好ましい。
感光性組成物層は、所定量の不純物を含んでいてもよい。
不純物の具体例としては、ナトリウム、カリウム、マグネシウム、カルシウム、鉄、マンガン、銅、アルミニウム、チタン、クロム、コバルト、ニッケル、亜鉛、スズ、ハロゲン及びこれらのイオンが挙げられる。なかでも、ハロゲン化物イオン、ナトリウムイオン、及びカリウムイオンは不純物として混入し易いため、下記の含有量にすることが好ましい。
下限は、質量基準で、感光性組成物層の全質量に対して、10ppb以上とすることができ、100ppb以上とすることができる。これら化合物は、上記の金属の不純物と同様の方法で含有量を抑制できる。また、公知の測定法により定量できる。
感光性組成物層は、顔料を含む着色樹脂層となっていてもよい。
近年の電子機器が有する液晶表示窓には、液晶表示窓を保護するために、透明なガラス基板等の裏面周縁部に黒色の枠状遮光層が形成されたカバーガラスが取り付けられている場合がある。このような遮光層を形成するために着色樹脂層が使用され得る。
顔料としては、所望とする色相に合わせて適宜選択すればよく、黒色顔料、白色顔料、黒色及び白色以外の有彩色の顔料の中から選択できる。なかでも、黒色系のパターンを形成する場合には、顔料として黒色顔料が好適に選択される。
ここで、粒径とは、電子顕微鏡で撮影した顔料粒子の写真像から顔料粒子の面積を求め、顔料粒子の面積と同面積の円を考えた場合の円の直径を指し、数平均粒径は、任意の100個の粒子について上記の粒径を求め、求められた100個の粒径を平均して得られる平均値である。
また、酸化チタンの表面は、シリカ処理、アルミナ処理、チタニア処理、ジルコニア処理、又は有機物処理が施されていてもよく、二つ以上の処理が施されてもよい。これにより、酸化チタンの触媒活性が抑制され、耐熱性及び褪光性等が改善される。
加熱後の感光性組成物層の厚みを薄くする観点から、酸化チタンの表面への表面処理としては、アルミナ処理及びジルコニア処理の少なくとも一方が好ましく、アルミナ処理及びジルコニア処理の両方が特に好ましい。
有彩色の顔料としては、例えば、ビクトリア・ピュアーブルーBO(Color Index(以下C.I.)42595)、オーラミン(C.I.41000)、ファット・ブラックHB(C.I.26150)、モノライト・エローGT(C.I.ピグメント・エロー12)、パーマネント・エローGR(C.I.ピグメント・エロー17)、パーマネント・エローHR(C.I.ピグメント・エロー83)、パーマネント・カーミンFBB(C.I.ピグメント・レッド146)、ホスターバームレッドESB(C.I.ピグメント・バイオレット19)、パーマネント・ルビーFBH(C.I.ピグメント・レッド11)、ファステル・ピンクBスプラ(C.I.ピグメント・レッド81)、モナストラル・ファースト・ブルー(C.I.ピグメント・ブルー15)、モノライト・ファースト・ブラックB(C.I.ピグメント・ブラック1)及びカーボン、C.I.ピグメント・レッド97、C.I.ピグメント・レッド122、C.I.ピグメント・レッド149、C.I.ピグメント・レッド168、C.I.ピグメント・レッド177、C.I.ピグメント・レッド180、C.I.ピグメント・レッド192、C.I.ピグメント・レッド215、C.I.ピグメント・グリーン7、C.I.ピグメント・ブルー15:1、C.I.ピグメント・ブルー15:4、C.I.ピグメント・ブルー22、C.I.ピグメント・ブルー60、C.I.ピグメント・ブルー64、及びC.I.ピグメント・バイオレット23等が挙げられる。なかでも、C.I.ピグメント・レッド177が好ましい。
分散液は、黒色顔料と顔料分散剤とをあらかじめ混合して得られる混合物を、有機溶剤(又はビヒクル)に加えて分散機で分散させることによって調製されるものでもよい。顔料分散剤は、顔料及び溶剤に応じて選択すればよく、例えば市販の分散剤を使用することができる。なお、ビヒクルとは、顔料分散液とした場合に顔料を分散させている媒質の部分を指し、液状であり、黒色顔料を分散状態で保持するバインダー成分と、バインダー成分を溶解及び希釈する溶剤成分(有機溶剤)と、を含む。
マレイミド誘導体は、マレイミドの少なくとも1つの水素原子が置換基により置換された構造を有する。マレイミド誘導体としては、例えば、第1級アミノ基、第2級アミノ基、第3級アミノ基、第4級アンモニウム塩基及び含窒素複素環基からなる群より選択される少なくとも1種の原子団を含むマレイミド誘導体が挙げられる。マレイミド誘導体は、第4級アンモニウム塩基を含むマレイミド誘導体が好ましい。
分散助剤としては、例えば、有機色素残基を有する化合物が挙げられる。有機色素としては、例えば、フタロシアニン系顔料、ジケトピロロピロール系顔料、アントラキノン系顔料、キナクリドン系顔料、ジオキサジン系顔料、ペリノン系顔料、ペリレン系顔料、チアジンインジゴ系顔料、トリアジン系顔料、ベンズイミダゾロン系顔料、ベンゾイソインドール等のインドール系顔料、イソインドリン系顔料、イソインドリノン系顔料、キノフタロン系顔料、ナフトール系顔料、スレン系顔料、金属錯体系顔料、アゾ、ジスアゾ、ポリアゾ等のアゾ系顔料等が挙げられる。有機色素残基を有する化合物は、酸性置換基、塩基性置換基又は中性置換基を有していてもよい。酸性置換基としては、例えば、スルホ基、カルボキシ基及びリン酸基が挙げられる。塩基性置換基としては、例えば、スルホンアミド基及びアミノ基が挙げられる。中性置換基としては、例えば、フェニル基及びフタルイミドアルキル基が挙げられる。分散助剤の態様は、特開2021-012355号公報の段落[0067]~[0084]に記載された事項から選択されてもよい。
第2実施形態においても、第1実施形態で記載した、仮支持体、感光性組成物層及び保護フィルムの関係を満たすことが好ましい。
転写フィルムは、熱可塑性樹脂層を有していてもよい。
熱可塑性樹脂層は、通常、仮支持体と感光性組成物層との間に配置される。転写フィルムが熱可塑性樹脂層を備えることで、転写フィルムと基板との貼合工程における基板への追従性が向上して、基板と転写フィルムとの間の気泡の混入を抑制できる。この結果として、熱可塑性樹脂層に隣接する層(例えば仮支持体)との密着性を担保できる。
熱可塑性樹脂としては、アルカリ可溶性樹脂であることが好ましい。
アルカリ可溶性樹脂としては、例えば、アクリル樹脂、ポリスチレン樹脂、スチレン-アクリル系共重合体、ポリウレタン樹脂、ポリビニルアルコール、ポリビニルホルマール、ポリアミド樹脂、ポリエステル樹脂、ポリアミド樹脂、エポキシ樹脂、ポリアセタール樹脂、ポリヒドロキシスチレン樹脂、ポリイミド樹脂、ポリベンゾオキサゾール樹脂、ポリシロキサン樹脂、ポリエチレンイミン、ポリアリルアミン、及びポリアルキレングリコールが挙げられる。
ここで、アクリル樹脂は、(メタ)アクリル酸に由来する構成単位、(メタ)アクリル酸エステルに由来する構成単位、及び(メタ)アクリル酸アミドに由来する構成単位からなる群から選ばれた少なくとも1種の構成単位を有する樹脂を意味する。
アクリル樹脂としては、(メタ)アクリル酸に由来する構成単位、(メタ)アクリル酸エステルに由来する構成単位、及び(メタ)アクリル酸アミドに由来する構成単位の合計含有量が、アクリル樹脂の全質量に対して50質量%以上であることが好ましい。
なかでも、(メタ)アクリル酸に由来する構成単位及び(メタ)アクリル酸エステルに由来する構成単位の合計含有量が、アクリル樹脂の全質量に対して、30~100質量%が好ましく、50~100質量%がより好ましい。
酸基としては、カルボキシ基、スルホ基、リン酸基、及びホスホン酸基が挙げられ、カルボキシ基が好ましい。
アルカリ可溶性樹脂は、現像性の観点から、酸価60mgKOH/g以上のアルカリ可溶性樹脂がより好ましく、酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂が更に好ましい。
アルカリ可溶性樹脂の酸価の上限は、特に制限されないが、300mgKOH/g以下が好ましく、250mgKOH/g以下がより好ましく、200mgKOH/g以下が更に好ましく、150mgKOH/g以下が特に好ましい。
例えば、特開2011-095716号公報の段落0025に記載のポリマーのうち酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂であるアルカリ可溶性樹脂、特開2010-237589号公報の段落0033~0052に記載のポリマーのうちの酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂、及び特開2016-224162号公報の段落0053~0068に記載のバインダーポリマーのうちの酸価60mgKOH/g以上のカルボキシ基含有アクリル樹脂が挙げられる。
上記カルボキシ基含有アクリル樹脂におけるカルボキシ基を有する構成単位の共重合比は、アクリル樹脂の全質量に対して、5~50質量%が好ましく、10~40質量%がより好ましく、12~30質量%が更に好ましい。
アルカリ可溶性樹脂としては、現像性及び隣接する層との密着性の観点から、(メタ)アクリル酸に由来する構成単位を有するアクリル樹脂が特に好ましい。
アルカリ可溶性樹脂の含有量は、現像性及び隣接する層との密着性の観点から、熱可塑性樹脂層の全質量に対して、10~99質量%が好ましく、20~90質量%がより好ましく、40~80質量%が更に好ましく、50~75質量%が特に好ましい。
熱可塑性樹脂層は、発色時の波長範囲400~780nmにおける最大吸収波長が450nm以上であり、酸、塩基、又はラジカルにより最大吸収波長が変化する色素(単に「色素B」ともいう。)を含むことが好ましい。
色素Bの好ましい態様は、後述する点以外は、上述した色素Nの好ましい態様と同様である。
熱可塑性樹脂層は、露光部及び非露光部の視認性並びに解像性の観点から、色素Bとしての酸により最大吸収波長が変化する色素、及び後述する光により酸を発生する化合物の両者を含むことが好ましい。
色素Bの含有量は、露光部及び非露光部の視認性の観点から、熱可塑性樹脂層の全質量に対して、0.2質量%以上が好ましく、0.2~6質量%がより好ましく、0.2~5質量%が更に好ましく、0.25~3.0質量%が特に好ましい。
メチルエチルケトン100mLに、色素0.001g及び0.01gを溶かした溶液を調製する。得られた各溶液に、光ラジカル重合開始剤Irgacure OXE01(商品名、BASFジャパン株式会社)を加え、365nmの光を照射することによりラジカルを発生させ、全ての色素を発色状態にする。その後、大気雰囲気下で、分光光度計(UV3100、(株)島津製作所製)を用いて、液温が25℃である各溶液の吸光度を測定し、検量線を作成する。
次に、色素に代えて熱可塑性樹脂層0.1gをメチルエチルケトンに溶かすこと以外は上記と同様の方法で、色素を全て発色させた溶液の吸光度を測定する。得られた熱可塑性樹脂層を含む溶液の吸光度から、検量線に基づいて熱可塑性樹脂層に含まれる色素の量を算出する。
なお、熱可塑性樹脂層3gとは、組成物の固形分の3gと同様である。
熱可塑性樹脂層は、光により酸、塩基、又はラジカルを発生する化合物(単に「化合物C」ともいう。)を含んでもよい。
化合物Cとしては、紫外線及び可視光線等の活性光線を受けて、酸、塩基、又はラジカルを発生する化合物が好ましい。
化合物Cとしては、公知の、光酸発生剤、光塩基発生剤、及び光ラジカル重合開始剤(光ラジカル発生剤)を使用できる。
熱可塑性樹脂層は、解像性の観点から、光酸発生剤を含んでもよい。
光酸発生剤としては、上述したネガ型感光性組成物層が含んでもよい光カチオン重合開始剤が挙げられ、後述する点以外は好ましい態様も同じである。
また、光酸発生剤としては、以下の構造を有する光酸発生剤も好ましい。
熱可塑性樹脂層は、光ラジカル重合開始剤を含んでもよい。
光ラジカル重合開始剤としては、上述したネガ型感光性組成物層が含んでもよい光ラジカル重合開始剤が挙げられ、好ましい態様も同じである。
熱可塑性樹脂組成物は、光塩基発生剤を含んでもよい。
光塩基発生剤としては、公知の光塩基発生剤であれば特に制限されず、例えば、2-ニトロベンジルシクロヘキシルカルバメート、トリフェニルメタノール、O-カルバモイルヒドロキシルアミド、O-カルバモイルオキシム、[[(2,6-ジニトロベンジル)オキシ]カルボニル]シクロヘキシルアミン、ビス[[(2-ニトロベンジル)オキシ]カルボニル]ヘキサン1,6-ジアミン、4-(メチルチオベンゾイル)-1-メチル-1-モルホリノエタン、(4-モルホリノベンゾイル)-1-ベンジル-1-ジメチルアミノプロパン、N-(2-ニトロベンジルオキシカルボニル)ピロリジン、ヘキサアンミンコバルト(III)トリス(トリフェニルメチルボレート)、2-ベンジル-2-ジメチルアミノ-1-(4-モルホリノフェニル)-ブタノン、2,6-ジメチル-3,5-ジアセチル-4-(2-ニトロフェニル)-1,4-ジヒドロピリジン、及び2,6-ジメチル-3,5-ジアセチル-4-(2,4-ジニトロフェニル)-1,4-ジヒドロピリジンが挙げられる。
化合物Cの含有量は、露光部及び非露光部の視認性並びに解像性の観点から、熱可塑性樹脂層の全質量に対して、0.1~10質量%が好ましく、0.5~5質量%がより好ましい。
熱可塑性樹脂層は、解像性、隣接する層との密着性、及び現像性の観点から、可塑剤を含むことが好ましい。
可塑剤は、アルカリ可溶性樹脂よりも分子量(オリゴマー又はポリマーであり分子量分布を有する場合は重量平均分子量)が小さいことが好ましい。可塑剤の分子量(重量平均分子量)は、200~2,000が好ましい。
可塑剤は、アルカリ可溶性樹脂と相溶して可塑性を発現する化合物であれば特に制限されないが、可塑性付与の観点から、可塑剤は、分子中にアルキレンオキシ基を有することが好ましく、ポリアルキレングリコール化合物がより好ましい。可塑剤に含まれるアルキレンオキシ基は、ポリエチレンオキシ構造又はポリプロピレンオキシ構造を有することがより好ましい。
可塑剤として用いられる(メタ)アクリレート化合物としては、上述したネガ型感光性組成物層に含まれる重合性化合物として記載した(メタ)アクリレート化合物が挙げられる。
転写フィルムにおいて、熱可塑性樹脂層とネガ型感光性組成物層とが直接接触して積層される場合、熱可塑性樹脂層及びネガ型感光性組成物層がいずれも同じ(メタ)アクリレート化合物を含むことが好ましい。同じ(メタ)アクリレート化合物を熱可塑性樹脂層及びネガ型感光性組成物層がそれぞれ含むことで、層間の成分拡散が抑制され、保存安定性が向上するためである。
また、可塑剤として用いられる(メタ)アクリレート化合物としては、熱可塑性樹脂層の解像性、隣接する層との密着性、及び現像性の観点から、一分子中に2つ以上の(メタ)アクリロイル基を有する多官能(メタ)アクリレート化合物が好ましい。
更に、可塑剤として用いられる(メタ)アクリレート化合物としては、酸基を有する(メタ)アクリレート化合物又はウレタン(メタ)アクリレート化合物も好ましい。
可塑剤の含有量は、熱可塑性樹脂層の解像性、隣接する層との密着性、及び現像性の観点から、熱可塑性樹脂層の全質量に対して、1~70質量%が好ましく、10~60質量%がより好ましく、20~50質量%が更に好ましい。
熱可塑性樹脂層は、増感剤を含んでもよい。
増感剤としては、特に制限されず、上述したネガ型感光性組成物層が含んでもよい増感剤が挙げられる。
増感剤の含有量は、目的により適宜選択できるが、光源に対する感度の向上、並びに、露光部及び非露光部の視認性の観点から、熱可塑性樹脂層の全質量に対して、0.01~5質量%が好ましく、0.05~1質量%がより好ましい。
熱可塑性樹脂層は、上記成分以外に、必要に応じて界面活性剤等の公知の添加剤を含んでもよい。
また、熱可塑性樹脂層については、特開2014-085643号公報の段落0189~0193に記載されており、この公報に記載の内容は本明細書に組み込まれる。
転写フィルムは、中間層を有していてもよい。
転写フィルム10において、中間層5は、熱可塑性樹脂層3と感光性組成物層7との間に存在することにより、熱可塑性樹脂層3及び感光性組成物層7の塗布形成の際及び塗布形成後の保存の際に生じ得る成分の混合を抑制できる。
中間層としては、水溶性樹脂を含む水溶性樹脂層が使用できる。
また、中間層としては、特開平5-072724号公報に「分離層」として記載されている、酸素遮断機能のある酸素遮断層も使用できる。中間層が酸素遮断層であると、露光時の感度が向上し、露光機の時間負荷が低減し、生産性が向上するため、好ましい。
中間層として用いられる酸素遮断層は、上記公報等に記載された公知の層から適宜選択すればよい。中でも、低い酸素透過性を示し、水又はアルカリ水溶液(22℃の炭酸ナトリウムの1質量%水溶液)に分散又は溶解する酸素遮断層が好ましい。
以下、水溶性樹脂層(中間層)が含み得る各成分について説明する。
上記樹脂は、その一部又は全部として、水溶性樹脂を含む。
水溶性樹脂として使用可能な樹脂としては、例えば、ポリビニルアルコール系樹脂、ポリビニルピロリドン系樹脂、セルロース系樹脂、アクリルアミド系樹脂、ポリエチレンオキサイド系樹脂、ゼラチン、ビニルエーテル系樹脂、ポリアミド樹脂、及びこれらの共重合体等の樹脂が挙げられる。
また、水溶性樹脂としては、(メタ)アクリル酸/ビニル化合物の共重合体等も使用できる。(メタ)アクリル酸/ビニル化合物の共重合体としては、(メタ)アクリル酸/(メタ)アクリル酸アリルの共重合体が好ましく、メタクリル酸/メタクリル酸アリルの共重合体がより好ましい。
水溶性樹脂が(メタ)アクリル酸/ビニル化合物の共重合体である場合、各組成比(モル%)としては、例えば、90/10~20/80が好ましく、80/20~30/70がより好ましい。
水溶性樹脂の分散度(Mw/Mn)は、1~10が好ましく、1~5がより好ましい。
水溶性樹脂の含有量は特に制限されないが、酸素遮断性、並びに、層間混合抑制能をより向上させる点で、水溶性樹脂層(中間層)の全質量に対して、50質量%以上が好ましく、70質量%以上がより好ましく、80質量%以上が更に好ましく、90質量%以上が特に好ましい。なお、その上限値としては特に制限されないが、例えば、99.9質量%以下が好ましく、99.8質量%以下が更に好ましい。
中間層は、必要に応じて界面活性剤などの公知の添加剤を含んでいてもよい。
・密着力の関係1:中間層と感光性組成物層との密着力が、感光性組成物層と保護フィルムとの密着力より大きい。
・密着力の関係2:仮支持体と中間層との密着力が、感光性組成物層と保護フィルムとの密着力より大きい。
上記密着力の関係1及び2を満たす場合、転写フィルムから保護フィルムを剥離する際に、感光性組成物層と保護フィルムとの界面で剥離が発生し、転写フィルムの使用に適する。
・密着力の関係3:中間層と感光性組成物層との密着力が、仮支持体と中間層との密着力より大きい。
上記密着力の関係3を満たす場合、後段で詳述する仮支持体剥離工程において、仮支持体と中間層との間で剥離が発生し、中間層が感光性組成物層側に残存しやすい。結果として、中間層が酸素遮断層等として機能しやすい。
第2実施形態の転写フィルムの製造方法は特に制限されず、公知の方法を使用できる。
上記の転写フィルム20の製造方法としては、例えば、仮支持体11の表面に熱可塑性樹脂組成物を塗布して塗膜を形成し、更にこの塗膜を乾燥して熱可塑性樹脂層13を形成する工程と、熱可塑性樹脂層13の表面に水溶性樹脂組成物を塗布して塗膜を形成し、更にこの塗膜を乾燥して中間層15を形成する工程と、中間層15の表面に感光性組成物を塗布して塗膜を形成し、更にこの塗膜を乾燥して感光性組成物層17を形成する工程と、感光性組成物層17上に、保護フィルム19を圧着させる工程と、を含む方法が挙げられる。
上述の製造方法により、仮支持体11、熱可塑性樹脂層13、中間層15、感光性組成物層17、及び保護フィルム19を備える転写フィルム20を製造できる。
上記の製造方法により転写フィルム20を製造した後、転写フィルム20を巻き取ることにより、ロール形態の転写フィルムを作製及び保管してもよい。ロール形態の転写フィルムは、後述するロールツーロール方式での基板との貼合工程にそのままの形態で提供できる。
仮支持体上に熱可塑性樹脂層を形成する方法としては特に制限されず、公知の方法が使用できる。例えば、仮支持体上に熱可塑性樹脂層形成用組成物を塗布し、そして、必要に応じて乾燥させることにより形成できる。
熱可塑性樹脂層形成用組成物としては、上述した熱可塑性樹脂層を形成する各種成分と溶剤とを含むのが好ましい。なお、熱可塑性樹脂層形成用組成物において、組成物の全固形分に対する各成分の含有量の好適範囲は、上述した熱可塑性樹脂層の全質量に対する各成分の含有量の好適範囲と同じである。
溶剤としては、溶剤以外の各成分を溶解又は分散可能であれば特に制限されず、公知の溶剤を使用できる。溶剤としては、後述する感光性組成物が含む溶剤と同様のものが挙げられ、好適態様も同じである。
溶剤の含有量は、組成物の全固形分100質量部に対して、50~1,900質量部が好ましく、100~900質量部がより好ましい。
水溶性樹脂組成物としては、上述した中間層(水溶性樹脂層)を形成する各種成分と溶剤とを含むのが好ましい。なお、水溶性樹脂組成物において、組成物の全固形分に対する各成分の含有量の好適範囲は、上述した水溶性樹脂層の全質量に対する各成分の含有量の好適範囲と同じである。
溶剤としては、水溶性樹脂を溶解又は分散可能であれば特に制限されず、水及び水混和性の有機溶剤からなる群より選択される少なくとも1種が好ましく、水又は水と水混和性の有機溶剤との混合溶剤がより好ましい。
水混和性の有機溶剤としては、例えば、炭素数1~3のアルコール、アセトン、エチレングリコール、及びグリセリンが挙げられ、炭素数1~3のアルコールが好ましく、メタノール又はエタノールがより好ましい。
溶剤を、1種単独で使用してもよく、2種以上使用してもよい。
溶剤の含有量は、組成物の全固形分100質量部に対して、50~2,500質量部が好ましく、50~1,900質量部がより好ましく、100~900質量部が更に好ましい。
生産性に優れる点、及び、上述した感光性組成物層が形成し易い点で、上述した感光性組成物層を構成する成分(例えば、バインダーポリマー、重合性化合物、及び、重合開始剤等)、及び、溶剤を含む感光性組成物を使用して塗布法により形成されるのが望ましい。
第2実施形態の転写フィルムの製造方法としては、具体的には、中間層上に感光性組成物を塗布して塗膜を形成し、この塗膜に所定温度にて乾燥処理を施して感光性組成物層を形成する方法であるのが好ましい。
溶剤としては、溶剤以外の各成分を溶解又は分散可能であれば特に制限されず、公知の溶剤を使用できる。具体的には、例えば、アルキレングリコールエーテル溶剤、アルキレングリコールエーテルアセテート溶剤、アルコール溶剤(メタノール及びエタノール等)、ケトン溶剤(アセトン及びメチルエチルケトン等)、芳香族炭化水素溶剤(トルエン等)、非プロトン性極性溶剤(N,N-ジメチルホルムアミド等)、環状エーテル溶剤(テトラヒドロフラン等)、エステル溶剤(酢酸nプロピル等)、アミド溶剤、ラクトン溶剤、並びにこれらの2種以上を含む混合溶剤が挙げられる。
アルキレングリコールエーテルアセテート溶剤としては、例えば、エチレングリコールモノアルキルエーテルアセテート、プロピレングリコールモノアルキルエーテルアセテート、ジエチレングリコールモノアルキルエーテルアセテート、及びジプロピレングリコールモノアルキルエーテルアセテートが挙げられる。
溶剤としては、国際公開第2018/179640号の段落0092~0094に記載された溶剤、及び特開2018-177889公報の段落0014に記載された溶剤を用いてもよく、これらの内容は本明細書に組み込まれる。
溶剤を、1種単独で使用してもよく、2種以上使用してもよい。
溶剤の含有量は、組成物の全固形分100質量部に対し、50~1,900質量部が好ましく、100~1200質量部が更に好ましく、100~900質量部が更に好ましい。
また、乾燥時間としては、20秒以上が好ましく、40秒以上がより好ましく、60秒以上が更に好ましい。また、その上限値としては特に制限されないが、600秒以下が好ましく、300秒以下がより好ましい。
更に、保護フィルムを感光性組成物層に貼り合わせることにより、第2実施形態の転写フィルムを製造できる。
保護フィルムを感光性組成物層に貼り合わせる方法は特に制限されず、公知の方法が挙げられる。
保護フィルムを感光性組成物層に貼り合わせる装置としては、真空ラミネーター、及び、オートカットラミネーター等の公知のラミネーターが挙げられる。
ラミネーターはゴムローラー等の任意の加熱可能なローラーを備え、加圧及び加熱ができるものが好ましい。
本発明の転写フィルムは、種々の用途に適用できる。例えば、電極保護膜、絶縁膜、平坦化膜、オーバーコート膜、ハードコート膜、パッシベーション膜、隔壁、スペーサ、マイクロレンズ、光学フィルター、反射防止膜、エッチングレジスト、及びめっき部材などに適用できる。より具体的な例として、タッチパネル電極の保護膜又は絶縁膜、プリント配線板の保護膜又は絶縁膜、TFT基板の保護膜又は絶縁膜、カラーフィルター、カラーフィルター用オーバーコート膜、配線形成のためのエッチングレジスト等を挙げることができる。
上述した転写フィルムを用いて、導体パターンを有する積層体を製造することができる。導体パターンを有する積層体の製造方法は、上述した転写フィルムを用いる方法であれば特に制限されないが、本発明の導体パターンを有する積層体の製造方法は、以下の製造方法が好ましい。
転写フィルムから、保護フィルムを剥離して感光性組成物層の表面を露出させる剥離工程と、
感光性組成物層の露出した表面が、表面に導電層を有する基板の導電層と接するように、転写フィルムと導電層を有する基板とを貼合する貼合工程と、
感光性組成物層を露光する露光工程と、
露光された感光性組成物層に対して現像処理を実施してレジストパターンを形成する現像工程と、
レジストパターンが配置されていない領域にある導電層に、エッチング処理を行うエッチング工程、及び、めっき処理を行うめっき処理工程のいずれか1つと、
レジストパターンを剥離するレジストパターン剥離工程と、
更に、めっき処理工程を有する場合は、レジストパターン剥離工程によって露出した導電層を除去し、基板上に導体パターンを形成する除去工程と、を有する、導体パターンを有する積層体の製造方法であって、
貼合工程と露光工程との間、又は、露光工程と現像工程との間に、更に、仮支持体を剥離する仮支持体剥離工程を有する、導体パターンを有する積層体の製造方法。
また、上記好ましい導体パターンを有する積層体の製造方法が有していてもよい工程についても説明する。
剥離工程は、転写フィルムから保護フィルムを剥離する工程である。
剥離工程を実施すると、転写フィルムの感光性組成物層の表面が露出する。
保護フィルムの剥離の方法は特に制限されず、公知の方法で行うことができる。例えば、保護フィルムは、ロール状に巻き取りながら剥離することができる。
貼合工程は、感光性組成物層の露出した表面が、表面に導電層を有する基板の導電層と接するように、転写フィルムと導電層を有する基板とを貼合する工程である。
貼合工程を実施すると、基板、導電層、感光性組成物層、及び、仮支持体をこの順に有する積層体(感光性組成物層付き基板)が得られる。
基板の好ましい態様としては、例えば、国際公開第2018/155193号の段落[0140]に記載があり、この内容は本明細書に組み込まれる。樹脂基板の材料としては、シクロオレフィンポリマー及びポリイミドが好ましい。樹脂基板の厚みは5~200μmが好ましく、10~100μmがより好ましい。
また、基板上には導電層を1層のみ配置してもよいし、2層以上配置してもよい。導電層を2層以上配置する場合は、異なる材質の導電層を有することが好ましい。
導電層の好ましい態様としては、例えば、国際公開第2018/155193号の段落[0141]に記載があり、この内容は本明細書に組み込まれる。
金属細線としては、銀、銅等の細線が挙げられる。なかでも、銀メッシュ、銀ナノワイヤー等の銀導電性材料が好ましい。
上記圧着の方法としては特に制限はなく、公知の転写方法、及び、ラミネート方法を使用できる。なかでも、感光性組成物層の表面を、導電部を有する基板に重ね、ロール等による加圧及び加熱が行われることが好ましい。
貼り合せには、真空ラミネーター、及び、オートカットラミネーター等の公知のラミネーターを使用できる。
ラミネート温度としては特に制限されないが、例えば、70~130℃であるのが好ましい。
露光工程は、感光性組成物層をパターン露光する工程である。
露光工程、及び、後述する現像工程を行うことで、基板上の導電層上に、導電層の少なくとも一部を保護するレジストパターンが形成される。
なお、ここで、「パターン露光」とは、パターン状に露光する形態、すなわち、露光部と非露光部とが存在する形態の露光を指す。
パターン露光における露光領域と未露光領域との位置関係は特に制限されず、適宜調整される。
感光性組成物層の基板とは反対側から露光してもよく、感光性組成物層の基板側から露光してもよい。
露光量は、5~200mJ/cm2が好ましく、10~200mJ/cm2がより好ましい。
仮支持体剥離工程は、貼合工程と露光工程との間、又は、露光工程と後述する現像工程との間に、感光性組成物層付き基板から仮支持体を剥離する工程である。
剥離方法は特に制限されず、特開2010-072589号公報の段落[0161]~[0162]に記載されたカバーフィルム剥離機構と同様の機構を使用できる。
現像工程は、露光された感光性組成物層を現像して、レジストパターンを形成する工程である。
上記感光性組成物層の現像は、現像液を用いて行うことができる。
現像液として、アルカリ性水溶液が好ましい。アルカリ性水溶液に含まれ得るアルカリ性化合物としては、例えば、水酸化ナトリウム、水酸化カリウム、炭酸ナトリウム、炭酸カリウム、炭酸水素ナトリウム、炭酸水素カリウム、テトラメチルアンモニウムヒドロキシド、テトラエチルアンモニウムヒドロキシド、テトラプロピルアンモニウムヒドロキシド、テトラブチルアンモニウムヒドロキシド、及び、コリン(2-ヒドロキシエチルトリメチルアンモニウムヒドロキシド)が挙げられる。
現像及び/又はリンス処理の後、余分な液を導電層付き基板上から除去する乾燥処理を行ってもよい。
上記製造方法においては、エッチング工程又は後述するめっき処理工程のいずれか一方を実施する。
エッチング工程は、レジストパターンが配置されていない領域にある導電層に、エッチング処理を行う。
エッチング工程により、レジストパターンのパターンに対応した導体パターンが形成される。
エッチング処理の方法としては、公知の方法を適用でき、例えば、特開2017-120435号公報の段落[0209]~[0210]に記載の方法、特開2010-152155号公報の段落[0048]~[0054]等に記載の方法、エッチング液に浸漬するウェットエッチング法、及び、プラズマエッチング等のドライエッチングによる方法が挙げられる。
酸性のエッチング液としては、例えば、塩酸、硫酸、硝酸、酢酸、フッ酸、シュウ酸及びリン酸から選択される酸性成分単独の水溶液、並びに、酸性成分と、塩化第2鉄、フッ化アンモニウム及び過マンガン酸カリウムから選択される塩との混合水溶液が挙げられる。酸性成分は、複数の酸性成分を組み合わせた成分であってもよい。
アルカリ性のエッチング液としては、水酸化ナトリウム、水酸化カリウム、アンモニア、有機アミン、及び、有機アミンの塩(テトラメチルアンモニウムハイドロオキサイド等)から選択されるアルカリ成分単独の水溶液、並びに、アルカリ成分と塩(過マンガン酸カリウム等)との混合水溶液が挙げられる。アルカリ成分は、複数のアルカリ成分を組み合わせた成分であってもよい。
めっき工程は、レジストパターンが配置されていない領域にある導電層に、めっき処理を行う工程である。
めっき処理の方法としては、例えば、電解めっき法及び無電解めっき法が挙げられ、生産性の点から、電解めっき法が好ましい。
めっき工程を実施すると、導電層付き基板上に、レジストパターンが配置されていない領域(レジストパターンの開口部)と同様のパターン形状を有するめっき層が得られる。
めっき処理工程を実施する場合、導電層は金属層であることが好ましい。
具体的には、銅、クロム、鉛、ニッケル、金、銀、すず、及び、亜鉛等の金属、並びに、これらの金属の合金が挙げられる。
なかでも、めっき層は、導電パターンの導電性がより優れる点から、銅又はその合金を含むことが好ましい。また、導体パターンの導電性がより優れる点から、めっき層は、主成分として銅を含むことが好ましい。
レジストパターン剥離工程は、残存するレジストパターンを剥離する工程である。
残存する樹脂パターンを除去する方法としては特に制限されないが、薬品処理により除去する方法が挙げられ、除去液を用いて除去する方法が好ましい。
感光性樹脂層の除去方法としては、液温が好ましくは30~80℃、より好ましくは50~80℃である撹拌中の除去液に、残存する樹脂パターンを有する基板を、1~30分間浸漬する方法が挙げられる。
除去液としては、例えば、無機アルカリ成分又は有機アルカリ成分を、水、ジメチルスルホキシド、N-メチルピロリドン又はこれらの混合溶液に溶解させた除去液が挙げられる。無機アルカリ成分としては、例えば、水酸化ナトリウム及び水酸化カリウムが挙げられる。有機アルカリ成分としては、第1級アミン化合物、第2級アミン化合物、第3級アミン化合物及び第4級アンモニウム塩化合物が挙げられる。
また、除去液を使用し、スプレー法、シャワー法及びパドル法等の公知の方法により除去してもよい。
除去工程は、レジストパターン剥離工程によって露出した導電層を除去して、基板上に導体パターンを形成する工程である。
除去工程では、めっき工程によって形成されためっき層をエッチングレジストとして使用し、非パターン形成領域(言い換えると、めっき層で保護されていない領域)に位置する導電層のエッチング処理を行う。
公知のエッチング液の一態様としては、例えば、塩化第二鉄溶液、塩化第二銅溶液、アンモニアアルカリ溶液、硫酸-過酸化水素混合液、及び、リン酸-過酸化水素混合液等が挙げられる。
導体パターンを有する積層体の製造方法は、上述した工程以外の任意の工程(その他の工程)を含んでもよい。
例えば、国際公開第2019/022089号の段落[0172]に記載の可視光線反射率を低下させる工程、国際公開第2019/022089号の段落[0172]に記載の絶縁膜上に新たな導電層を形成する工程等が挙げられるが、これらの工程に制限されない。
導体パターンを有する積層体の製造方法は、基材が有する複数の導電層の一部又は全ての可視光線反射率を低下させる処理を行う工程を含んでいてもよい。
可視光線反射率を低下させる処理としては、酸化処理が挙げられる。基材が銅を含む導電層を有する場合、銅を酸化処理して酸化銅とし、導電層を黒化することにより、導電層の可視光線反射率を低下させることができる。
可視光線反射率を低下させる処理については、特開2014-150118号公報の段落0017~0025、並びに、特開2013-206315号公報の段落0041、段落0042、段落0048及び段落0058に記載されており、これらの公報に記載の内容は本明細書に組み込まれる。
導体パターンを有する積層体の製造方法は、導体パターンの表面に絶縁膜を形成する工程と、絶縁膜の表面に新たな導電層を形成する工程と、を含むことも好ましい。
上記の工程により、第一の電極パターンと絶縁した第二の電極パターンを形成することができる。
絶縁膜を形成する工程としては、特に制限されず、公知の永久膜を形成する方法が挙げられる。また、絶縁性を有する感光性材料を用いて、フォトリソグラフィにより所望のパターンの絶縁膜を形成してもよい。
絶縁膜上に新たな導電層を形成する工程は、特に制限されず、例えば、導電性を有する感光性材料を用いて、フォトリソグラフィにより所望のパターンの新たな導電層を形成してもよい。
上記製造方法により製造される導体パターンを有する積層体は、種々の装置に適用することができる。上記の製造方法により製造される導体パターンを有する積層体を備えた装置としては、例えば、表示装置、プリント配線板、半導体パッケージ、入力装置が挙げられ、タッチパネルが好ましく、静電容量型タッチパネルがより好ましい。また、上記入力装置は、有機EL表示装置及び液晶表示装置等の表示装置に適用できる。
上述した転写フィルムを用いることにより、被転写体へ感光性組成物層を転写することができる。
なかでも、本発明の転写フィルムは、タッチパネルの製造に用いられることが好ましい。
なかでも、本発明の積層体の製造方法は、
転写フィルムから、保護フィルムを剥離して感光性組成物層の表面を露出させる剥離工程と、
転写フィルムが有する仮支持体とは反対側の表面を、導電部を有する基板に接触させて貼り合わせ、基板、導電層、感光性組成物層、及び、仮支持体をこの順に有する感光性組成物層付き基板を得る貼合工程と、
感光性組成物層をパターン露光する露光工程と、
露光された感光性組成物層を現像して、導電層を保護する保護膜パターンを形成する現像工程と、を有し、
更に、貼合工程と露光工程との間、又は、露光工程と現像工程との間に、感光性組成物層付き基板から仮支持体を剥離する仮支持体剥離工程と、を有する、積層体の製造方法であるのが好ましい。
以下、上記工程の手順について詳述する。
積層体の製造方法における剥離工程、現像工程、及び仮支持体剥離工程については、上述した積層体の製造方法における剥離工程、現像工程、及び仮支持体剥離工程と同じであり、好適態様も同じである。
貼合工程は、転写フィルムが有する仮支持体とは反対側の表面を、導電部を有する基板に接触させて貼り合わせ、基板、導電層、感光性組成物層、及び、仮支持体をこの順に有する感光性組成物層付き基板を得る工程である。
透明電極は、タッチパネル用電極として好適に機能し得る。透明電極は、ITO(酸化インジウムスズ)、及び、IZO(酸化インジウム亜鉛)等の金属酸化膜、並びに、金属メッシュ、及び、金属ナノワイヤー等の金属細線により構成されることが好ましい。
金属細線としては、銀、銅等の細線が挙げられる。なかでも、銀メッシュ、銀ナノワイヤー等の銀導電性材料が好ましい。
引き回し配線の材質である金属としては、金、銀、銅、モリブデン、アルミニウム、チタン、クロム、亜鉛、及び、マンガン、並びに、これらの金属元素の2種以上からなる合金が挙げられる。引き回し配線の材質としては、銅、モリブデン、アルミニウム、又は、チタンが好ましく、銅が特に好ましい。
露光工程は、感光性組成物層をパターン露光する工程である。
露光工程、及び、後述する現像工程を行うことで、基板上の導電層上に、導電層の少なくとも一部を保護する保護膜パターンが形成される。
なお、ここで、「パターン露光」とは、パターン状に露光する形態、すなわち、露光部と非露光部とが存在する形態の露光を指す。
露光工程の方法については、上記導体パターンを有する積層体と同様の方法が挙げられ、その好適態様も同様である。
上記積層体の製造方法は、上記現像工程によって得られたパターンを、露光する工程(ポスト露光工程)、及び/又は、加熱する工程(ポストベーク工程)を有していてもよい。
ポスト露光工程及びポストベーク工程の両方を含む場合、ポスト露光の後、ポストベークを実施することが好ましい。ポスト露光の露光量は、100~5000mJ/cm2が好ましく、200~3000mJ/cm2がより好ましい。ポストベークの温度は、80℃~250℃が好ましく、90℃~160℃がより好ましい。ポストベークの時間は、1分~180分が好ましく、10分~60分がより好ましい。
本発明の積層体の製造方法により製造される積層体は、種々の装置に適用することができる。上記積層体を備えた装置としては、例えば、表示装置、プリント配線板、半導体パッケージ、入力装置等が挙げられ、タッチパネルであることが好ましく、静電容量型タッチパネルであることがより好ましい。また、上記入力装置は、有機エレクトロルミネッセンス表示装置、液晶表示装置等の表示装置に適用することができる。
積層体がタッチパネルに適用される場合、感光性組成物層から形成されるパターンは、タッチパネル用電極又はタッチパネル用配線の保護膜として用いられることが好ましい。つまり、転写フィルムに含まれる感光性組成物層は、タッチパネル用電極保護膜又はタッチパネル用配線の形成に用いられることが好ましい。
以下の実施例に示す材料、使用量、割合、処理内容、及び、処理手順等は、本発明の趣旨を逸脱しない限り適宜変更できる。従って、本発明の範囲は以下に示す実施例により限定的に解釈されるべきではない。
以下に示す手順で実施例及び比較例に用いた転写フィルムを作製した。
各実施例及び比較例の転写フィルムの作製に用いた組成物等についてまず説明する。
仮支持体は、下記仮支持体Aを用いた。
・仮支持体A:厚さ16μmのPETフィルム(16QS62、東レ社製)
下記の中間層形成用組成物Aを調製した。
・PVA205(ポリビニルアルコール、(株)クラレ製、鹸化度=88%、重合度550):32.2質量部
・ポリビニルピロリドン(アイエスピー・ジャパン社製、K-30):14.9質量部
・蒸留水:524質量部
・メタノール:429質量部
下記の感光性樹脂形成用組成物Aを調製した。
・スチレン/メタクリル酸/メタクリル酸メチル=52/29/19(質量%)共重合体のプロピレングリコールモノメチルエーテルアセテート溶液(固形分濃度30.0%、重量平均分子量:70000):25質量部
・NKエステルBPE-500(新中村化学工業社製):3質量部
・NKエステルHD-N(新中村化学社製):2質量部
・B-CIM(黒金化成製):1質量部
・SB-PI 701(三洋貿易社製):0.1質量部
・ロイコクリスタルバイオレット(東京化成工業社製):0.05質量部
・メチルエチルケトン(三協化学社製):40質量部
・プロピレングリコールモノメチルエーテルアセテート(昭和電工社製):30質量部
保護フィルムとして、後段の表1に示す厚み及び算術平均粗さRa1及びRa2を有する保護フィルムを準備した。
なお、算術平均粗さRa1及びRa2は、上記で説明したように、微細形状測定器(ET-350K、(株)小坂研究所製)を用いて測定し、三次元解析ソフト(TDA-22、(株)小坂研究所製)で解析して算術平均粗さRa1及びRa2を求めた。
なお、微細形状測定器による測定条件は以下の通りとした。
・触針圧:0.04mN
・測定長さ:0.5mm
・送り速さ:0.1mm/秒
・ラインピッチ:5μm
・ライン数:40本
・高さ倍率:50000倍
・測定方向:MD(Machine Direction)方向
代表的に実施例1に用いた転写フィルムの作製について説明する。
上記仮支持体Aの一方の表面に、乾燥後の膜厚が5μmとなるように、上記感光性組成物層形成用組成物Aを塗布し、100℃で2分間乾燥して感光性組成物層Aを形成した。
次いで、感光性組成物層Aの表面と、保護フィルムAの算術平均粗さRa1を測定した側の表面とが対向するように貼合した。貼合には、大成ラミネータ社製 VAII-700を用い、貼合条件は、ローラー温度を100℃、圧力を0.08MPa、搬送速度を3m/分とした。
なお、実施例4に関しては、感光性組成物層を形成する前に、上記仮支持体Aの一方の表面に、乾燥後の膜厚が2μmとなるように上記中間層形成用組成物Aを塗布し、100℃で2分間乾燥して中間層Aを形成した。その後、中間層Aの表面上に感光性組成物層Aを形成した以外は、実施例1と同様にして転写フィルムを作製した。
他の実施例及び比較例に用いた転写フィルムに関しては、後段の表1に記載するように保護フィルムの種類を変更した以外は、実施例1と同様にして転写フィルムを作製した。
作製した転写フィルムについて、以下の評価を実施した。
作製した各転写フィルムについて、保護フィルム側から光学顕微鏡で10cm角の面積を検査し、転写フィルム内に存在する気泡の数をカウントした。気泡は、感光性組成物層と保護フィルムとの界面に存在していた。なお、光学顕微鏡の倍率は10倍とし、反射モードで測定した。
転写フィルム内に存在する気泡の数について、以下の基準で評価した。実用上、転写フィルムの気泡の数は、C以上の評価が好ましい。
・A:10cm角内に気泡が0個
・B:10cm角内に気泡が1~5個
・C:10cm角内に気泡が6~10個
・D:10cm角内に気泡が11個以上
作製した各転写フィルムについて、保護フィルム側から蛍光灯下で目視にて観察し、蛍光灯の光の反射から転写フィルムの欠陥を検査した。目視にて欠陥が認められる場合、その部分をマーキングした。マーキングした部分について、光学顕微鏡を用いて異物の有無を観察した。
目視での欠陥が認められる部分の個数に対して、実際に異物があることが光学顕微鏡で確認された個数の割合を算出して、欠陥検出率(%)とし、以下の基準にしたがって欠陥検査性を評価した。実用上、欠陥検査性は、C以上の評価が好ましい。なお、下記評価が高いほど、目視でも容易に欠陥検査を行うことができることを表す。
・A:欠陥検出率が90%超100以下%
・B:欠陥検出率が80%超90%以下
・C:欠陥検出率が70%超80%以下
・D:欠陥検出率が70%以下
ロール状の転写フィルムから、保護フィルムを巻き取りながら転写フィルムを剥離した。巻き取り時の条件は、室温で、巻き取り速度は4m/分、巻き芯はプラスチック製で直径3インチであった。
上記条件で、100m連続して巻き取った際の巻き取り端面の位置ずれから、下記基準で保護フィルムの巻き取り性を評価した。巻き取り端面とは、保護フィルムの巻き取ったロールにおいて、保護フィルムの長手方向に沿った保護フィルムの端で形成されるロールの端面をいい、巻き取り端面の位置ずれとは、巻き始めの巻き取り端面の位置からの保護フィルムの長手方向と直交する方向(ロールの軸方向)の最大の位置ずれをいう。なお、巻き取り端面の位置ずれは、主に保護フィルム巻き取り時の保護フィルムの一方の面と他方の面とで生じるブロッキングに由来して生じると考えられる。
・A:巻き取り端面の位置ずれが3mm未満
・B:巻き取り端面の位置ずれが3mm以上6mm未満
・C:巻き取り端面の位置ずれが6mm以上10mm未満
・D:巻き取り端面の位置ずれが10mm以上
厚さ0.5μmの銅層が表面に形成された厚み0.5mmのガラス基板(表面に導電層を有する基板)を準備した。
転写フィルムの保護フィルムを剥離して感光性組成物層を露出させ、上記基板の銅層と感光性組成物層とが密着するように基板と転写フィルムとをラミネートした。ラミネートは、温度100℃、速度1m/分、圧力1MPaで実施した。
次いで、ライン及びスペースが10μmのラインアンドスペースパターンを有するマスクを用い、高圧水銀灯で露光した。露光量は、現像後のレジストパターンが、上記ラインアンドスペースパターンを再現する露光量とした。
露光後、30℃の1.0質量%の炭酸ナトリウム水溶液(pH=11.4)を現像液に用いてシャワー現像を30秒間行った。シャワーノズルはフラットノズルを用い、シャワー圧は1MPaとした。現像処理により、ライン及びスペースが10μmのラインアンドスペースパターンのレジストパターンが形成された。
上記手順で形成したレジストパターンについて、基板と垂直方向からSEMで観察し、パターン欠陥(例えば、パターンの一部の欠損)の有無を確認した。観察倍率は500倍として行った。上記観察で確認されたパターン欠陥の個数から、下記基準にしたがってパターン欠陥抑制性の評価を行った。
・A:パターン欠陥数が0~4個
・B:パターン欠陥数が5~9個
・C:パターン欠陥数が10~19個
・D:パターン欠陥数が20個以上
上記パターン欠陥抑制性の評価と同様にして、転写フィルムと基板とをラミネートした。
次いで、ライン及びスペースがそれぞれ3~10μm(1μm刻み)のラインアンドスペースパターンを有するマスクを用い、高圧水銀灯で露光した。露光量は、現像後のレジストパターンにおいて、10μmのラインアンドスペースパターンに対応する部分が、10μmのラインアンドスペースパターンを再現する露光量とした。
露光後、上記パターン欠陥抑制性の評価と同様にして現像処理を行い、SEMでレジストパターンを観察した。レジストパターンが形成された最小のライン及びスペースの幅で解像性を評価した。
なお、実施例4については、露光前に仮支持体を剥離してから露光を実施した。
上記作製した転写フィルムの各構成、及び、その評価結果について表1に示す。
表1中、「露光時仮支持体剥離」欄の記載について、「A」は、露光前に仮支持体を剥離してから露光を実施したことを表し、「B」は、露光時に仮支持体を剥離せずに露光したことを表す。
実施例3と他の実施例との比較から、算術平均粗さRa1が、0.050μm以下である場合、パターン欠陥抑制性により優れることが確認された。
実施例5と他の実施例との比較から、算術平均粗さRa2が、0.150μm未満である場合、欠陥検査性により優れることが確認された。
実施例6と他の実施例との比較から、保護フィルムの厚さが、10~30μmである場合、転写フィルムの気泡及びパターン欠陥抑制性により優れることが確認された。
1,11 仮支持体
2,12 組成物層
3,17 感光性組成物層
5 屈折率調整層
7,19 保護フィルム
13 熱可塑性樹脂層
15 中間層
Claims (8)
- 仮支持体と、感光性組成物層と、保護フィルムとをこの順に有する転写フィルムであって、
前記保護フィルムが、ポリプロピレンを含み、
前記保護フィルムの前記感光性組成物層側の表面の算術平均粗さRa1が、前記保護フィルムの前記感光性組成物層とは反対側の表面の算術平均粗さRa2よりも小さい、転写フィルム。 - 前記算術平均粗さRa1が、0.050μm以下である、請求項1に記載の転写フィルム。
- 前記算術平均粗さRa2が、0.050μm超である、請求項1又は2に記載の転写フィルム。
- 前記算術平均粗さRa2が、0.150μm未満である、請求項1又は2に記載の転写フィルム。
- 前記保護フィルムの厚さが、10~30μmである、請求項1又は2に記載の転写フィルム。
- 請求項1又は2に記載の転写フィルムを用いて形成した、導体パターンを有する積層体。
- 請求項1又は2に記載の転写フィルムから、前記保護フィルムを剥離して前記感光性組成物層の表面を露出させる剥離工程と、
前記感光性組成物層の露出した表面が、表面に導電層を有する基板の前記導電層と接するように、前記転写フィルムと前記導電層を有する基板とを貼合する貼合工程と、
前記感光性組成物層を露光する露光工程と、
露光された前記感光性組成物層に対して現像処理を実施してレジストパターンを形成する現像工程と、
前記レジストパターンが配置されていない領域にある前記導電層に、エッチング処理を行うエッチング工程、及び、めっき処理を行うめっき処理工程のいずれか1つと、
前記レジストパターンを剥離するレジストパターン剥離工程と、
更に、前記めっき処理工程を有する場合は、前記レジストパターン剥離工程によって露出した前記導電層を除去し、前記基板上に導体パターンを形成する除去工程と、を有する、導体パターンを有する積層体の製造方法であって、
前記貼合工程と前記露光工程との間、又は、前記露光工程と前記現像工程との間に、更に、前記仮支持体を剥離する仮支持体剥離工程を有する、導体パターンを有する積層体の製造方法。 - 仮支持体上に感光性組成物層を形成する工程と、
前記感光性組成物層の前記仮支持体とは反対側の面に保護フィルムを貼合する工程とを含む転写フィルムの製造方法であって、
前記保護フィルムが、ポリプロピレンを含み、
前記保護フィルムの前記感光性組成物層側の表面の算術平均粗さRa1が、前記保護フィルムの前記感光性組成物層とは反対側の表面の算術平均粗さRa2よりも小さい、転写フィルムの製造方法。
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