JP6938149B2 - 検査用カバーフィルム、検査部材、および検査部材の製造方法 - Google Patents
検査用カバーフィルム、検査部材、および検査部材の製造方法 Download PDFInfo
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- JP6938149B2 JP6938149B2 JP2016250108A JP2016250108A JP6938149B2 JP 6938149 B2 JP6938149 B2 JP 6938149B2 JP 2016250108 A JP2016250108 A JP 2016250108A JP 2016250108 A JP2016250108 A JP 2016250108A JP 6938149 B2 JP6938149 B2 JP 6938149B2
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Description
〔検査用カバーフィルム〕
図1には、本実施形態に係る検査用カバーフィルム1が示される。この検査用カバーフィルム1は、基材10と、基材10の片面側の全体に積層された熱可塑性樹脂層20とを備える。なお、本実施形態に係る検査用カバーフィルム1において、熱可塑性樹脂層20は、検査用カバーフィルム1の片側の最外層を構成する。
(1)基材
本実施形態に係る検査用カバーフィルム1において、基材10の構成は、当該基材10を備える検査部材100を用いて検査を行うことが可能である限り、特に限定されない。しかしながら、良好な検査を可能とする観点から、基材10は、検査において使用される光(以下「検査光」という場合がある。)に対して透過性を有するとともに、光学的等方性を有することが好ましい。
本実施形態に係る検査用カバーフィルム1において、熱可塑性樹脂層20を構成する熱可塑性樹脂は、熱融着により検査用カバーフィルム1と基板2とを良好に固定できるとともに、検査に悪影響を与えないものである限り、特に限定されない。
本実施形態に係る検査用カバーフィルム1は、検査において使用される光に対して透過性を有することが好ましい。これにより、当該検査用カバーフィルム1を備える検査部材100を用いて検査する際に、検査光が検査用カバーフィルム1を良好に透過するようになる結果、検査部材100の検査精度が向上する。
本実施形態に係る検査用カバーフィルム1の製造方法は、特に限定されず、例えば、熱可塑性樹脂層20を構成するための材料を含む塗工液を基材10の片面上に塗工し、乾燥して熱可塑性樹脂層20を形成する方法、基材10の片面上に、熱可塑性樹脂層20を構成するための材料を押出ラミネートする方法、基材10を構成するための材料と熱可塑性樹脂層20を構成するための材料とを共押出成形する方法等が挙げられる。
図2には、本実施形態に係る検査部材100の断面図が示される。検査部材100は、少なくとも1つ以上の溝4が片面に設けられた基板2と、基板2における溝4が設けられた面側に積層された、本実施形態に係る検査用カバーフィルム1とを備える。
(1)基板
本実施形態に係る検査部材100において、基板2は、当該基板2を備える検査部材100を用いて検査を行うことが可能である限り、特に限定されない。しかしながら、良好な検査を可能とする観点から、基板2は、検査光に対して透過性を有することが好ましい。
本実施形態に係る検査部材100は、検体を溝4に収容するための開口部を備えていてもよい。当該開口部は、検査用カバーフィルム1および基板2の少なくとも一方に設けてよいものの、特に検査用カバーフィルム1に設けることが好ましい。開口部の形状や大きさは、検体を溝4に収容するために用いる収容手段に適した形状とすることが好ましい。当該収容手段としては、注射器、ピペット等を使用することができるが、例えば、注射器を使用する場合には、開口部は、当該注射器が備える注射針の先端を溝4にまで到達させることができる形状および大きさを有することが好ましい。また、本実施形態に係る検査部材100が上記開口部を備える場合、エア抜け用の穴も備えることが好ましい。
本実施形態に係る検査部材100において、基材10を構成する材料のガラス転移温度をTg1とし、熱可塑性樹脂層20を構成する熱可塑性樹脂のガラス転移温度をTg2とし、基板2を構成する材料のガラス転移温度をTg3とした場合、下記式(1)および下記式(2)の少なくとも一方を満たすことが好ましい。
Tg1>Tg2 …(1)
Tg3>Tg2 …(2)
本実施形態に係る検査部材100は、熱可塑性樹脂層20の熱融着により、前述した検査用カバーフィルム1における熱可塑性樹脂層20側の面と、基板2における溝4が存在する側の面とを貼り合わせることで製造することができる。特に、検査部材100の製造方法は、基板2における溝4が設けられた面と、検査用カバーフィルム1における熱可塑性樹脂層20側の面とを、溝4が熱可塑性樹脂層20によって埋まることがなく熱融着し、基板2と検査用カバーフィルム1とを接着する工程を備えることが好ましい。この場合、加熱して溶融した状態にある熱可塑性樹脂層20を基板2に積層することができれば、具体的な手法は限定されず、例えば、熱ラミネート、熱圧着等により行うことができる。特に、溶融した熱可塑性樹脂層20の溝4への入り込みや、溝4の熱による変形を効果的に抑制するとともに、簡便であるという観点から、熱ラミネートを行うことが好ましい。
本実施形態に係る検査部材100は、検体の光学的な検査のために使用することができる。具体的には、検査部材100における溝4に検体を収容した後、検査部材100の外部から、収容された検体に対して光を照射し、それによって生じた光を検査部材100外で測定する。
(1)基板の作製
ポリカーボネート樹脂(帝人社製,製品名「パンライトAD−5503」,Tg:145℃)を射出成型して、片面に3つの溝を有する基板(図2の基板2を参照)を形成した。当該基板は、直径12cm、厚さ1.2mmのディスク状の形状を有しており、平面視における中央には、外周と同心円となる直径1.5cmの円形の孔が設けられている。そして、3つの溝は、平面視で基板の外周と同心円状に0.25mm間隔で設けられており、それぞれ幅w1が200nm、深さd1が200nmとなっている。3つの溝のうち、基板の外周に最も近位な溝と、基板の外周との距離は、2cmとなっている。なお、当該基板における溝が存在する面とは反対側の面の算術平均粗さ(Ra)を測定したところ、120nmであり、検査光(波長:0.63μm)の透過率は92%であり、ヘイズ値は0.1%であった。
熱可塑性樹脂としてのポリエステル樹脂(東洋紡社製,製品名「バイロナールMD−1245」,重量平均分子量:20,000,Tg:61℃)100質量部と、水40質量部と、イソプロピルアルコール60質量部とを混合し、固形分濃度約15質量%の熱可塑性樹脂組成物の塗工液を調製した。基材としての、ポリカーボネートフィルム(帝人社製,製品名「ピュアエース」,厚さ:100μm,粘着剤層を形成する面とは反対側の面の算術平均粗さ(Ra):150nm,検査光(波長:0.63μm)の透過率:90%以上,ヘイズ値:0.3%以下,Tg:160℃)の一方の面に対して、調製した熱可塑性樹脂組成物の塗工液をマイヤーバーによって塗工し、得られた塗膜を120℃、1分間加熱乾燥して、基材の片面に、厚さが1μmの熱可塑性樹脂層が積層されてなる積層体を得た。
続いて、工程(1)で作製した基板における溝が存在する面と、工程(2)で作製した検査用カバーフィルムにおける熱可塑性樹脂層側の面とを、加熱プレス機を用いて、加熱温度140℃、圧力1MPaで、10分間熱圧着することで貼り合わせた。これにより、検査部材を製造した。
熱可塑性樹脂としてのポリエステル樹脂(東洋紡社製,製品名「バイロナールMD−1100」,重量平均分子量20,000,Tg:40℃)100質量部と、水40質量と、イソプロピルアルコール60質量部とを混合し、固形分濃度約15質量%に希釈し、熱可塑性樹脂組成物の塗工液を調製した。
(1)検査用カバーフィルムの作製
ポリカーボネートフィルム(帝人社製,製品名「ピュアエース」,厚さ:100μm,粘着剤層を形成する面とは反対側の面の算術平均粗さ(Ra):150nm,検査光(波長:0.63μm)の透過率:90%以上,ヘイズ値:0.3%以下,Tg:160℃)を、実施例1の工程(1)で作製した基板と平面視で同じ形状にカットした。具体的には、直径12cmであり、中央には外周と同心円となる直径1.5cmの円形の孔が設けられたディスク状にカットした。これにより、検査用カバーフィルムを得た。
続いて、実施例の工程(1)で作製した基板における溝が存在する面と、上記工程(1)で作製した検査用カバーフィルムとを、加熱プレス機を用いて、加熱温度250℃、圧力1MPaで、1分間熱圧着することで貼り合わせた。これにより、検査部材を製造した。
(1)粘着性組成物の塗工液の調製
アクリル酸2−エチルヘキシル20質量部、アクリル酸ブチル75質量部およびアクリル酸4−ヒドロキシブチル5質量部を共重合させて、アクリル酸エステル共重合体を調製した。このアクリル酸エステル共重合体の分子量を後述する方法で測定したところ、重量平均分子量(Mw)が20万であった。
<測定条件>
・GPC測定装置:東ソー社製,HLC−8020
・GPCカラム(以下の順に通過):東ソー社製
TSK guard column HXL−H
TSK gel GMHXL(×2)
TSK gel G2000HXL
・測定溶媒:テトラヒドロフラン
・測定温度:40℃
厚さ38μmのポリエチレンテレフタレートフィルムの片面にシリコーン系の剥離剤層が形成されてなる剥離シート(リンテック社製,製品名「SP−PET381031」)の剥離面上に、工程(1)において調製した粘着性組成物の塗工液をコンマコーターによって塗工し、得られた塗膜を90℃のオーブンで1分間乾燥させて、厚さ3μmの粘着剤層を形成した。これにより、粘着剤層付き剥離シートを得た。
続いて、工程(1)で作製した基板における溝が存在する面と、工程(2)で作製した検査用カバーフィルムにおける熱可塑性樹脂層側の面とを、温度25℃、圧力0.5MPa、速度0.5m/minでラミネートすることで貼り合わせた。これにより、検査部材を製造した。
実施例および比較例で製造した検査部材について、基板を固定した状態で、検査用カバーフィルムに指を押し当て、平面方向に力を加え、次の基準に基づいて密着性を評価した。
○:基板と検査用カバーフィルムとの界面でズレが生じなかった。
×:基板と検査用カバーフィルムとの界面でズレが生じた。
実施例および比較例で製造した検査部材の溝の断面を、電子顕微鏡(キーエンス社製,製品名「VE−9800」)を用いて観察し、次の基準に基づいて、熱可塑性樹脂層を構成する熱可塑性樹脂または粘着剤層を構成する粘着剤の溝への入り込みについて評価した。
○:入り込みが溝の断面の20%未満であった。
×:入り込みが溝の断面の20%以上であった。
実施例および比較例で製造した検査部材の溝の断面を、電子顕微鏡(キーエンス社製,製品名「VE−9800」)を用いて観察し、次の基準に基づいて、溝の変形について評価した。
○:溝の変形が生じていなかった。
×:溝の変形が生じていた。
10…基材
20…熱可塑性樹脂層
100…検査部材
2…基板
4…溝
Claims (8)
- 基材と、前記基材の片面側に積層された熱可塑性樹脂層とを備えた検査用カバーフィルムであって、
前記熱可塑性樹脂層は、前記検査用カバーフィルムの片側の最外層を構成し、
前記熱可塑性樹脂の厚さは、0.5μm以上、30μm以下であり、
前記基材を構成する材料のガラス転移温度をTg1とし、前記熱可塑性樹脂層を構成する熱可塑性樹脂のガラス転移温度をTg2とした場合、下記式(1)を満たす
Tg1>Tg2 …(1)
ことを特徴とする検査用カバーフィルム。 - 前記熱可塑性樹脂層を構成する熱可塑性樹脂のガラス転移温度(Tg2)が、35℃以上、150℃以下であることを特徴とする請求項1に記載の検査用カバーフィルム。
- 前記基材を構成する材料が、ポリカーボネート、ポリブチレンテレフタレート、シクロオレフィン樹脂およびアクリル樹脂の少なくとも1種であることを特徴とする請求項1または2に記載の検査用カバーフィルム。
- 前記検査用カバーフィルムの厚さが、30.5μm以上、330μm以下であることを特徴とする請求項1から3のいずれか1項に記載の検査用カバーフィルム。
- 少なくとも1つ以上の溝が片面に設けられた基板と、前記基板における前記溝が設けられた面側に積層された、請求項1から4のいずれか一項に記載の検査用カバーフィルムとを備え、前記溝に収容された検体に対して光学的な検査を行うための検査部材。
- 前記検査用カバーフィルムが、前記検査において使用される光に対して透過性を有することを特徴とする請求項5に記載の検査部材。
- 前記基板が、前記検査において使用される光に対して透過性を有することを特徴とする請求項5または6に記載の検査部材。
- 請求項5から7のいずれか一項に記載の検査部材の製造方法であって、
前記基板における前記溝が設けられた面と、前記検査用カバーフィルムにおける前記熱可塑性樹脂層側の面とを、前記溝が前記熱可塑性樹脂層によって埋まることがなく熱融着し、前記基板と前記検査用カバーフィルムとを接着する工程を備えることを特徴とする検査部材の製造方法。
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