JP6966860B2 - 検査用カバーフィルム、検査部材、および検査用カバーフィルムの製造方法 - Google Patents
検査用カバーフィルム、検査部材、および検査用カバーフィルムの製造方法 Download PDFInfo
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- JP6966860B2 JP6966860B2 JP2017076699A JP2017076699A JP6966860B2 JP 6966860 B2 JP6966860 B2 JP 6966860B2 JP 2017076699 A JP2017076699 A JP 2017076699A JP 2017076699 A JP2017076699 A JP 2017076699A JP 6966860 B2 JP6966860 B2 JP 6966860B2
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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の片面側に積層された親水性コート層20と、親水性コート層20における基材10とは反対の面側に部分的に積層された接着層30とを備える。検査用カバーフィルム1では、親水性コート層20における基材10とは反対の面に対して、接着層30が部分的に積層されていることにより、接着層30が存在せずに、親水性コート層20が露出している領域(以下において「親水性コート層露出部40」という場合がある。)が存在する。
(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、親水性コート層20を構成する材料は、得られる親水性コート層20の表面が検体に対して所望の濡れ性を有するとともに、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。当該材料としては、親水性を有する官能基を備える材料が好ましく、特に、親水性を有する官能基を表面に多数備える材料が好ましい。
R3SiO−(R2SiO)n−SiR3 …(1)
で示される骨格を有するポリシロキサンが挙げられる。上記式(1)中、Rは、それぞれ独立に、前述した親水性の官能基、または、炭化水素基(メチル基、ビニル基、アルキル基、アリル基等)といった疎水性の官能基である。但し、上記式(1)の骨格を有するポリシロキサンが所望の親水性を有するものとなるように、上記式(1)中における所定の数のRが、親水性の官能基となっている。なお、上記式(1)中、nは、正の整数である。
本実施形態に係る検査用カバーフィルム1において、接着層30を構成する材料は、検査用カバーフィルム1を基板2に対して良好に固定することができるとともに、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。当該材料としては、例えば、粘着剤、熱可塑性樹脂、接着剤、自着性剤等が挙げられる。なお、これらの材料は、1種を単独で用いてもよく、または2種以上組み合わせて用いてもよい。
上記粘着剤の具体例としては、アクリル系粘着剤、シリコーン系粘着剤、ゴム系粘着剤、ウレタン系粘着剤、ポリエステル系粘着剤、ポリビニルエーテル系粘着剤等が挙げられるが、良好な密着性を発揮するとともに、検査部材100を用いて検査に対して悪影響を与えにくいという観点から、アクリル系粘着剤、シリコーン系粘着剤またはゴム系粘着剤が好ましく、中でもアクリル系粘着剤が好ましい。また、接着層30を構成する粘着剤は、活性エネルギー線硬化性であってもよく、または、非活性エネルギー線硬化性であってもよい。
R1aSiO(4−a)/2 …(2)
(式中、R1は互いに同一又は異種の炭素数1〜12、好ましくは1〜8の非置換又は置換の1価炭化水素基であり、aは1.5〜2.8、好ましくは1.8〜2.5、より好ましくは1.95〜2.05の範囲の正数である。)
で示される化合物であって、かつ分子中に少なくとも2個のアルケニル基を有する化合物であることが好ましい。
上記熱可塑性樹脂としては、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。
接着層30の厚さは、0.5μm以上であることが好ましく、特に1μm以上であることが好ましく、さらには1.5μm以上であることが好ましい。また、当該厚さは、15μm以下であることが好ましく、特に5μm以下であることが好ましく、さらには2μm以下であることが好ましい。接着層30の厚さが0.5μm以上であることで、検査用カバーフィルム1を基板2に対してより良好に固定することが可能となる。また、接着層30の厚さが15μm以下であることで、検査に与える接着層30の厚さによる影響を低減することができ、得られる検査部材100において良好な検査を行い易くなる。
本実施形態に係る検査用カバーフィルム1では、基板2に積層されるまでの間、接着層30を保護するために、接着層30における基材10とは反対側の面に、剥離シートが積層されていてもよい。特に、接着層30が粘着剤からなる場合、剥離シートを積層することが好ましい。なお、剥離シートの平面視における形状は、基材10の平面視における形状と同一であることが好ましいものの、接着層30の平面視における形状と同一であってもよい。
本実施形態に係る検査用カバーフィルム1では、親水性コート層露出部40の表面における水接触角が、60°以下であることが好ましく、50°以下であることがより好ましく、特に25°以下であることが好ましく、さらには10°以下であることが好ましい。当該水接触角が60°以下であることで、親水性コート層20の表面に対して、検体がよりなじみ易くなり、検体が当該表面上をより濡れ広がり易くなる。それにより、検査部材100において、毛細管現象が促進され、検体が溝3に展開し易くなる。その結果、溝3への検体の収容をより容易に行うことが可能となる。なお、上記水接触角の下限値については、特に限定されないものの、通常、0°以上であり、1°以上であることが好ましく、特に4°以上であることが好ましく、さらには7°以上であることが好ましい。
本実施形態に係る検査用カバーフィルム1は、基材10の片面側に親水性コート層20を形成する工程(以下、「第1の工程」という場合がある。)と、親水性コート層20における基材10とは反対の面側に、接着層30を部分的に形成する工程(以下、「第2の工程」という場合がある。)とを備える製造方法により製造することが好ましい。
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3が片面に設けられた基板2と、基板2における溝3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。検査部材100では、検査用カバーフィルム1における親水性コート層露出部40の位置と、基板2における溝3とが、平面視で重なっている。
(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3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3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3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は、前述した検査用カバーフィルム1における接着層30側の面(前述した剥離シートが積層されている場合には、当該剥離シートを剥離して露出する接着層30の面)と、基板2における溝3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好ましい。このとき、検査用カバーフィルム1における親水性コート層露出部40に、基板2における溝3が平面視で含まれるように貼合が行われる。
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3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の外部で測定する。
ジペンタエリスリトールヘキサアクリレート(新中村化学工業社製,製品名「NKエステルA−DPH」)50質量部(固形分換算;以下同じ)と、特殊4級アンモニウム塩導入紫外線硬化型アクリレートポリマー(大成ファインケミカル社製,製品名「アクリット8WX−030」)125質量部と、オリゴ(2−ヒドロキシ−2−メチル−1−フェニル−プロパン−1−オン)(ランベルティー社製,製品名「Esacure KIP 150」)5質量部と、希釈溶剤としてのプロピレングリコールモノメチルエーテルとを均一に混合し、固形分濃度が15質量%である、アクリル系成分を含有する親水性コート層用塗布液C−1を調製した。
シロキサン成分としてのシロキサン樹脂を含むコート剤(コルコート社,製品名「コルコートN−103X」,固形分濃度:2質量%)を用意し、親水性コート層用塗布液C−2とした。
シリカ系成分を含むコート剤(丸昌産業社製,製品名「セルフェイスコート プラPT3」,固形分濃度:5質量%)を用意し、親水性コート層用塗布液C−3とした。
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−ヒドロキシエブチル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)20万であった。
ポリエステル樹脂(東洋紡社製,製品名「バイロナールMD−1100」,熱可塑性樹脂,重量平均分子量:20,000,Tg:40℃)を用意し、接着層用塗布液P−2とした。
<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℃
(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」)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。
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,親水性コート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)の片面全体に、親水性コート層用塗布液C−1を、マイヤーバーを用いて塗布し、得られた塗膜を70℃で1分間加熱乾燥した後、当該塗膜に対して以下の紫外線照射条件にて紫外線を照射して硬化させ、厚さ1500nmの親水性コート層を形成した。これにより、基材と親水性コート層とからなる積層体を得た。
[紫外線照射条件]
・紫外線照射装置:ジーエスユアサコーポレーション社製,製品名「窒素パージ小形コンベア式UV照射装置CSN2−40」
・光源:高圧水銀灯
・ランプ電力:1.4kW
・コンベアスピード:1.2m/min
・照度:100mW/cm2
・光量:240mJ/cm2
・窒素雰囲気下(酸素濃度1%以下)で紫外線照射
上記積層体を、平面視で、上記工程(1)で作製した基板と同じ形状に切り抜いた。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切り抜いた。
続いて、上記工程(1)で作製した基板における溝が存在する面と、上記工程(3)で作製した検査用カバーフィルムにおける粘着剤層側の面とを、温度25℃、圧力0.5MPaおよび速度0.5m/minの条件で貼り合わせた。この貼り合わせにより、基板における3つの溝は、平面視で、検査用カバーフィルムにおける親水性コート層露出部の内側に収まった。これにより、検査部材を製造した。なお、上記で製造した検査部材は良好に固定されていることを確認した。
親水性コート層用塗布液C−2を使用して、親水性コート層用塗布液C−2の塗膜を130℃で1分間加熱乾燥して硬化させることにより厚さ60nmの親水性コート層を形成した以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
親水性コート層用塗布液C−3を使用して、親水性コート層用塗布液C−3の塗膜を130℃で1分間加熱乾燥して硬化させることにより厚さ500nmの親水性コート層を形成した以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
親水性コート層用塗布液C−3を使用して、親水性コート層用塗布液C−3の塗膜を130℃で1分間加熱乾燥して硬化させることにより厚さ500nmの親水性コート層を形成し、接着層用塗布液P−2を使用して、120℃で1分間の加熱により厚さ1μmの接着層を形成し、さらに、基板と検査用カバーフィルムとを貼合するときの温度を90℃に変更した以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
基材のみを実施例1の工程(3)と同様に切り抜き、切り抜き後の基材の片面上に、親水性コート層を形成することなく、実施例1の工程(3)と同様に接着層を直接形成した以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
基材のみを実施例1の工程(3)と同様に切り抜き、切り抜き後の基材の片面にコロナ処理(放電量:556W・min/m2)を行い、当該コロナ処理面上に対して、親水性コート層を形成することなく、実施例1の工程(3)と同様に接着層を直接形成した以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
基材の片面全体に親水性コート層用塗布液C−2を塗布し、その塗膜を130℃で1分間加熱乾燥して硬化させることにより厚さ60nmの親水性コート層を形成することで得られた、基材と親水性コート層との積層体を、実施例1の工程(3)と同様にディスク状に切り抜いた後、切り抜かれた当該積層体の親水性コート層側の面に接着層用塗布液P−1をスクリーン印刷する際に、当該積層体における親水性コート層側の全面に接着層用塗布液P−1を塗布し、これにより親水性コート層露出部を形成しなかった以外は、実施例1と同様にして検査部材を製造した。なお、製造した検査部材は良好に固定されていることを確認した。
実施例1〜4で製造した検査用カバーフィルムの親水性コート層露出部の表面における水接触角を、全自動式接触角測定計(協和界面科学社製,DM−701)を使用して以下の条件で測定した。また、比較例1および2については、基材の接着層が設けられた面における、接着層が存在しない領域の水接触角を、上記と同様に測定した。これらの結果を表1に示す。なお、親水性コート層露出部も、上記のような接着層が存在しない領域も設けられていない比較例3の検査用カバーフィルムについては、本試験を行わなかった。
・純水の液滴量:2μl
・測定時間:滴下3秒後
・画像解析法:θ/2法
実施例1〜4および比較例1〜2で製造した検査用カバーフィルムと同様にして、試験サンプルとしての検査用カバーフィルムを作製した。但し、当該試験サンプルの形状は、以下に説明する形状とした。図3(a)および図3(b)に、当該形状の概略を示す。図3(a)は、試験サンプルとしての検査用カバーフィルム1を基材10側からみた平面図であり、図3(b)は、図3(a)に示される検査用カバーフィルム1の3b−3b線断面図である。なお、図3(a)および図3(b)は、実施例1〜4の検査用カバーフィルム1について示したものであり、比較例1〜2では、図中の親水性コート層20が省略されたものとなる。後述する図4(a)および図4(b)においても同様である。
◎:滴下後、3秒以内に、純水が他方の開口部に到達した。
○:滴下後、3秒超、5秒以内に、純水が他方の開口部に到達した。
△:滴下後、5秒超、10秒以内に、純水が他方の開口部に到達した。
×:純水が他方の開口部に到達するまで10秒を超える時間を要するか、または、流路の途中で展開が止まり、到達しなかった。
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、接着層を構成する材料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。
10…基材
20…親水性コート層
30…接着層
40…親水性コート層露出部
100…検査部材
2…基板
3…溝
4…水滴
50…流路
Claims (9)
- 基材と、前記基材の片面側に積層された親水性コート層と、前記親水性コート層における前記基材とは反対の面側に部分的に積層された接着層とを備えており、もって前記接着層が存在せずに、前記親水性コート層が露出している領域を有し、
前記親水性コート層の露出面の水接触角が、0°以上、60°以下であり、
前記基材および前記親水性コート層が、検査において使用される光に対して透過性を有する
ことを特徴とする検査用カバーフィルム。 - 前記親水性コート層が、シロキサン系成分、シリカ系成分およびアクリル系成分から選択される少なくとも一種を含む材料からな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。
- 前記接着層が、粘着剤および熱可塑性樹脂から選択される少なくとも一種を含む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。
- 前記接着層の厚さが、0.5μm以上、15μm以下であることを特徴とする請求項1〜3のいずれか一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1〜4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における、前記接着層が存在しない領域が、平面視で、前記基板の溝と重な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1〜4のいずれか一項に記載の検査用カバーフィルムの製造方法であって、
前記基材の片面側に前記親水性コート層を形成する工程と、
前記親水性コート層における前記基材とは反対の面側に、前記接着層を部分的に形成する工程と
を備えることを特徴とする検査用カバーフィルムの製造方法。 - 前記接着層を、前記親水性コート層における前記基材とは反対の面側に、前記接着層を形成する材料をスクリーン印刷することにより形成することを特徴とする請求項8に記載の検査用カバーフィルムの製造方法。
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