JP7061734B2 - 透明導電フィルム積層体及びその加工方法 - Google Patents
透明導電フィルム積層体及びその加工方法 Download PDFInfo
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- JP7061734B2 JP7061734B2 JP2021552394A JP2021552394A JP7061734B2 JP 7061734 B2 JP7061734 B2 JP 7061734B2 JP 2021552394 A JP2021552394 A JP 2021552394A JP 2021552394 A JP2021552394 A JP 2021552394A JP 7061734 B2 JP7061734 B2 JP 7061734B2
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Description
透明樹脂フィルム2は、非晶性シクロオレフィン系樹脂により形成されており、高透明性及び低吸水性の特性を有する。透明樹脂フィルム2として非晶性シクロオレフィン系樹脂フィルムを採用することにより、良好な光学特性を有する透明導電フィルムを備えた透明導電フィルム積層体が得られる。
透明樹脂フィルム2上に形成される透明導電層3を構成する導電材料としては、金属ナノワイヤを好適に使用することができる。金属ナノワイヤは、径がナノメーターオーダーのサイズである金属であり、ワイヤ状の形状を有する導電性材料である。なお、本実施形態では、金属ナノワイヤと混合して、または金属ナノワイヤに代えて、ポーラスあるいはノンポーラスのチューブ状の形状を有する導電性材料である金属ナノチューブを使用してもよい。本明細書において、「ワイヤ状」と「チューブ状」はいずれも線状であるが、前者は中央が中空ではないもの、後者は中央が中空であるものを意図する。性状は、柔軟であってもよく、剛直であってもよい。前者を「狭義の金属ナノワイヤ」、後者を「狭義の金属ナノチューブ」と呼び、以下、本願明細書において、「金属ナノワイヤ」は狭義の金属ナノワイヤと狭義の金属ナノチューブとを包括する意味で用いる。狭義の金属ナノワイヤ、狭義の金属ナノチューブは、単独で用いてもよく、混合して用いてもよい。
下記溶離液にバインダー樹脂を溶解させ、20時間静置した。この溶液におけるバインダー樹脂の濃度は0.05質量%である。
これを0.45μmメンブレンフィルターにて濾過し、濾液をGPC-MALSにて測定を実施し、絶対分子量基準の重量平均分子量を算出した。
GPC:昭和電工株式会社製Shodex(登録商標)SYSTEM21
カラム:東ソー株式会社製TSKgel(登録商標)G6000PW
カラム温度:40℃
溶離液:0.1mol/L NaH2PO4水溶液+0.1mol/L Na2HPO4水溶液
流速:0.64mL/min
試料注入量:100μL
MALS検出器:ワイアットテクノロジーコーポレーション、DAWN(登録商標) DSP
レーザー波長:633nm
多角度フィット法:Berry法
透明導電層3を保護するオーバーコート層4は、硬化性樹脂組成物の硬化膜であることが好ましい。硬化性樹脂組成物としては、(A)カルボキシ基を含有するポリウレタンと、(B)エポキシ化合物と、(C)硬化促進剤と、(D)溶媒と、を含むものが好ましい。硬化性樹脂組成物を上記透明導電層3上に印刷、塗布等により形成し、硬化させてオーバーコート層4を形成する。硬化性樹脂組成物の硬化は、熱硬化性樹脂組成物を加熱・乾燥させることにより行うことができる。
装置名:日本分光株式会社製HPLCユニット HSS-2000
カラム:ShodexカラムLF-804
移動相:テトラヒドロフラン
流速 :1.0mL/min
検出器:日本分光株式会社製 RI-2031Plus
温度 :40.0℃
試料量:サンプルル-プ 100μL
試料濃度:約0.1質量%に調製
100ml三角フラスコに試料約0.2gを精密天秤にて精秤し、これにエタノール/トルエン=1/2(質量比)の混合溶媒10mlを加えて溶解する。更に、この容器に指示薬としてフェノールフタレインエタノール溶液を1~3滴添加し、試料が均一になるまで十分に攪拌する。これを、0.1N水酸化カリウム-エタノール溶液で滴定し、指示薬の微紅色が30秒間続いたときを、中和の終点とする。その結果から下記の計算式を用いて得た値を、樹脂の酸価とする。
酸価(mg-KOH/g)=〔B×f×5.611〕/S
B:0.1N水酸化カリウム-エタノール溶液の使用量(ml)
f:0.1N水酸化カリウム-エタノール溶液のファクター
S:試料の採取量(g)
(a1)ポリイソシアネート化合物としては、通常、1分子当たりのイソシアナト基が2個であるジイソシアネートが用いられる。ポリイソシアネート化合物としては、たとえば、脂肪族ポリイソシアネート、脂環式ポリイソシアネート等が挙げられ、これらの1種を単独でまたは2種以上を組み合わせて用いることができる。(A)カルボキシ基を含有するポリウレタンがゲル化をしない範囲で、イソシアナト基を3個以上有するポリイソシアネートも少量使用することができる。
(a2)ポリオール化合物(ただし、(a2)ポリオール化合物には、後述する(a3)カルボキシ基を有するジヒドロキシ化合物は含まれない。)の数平均分子量は通常250~50,000であり、好ましくは400~10,000、より好ましくは500~5,000である。この分子量は前述した条件でGPCにより測定したポリスチレン換算の値である。
(a3)カルボキシ基を含有するジヒドロキシ化合物としては、ヒドロキシ基、炭素数が1または2のヒドロキシアルキル基から選択されるいずれかを2つ有する分子量が200以下のカルボン酸またはアミノカルボン酸であることが架橋点を制御できる点で好ましい。具体的には2,2-ジメチロ-ルプロピオン酸、2,2-ジメチロ-ルブタン酸、N,N-ビスヒドロキシエチルグリシン、N,N-ビスヒドロキシエチルアラニン等が挙げられ、この中でも、溶媒への溶解度から、2,2-ジメチロ-ルプロピオン酸、2,2-ジメチロ-ルブタン酸が特に好ましい。これらの(a3)カルボキシ基を含有するジヒドロキシ化合物は、1種単独でまたは2種以上を組み合わせて用いることができる。
(a4)モノヒドロキシ化合物として、グリコール酸、ヒドロキシピバリン酸等カルボン酸を有する化合物が挙げられる。
(a5)モノイソシアネート化合物としては、ヘキシルイソシアネート、ドデシルイソシアネート等が挙げられる。
[(芳香環含有化合物使用量)/(オーバーコート層4の質量((A)カルボキシ基を含有するポリウレタン質量+(B)エポキシ化合物質量+(C)硬化促進剤における硬化残基)]×100(%)
本実施形態においてキャリアフィルム1を形成する材料としては、優れた光透過性、耐傷性、耐水性を持ち、良好な機械的性質の観点から、ポリカーボネートフィルムを用いる。ポリカーボネートとしては、例えば、脂肪族ポリカーボネート、芳香族ポリカーボネート、脂肪族―芳香族ポリカーボネートなどが挙げられる。具体的には、例えば、ビスフェノールAポリカーボネート、分岐ビスフェノールAポリカーボネート、コポリカーボネート、ブロックコポリカーボネート、ポリエステルカーボネート、ポリホスホネートカーボネートなどが挙げられる。ポリカーボネート系樹脂には、ビスフェノールAポリカーボネートブレンド、ポリエステルブレンド、ABSブレンド、ポリオレフィンブレンド、スチレンー無水マレイン酸共重合体ブレンドのような他成分とブレンドしたものも含まれる。ポリカーボネート樹脂の市販品としては恵和株式会社製「オプコン(登録商標)」、帝人株式会社製「パンライト(登録商標)」等が挙げられる。キャリアフィルム1の厚みT2は、50~125μmの範囲であることが好ましい。この範囲であると、ハンドリングがし易い。キャリアフィルム1のより好ましい厚みは55~120μmであり、60~115μmであるとさらに好ましい。
透明導電フィルム積層体は、透明導電フィルム10または20と、その少なくとも一方の主面にて剥離可能に積層されたキャリアフィルム1と、を含む。
第一の実施形態にかかる透明導電フィルム積層体の製造方法は、透明樹脂フィルム2の一方の主面に透明導電層3とオーバーコート層4とがこの順序で積層された透明導電フィルム10を準備する工程と、上記透明導電フィルム10を構成する透明樹脂フィルム2の透明導電層3が積層されている側とは反対(他方)側の主面にキャリアフィルム1を積層する工程と、を含む。
<透明樹脂フィルム2の一方の主面に透明導電層3を有する透明導電フィルム10の作製>
<銀ナノワイヤの作製>
ポリ-N-ビニルピロリドンK-90(株式会社日本触媒製)(0.98g)、AgNO3(1.04g)及びFeCl3(0.8mg)を、エチレングリコール(250ml)に溶解し、150℃で1時間加熱反応した。得られた銀ナノワイヤ粗分散液をメタノール2000mlに分散させ、卓上小型試験機(日本ガイシ株式会社製、セラミック膜フィルター セフィルト使用、膜面積0.24m2、孔径2.0μm、寸法Φ30mm×250mm、ろ過差圧0.01MPa)に流し入れ、循環流速12L/min、分散液温度25℃にてクロスフロー濾過を実施し不純物を除去した後、全体量が100gになるまで濃縮し、銀ナノワイヤ(平均直径:26nm、平均長さ:20μm)のメタノール分散液を得た。得られた銀ナノワイヤの平均径の算出には、電界放出形走査電子顕微鏡JSM-7000F(日本電子株式会社製)を用い、任意に選択した100本の銀ナノワイヤの直径を測定し、その算術平均値を求めた。また、得られた銀ナノワイヤの平均長の算出には、形状測定レーザマイクロスコープVK-X200(キーエンス株式会社製)を用い、任意に選択した100本の銀ナノワイヤの長さを測定し、その算術平均値を求めた。また、上記メタノール、エチレングリコール、AgNO3、FeCl3は富士フイルム和光純薬株式会社製試薬を用いた。
上記ポリオール法で合成した銀ナノワイヤのメタノール分散液11g(銀ナノワイヤ濃度0.62質量%)、水3.5g、エタノール10.8g(富士フイルム和光純薬株式会社製)、プロピレングリコールモノメチルエーテル(PGME、富士フイルム和光純薬株式会社製)12.8g、プロピレングリコール1.2g(PG、旭硝子株式会社製)、PNVA(登録商標)水溶液(昭和電工株式会社製、固形分濃度10質量%、重量平均分子量90万)0.7gを混合し、ミックスローターVMR-5R(アズワン株式会社製)で1時間、室温、大気雰囲気下で撹拌(回転速度100rpm)して導電性インクとしての銀ナノワイヤインク40gを作製した。
プラズマ処理装置(積水化学工業株式会社製AP-T03)を用いてプラズマ処理(使用ガス:窒素、搬送速度:50mm/sec、処理時間:6sec、設定電圧:400V)した、透明樹脂フィルム2としてのA4サイズのシクロオレフィンポリマーフィルムZF14-013(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が13μm)上に、TQC自動フィルムアプリケータースタンダード(コーテック株式会社製)とワイヤレスバーOSP-CN-22L(コーテック株式会社製、バー形状/P(溝のピッチ):500μm、H(溝の深さ):42m、材質:SUS304)とを用いて銀ナノワイヤインクを全面に塗布した(塗工速度500mm/sec)。その後、恒温器HISPEC HS350(楠本化成株式会社製)で80℃、1分間、大気雰囲気下で熱風乾燥し、透明導電層3としての厚み90nmの銀ナノワイヤ層を形成した。
攪拌装置、温度計、コンデンサーを備えた2L三口フラスコに、ポリオール化合物としてC-1015N(株式会社クラレ製、ポリカーボネートジオール、原料ジオールモル比:1,9-ノナンジオール:2-メチル-1,8-オクタンジオール=15:85、分子量964)42.32g、カルボキシ基を含有するジヒドロキシ化合物として2,2-ジメチロールブタン酸(湖州長盛化工製)27.32g、および溶媒としてジエチレングリコールモノエチルエーテルアセテート(株式会社ダイセル製)158gを仕込み、90℃で前記2,2-ジメチロールブタン酸を溶解させた。
上記得られた(A)カルボキシ基含有ポリウレタンの溶液(カルボキシ基含有ポリウレタン含有率:45質量%)10.0gをポリ容器に量り取り、(D)溶媒として1-ヘキサノール85.3gと酢酸エチル85.2gを加え、ミックスローターVMR-5R(アズワン株式会社製)で12時間、室温、大気雰囲気下で撹拌(回転速度100rpm)した。均一であることを目視で確認したのち、(B)エポキシ化合物としてペンタエリスリトールテトラグリシジルエーテル(昭和電工株式会社製)0.63g、(C)硬化促進剤として、U-CAT5003(サンアプロ株式会社製)0.31gを加え、再度ミックスローターを用いて1時間撹拌し、オーバーコートインクを得た。オーバーコートインクの固形分中の芳香環含有化合物である硬化促進剤の割合は5.7質量%である。
透明樹脂フィルム2上に形成した透明導電層(銀ナノワイヤ層)3の上に、TQC自動フィルムアプリケータースタンダード(コーテック株式会社製)により、以下のようにオーバーコートインクを塗布した(塗工速度500mm/sec)。ワイヤレスバーOSP-CN-05Mを用いてウェット膜厚が5μmになるように塗布した。その後、恒温器HISPEC HS350(楠本化成株式会社製)で80℃、1分間、大気雰囲気下で熱風乾燥及び熱硬化し、オーバーコート層4(90nm)を形成した。
透明導電フィルム10を構成する透明樹脂フィルム2の銀ナノワイヤ層が形成されていない面に、キャリアフィルム1としてA4サイズのポリカーボネートフィルム(恵和株式会社製、PC#75KM65、ガラス転移温度147℃[カタログ値]、厚みT2が75μm、一方の主面にマット加工を施したもの)のマット加工処理されていない主面を圧着、積層し、透明導電フィルム積層体を形成した。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムRX4500(ARTON(登録商標)、JSR株式会社製、ガラス転移温度132℃[カタログ値]、厚みT1が15μm)を用いた以外は実施例1と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-023(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が23μm)を用いた以外は実施例1と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-050(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が50μm)を用いた以外は実施例1と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-100(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が100μm)を用いた以外は実施例1と同条件で検討した。その結果を表1に示す。
キャリアフィルム1にポリカーボネートフィルム(恵和株式会社製、HRPC#100KM40、ガラス転移温度175℃[カタログ値]、厚みT2が100μm、接着面の裏面にマット加工を施したもの)を用いた以外は実施例1と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムRX4500(ARTON(登録商標)、JSR株式会社製、ガラス転移温度132℃[カタログ値]、厚みT1が15μm)を用いた以外は実施例6と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-023(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が23μm)を用いた以外は実施例6と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-050(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が50μm)を用いた以外は実施例6と同条件で検討した。その結果を表1に示す。
透明導電フィルム10の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-100(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が100μm)を用いた以外は実施例6と同条件で検討した。その結果を表1に示す。
実施例11
透明樹脂フィルム2としてのシクロオレフィンポリマーフィルムZF14-013の一方の主面(第一面)に、実施例1と同条件で透明導電層(銀ナノワイヤ層)3とオーバーコート層4を作製した。続いて、透明導電層3が形成されていないもう一方の主面(第二面)に、実施例1と同条件で透明導電層(銀ナノワイヤ層)3とオーバーコート層4を形成し、透明樹脂フィルム2の両方の主面に透明導電層(銀ナノワイヤ層)4を有する透明導電フィルム20を得た。
透明導電フィルム20の第一面のオーバーコート層4に、キャリアフィルム1のマット加工されていない主面を圧着、積層し、透明導電フィルム積層体を形成した。その結果を表1に示す。
透明導電フィルム20の作製に、透明樹脂フィルム2としてシクロオレフィンポリマーフィルムZF14-100(ZEONOR(登録商標)、日本ゼオン株式会社製、ガラス転移温度136℃[カタログ値]、厚みT1が100μm)を用いた以外は実施例11と同条件で検討した。その結果を表1に記す。
キャリアフィルム1として粘着剤層付きポリカーボネートフィルム(恵和株式会社製、PC#75KM65/H915、ガラス転移温度147℃[カタログ値]、厚みT2が75μm)を用いた以外は実施例1と同条件で検討した。粘着剤層を介して貼りあわせた。その結果を表1に示す。
キャリアフィルム1として粘着剤層付きポリカーボネートフィルム(恵和株式会社製、HRPC#100KM40/H915、ガラス転移温度175℃[カタログ値]、厚みT2が100μm)を用いた以外は実施例1と同条件で検討した。粘着剤層を介して貼りあわせた。その結果を表1に示す。
比較例3
キャリアフィルム1として粘着剤層付きポリカーボネートフィルム(恵和株式会社製、PC#75KM65/H915、ガラス転移温度147℃[カタログ値]、厚みT2が75μm)を用いた以外は実施例11と同条件で検討した。粘着剤層を介して貼りあわせた。その結果を表1に示す。
(1)厚みの測定
厚みは1μm以上の厚みを有するものに関してはマイクロゲージ式厚み計にて測定を行った。また1μm未満の金属ナノワイヤを含む透明導電層3およびオーバーコート層4の厚みは光干渉法に基づく膜厚測定システムF20-UV(フィルメトリクス株式会社製)を用いて測定した。
実施例及び比較例で得られたA4サイズの透明導電フィルム積層体を長手方向の略中央で裁断して15cm(元のA4サイズの長手方向)×21cm(A4サイズの短手方向)のA5サイズの試験片を作製した。この試験片を、前面扉にガラス窓のついた乾燥機VO-420(Advantec製)に入れ、オーバーコート層4が上になる状態で100℃、30分加熱した。
Claims (9)
- 透明導電フィルムと、前記透明導電フィルムに積層されたキャリアフィルムと、を含む透明導電フィルム積層体であって、
前記キャリアフィルムが粘着剤層を有さないポリカーボネートフィルムであり、
前記透明導電フィルムが、透明樹脂フィルムの一方又は両方の主面に、金属ナノワイヤ及びバインダー樹脂を含む透明導電層と、オーバーコート層と、がこの順序に積層されて構成され、
前記透明樹脂フィルムが、非晶性シクロオレフィン系樹脂からなり、
前記透明導電フィルム積層体は、前記オーバーコート層が最外層となるように、前記キャリアフィルムが前記透明導電フィルムに剥離可能に積層されていることを特徴とする透明導電フィルム積層体。 - 前記金属ナノワイヤ及びバインダー樹脂を含む透明導電層と、オーバーコート層と、がこの順序で、前記透明樹脂フィルムの一方の主面に積層されている、請求項1に記載の透明導電フィルム積層体。
- 前記金属ナノワイヤ及びバインダー樹脂を含む透明導電層と、オーバーコート層と、がこの順序で、前記透明樹脂フィルムの両方の主面にそれぞれ積層されている、請求項1に記載の透明導電フィルム積層体。
- 前記キャリアフィルムの厚みT2が、50~125μmである請求項1~3のいずれか一項に記載の透明導電フィルム積層体。
- 前記透明樹脂フィルムの厚みT1が、5~150μmである請求項1~4のいずれか一項に記載の透明導電フィルム積層体。
- 前記透明導電層に含まれる金属ナノワイヤが、銀ナノワイヤである請求項1~5のいずれか一項に記載の透明導電フィルム積層体。
- 請求項1~6のいずれか一項に記載の透明導電フィルム積層体を加熱加工する工程と、前記透明導電フィルム積層体の透明導電フィルムとキャリアフィルムとを剥離する工程と、を含む透明導電フィルム積層体の加工方法。
- 前記加熱加工する工程が、オーバーコート層の上に導電ペーストにより形成した導電ペーストパターンを乾燥及び/又は熱硬化し導電パターンを形成する工程である、請求項7に記載の透明導電フィルム積層体の加工方法。
- 前記透明樹脂フィルムに前記キャリアフィルムを剥離可能に積層する工程と、
前記透明樹脂フィルムの、前記キャリアフィルムが積層されている側とは反対側の主面上に前記透明導電層と前記オーバーコート層とを順次形成する工程と、
前記オーバーコート層に前記キャリアフィルムを剥離可能に積層する工程と、
前記透明樹脂フィルムに積層されたキャリアフィルムを剥離する工程と、
前記透明樹脂フィルムの、前記透明導電層が積層された主面とは反対側の主面に前記透明導電層と前記オーバーコート層とを順次形成する工程と、
を備える、請求項3に記載の透明導電フィルム積層体の製造方法。
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