WO2012081680A1 - 感光性エレメント、レジストパターンの形成方法及びプリント配線板の製造方法 - Google Patents
感光性エレメント、レジストパターンの形成方法及びプリント配線板の製造方法 Download PDFInfo
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- WO2012081680A1 WO2012081680A1 PCT/JP2011/079097 JP2011079097W WO2012081680A1 WO 2012081680 A1 WO2012081680 A1 WO 2012081680A1 JP 2011079097 W JP2011079097 W JP 2011079097W WO 2012081680 A1 WO2012081680 A1 WO 2012081680A1
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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
- G03F7/004—Photosensitive materials
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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
- G03F7/004—Photosensitive materials
- G03F7/0047—Photosensitive materials characterised by additives for obtaining a metallic or ceramic pattern, e.g. by firing
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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
- G03F7/004—Photosensitive materials
- G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
- G03F7/028—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with photosensitivity-increasing substances, e.g. photoinitiators
- G03F7/031—Organic compounds not covered by group G03F7/029
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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
- G03F7/004—Photosensitive materials
- G03F7/027—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds
- G03F7/032—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with binders
- G03F7/033—Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds with binders the binders being polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. vinyl polymers
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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
- G03F7/004—Photosensitive materials
- G03F7/085—Photosensitive compositions characterised by adhesion-promoting non-macromolecular additives
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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
- G03F7/004—Photosensitive materials
- G03F7/09—Photosensitive materials characterised by structural details, e.g. supports, auxiliary layers
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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
- G03F7/20—Exposure; Apparatus therefor
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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
- G03F7/40—Treatment after imagewise removal, e.g. baking
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0073—Masks not provided for in groups H05K3/02 - H05K3/46, e.g. for photomechanical production of patterned surfaces
- H05K3/0076—Masks not provided for in groups H05K3/02 - H05K3/46, e.g. for photomechanical production of patterned surfaces characterised by the composition of the mask
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/02—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding
- H05K3/06—Apparatus or processes for manufacturing printed circuits in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding the conductive material being removed chemically or electrolytically, e.g. by photo-etch process
- H05K3/061—Etching masks
- H05K3/064—Photoresists
Definitions
- the present invention relates to a photosensitive element, a resist pattern forming method using the same, and a printed wiring board manufacturing method.
- photosensitive layer a layer made of a photosensitive resin composition
- support film a support film
- protective film a layer made of a photosensitive resin composition
- the printed wiring board is manufactured as follows, for example. First, after peeling off the protective film of the photosensitive element from the photosensitive layer, the photosensitive layer is laminated on the conductive film of the circuit forming substrate. Next, after pattern exposure is performed on the photosensitive layer, an unexposed portion is removed with a developing solution to form a resist pattern. And a printed wiring board is formed by patterning a conductive film based on this resist pattern.
- an alkali developing type such as a sodium carbonate solution is mainly used.
- the developer generally needs to have an ability to dissolve the photosensitive layer to some extent, and at the time of development, the photosensitive layer is dissolved or dispersed in the developer.
- the contact area between the circuit forming substrate and the photosensitive layer, which is a resist material has become smaller.
- the photosensitive layer is required to have excellent mechanical strength, chemical resistance, and flexibility in the etching or plating process, as well as excellent adhesion to the circuit forming substrate and excellent resolution in pattern formation.
- a material capable of forming a resist pattern having a line width and a space width of 10 ⁇ m or less is particularly desired for use as a package substrate. Further, in order to improve insulation reliability between wirings, the shape of the resist pattern is made close to a rectangle. It is needed.
- the photosensitive layer is laminated on the substrate and then exposed without peeling off the support film.
- a light-transmitting material may be employed for the support film.
- the support film is required to have a certain thickness (generally 10 ⁇ m to 30 ⁇ m).
- inorganic or organic fine particles are generally contained in the support film. For this reason, the conventional support film has increased haze, and the fine particles contained in the support film cause light scattering at the time of exposure, which tends to fail to meet the demand for higher resolution of the photosensitive film.
- a support film provided on a photosensitive element is peeled off before exposure and exposure is performed without using a support film.
- the phototool may be directly adhered to the photosensitive layer.
- the photosensitive layer usually has a certain degree of adhesiveness, it is difficult to remove the adhered phototool when the phototool is directly adhered to the photosensitive layer for exposure. Further, the phototool is contaminated by the photosensitive layer, or the photosensitive layer is exposed to oxygen in the atmosphere by peeling the support film, so that the photosensitivity is likely to be lowered.
- Patent Documents 1 and 2 disclose a method in which two or more photosensitive layers are formed, and a layer that directly adheres to the phototool is made non-adhesive.
- Patent Documents 3 to 8 propose a method of providing an intermediate layer between a support film and a photosensitive layer.
- the haze is lowered by containing inorganic or organic fine particles having an average particle size of about 0.01 to 5 ⁇ m on the outermost surface of one side of the support film, and exposure is performed through the support film.
- a method capable of increasing the resolution has been proposed.
- Patent Documents 1 to 8 require an extra coating process for providing an intermediate layer or a plurality of photosensitive layers, and the number of manufacturing processes increases.
- the photosensitive layer is exposed to oxygen in the atmosphere when placed on the substrate, so it is difficult to maintain high photosensitivity.
- the means described in Patent Documents 3 to 8 since the intermediate layer is thin, handling of the photosensitive element is not easy.
- Patent Documents 9 and 10 can achieve high resolution, but as the photosensitive layer is made thinner, the resist pattern becomes chipped and printed wiring It has been found that the production yield of the plate tends to decrease.
- the substrate surface roughness (Ra) with which the photosensitive layer comes into contact is smooth and less than 300 nm, so the adhesion is reduced.
- the production yield of the printed wiring board tends to decrease.
- the present invention has been made in view of the above circumstances, and in a photosensitive element including a layer made of a photosensitive resin composition, adhesion and resolution can be achieved even on a substrate having a substrate surface roughness (Ra) of less than 300 nm.
- An object of the present invention is to provide a photosensitive element that is good and sufficiently reduces a minute defect of a resist and that can form a resist pattern having a cross-sectional shape closer to a rectangle, and a method of forming a resist pattern using the photosensitive element. .
- the present invention is a photosensitive element comprising a support film and a photosensitive layer derived from the photosensitive resin composition formed on the support film, wherein the haze of the support film is 0.01 to 1.5%.
- the total number of particles having a diameter of 5 ⁇ m or more and aggregates having a diameter of 5 ⁇ m or more contained in the support film is 5 / mm 2 or less, and the photosensitive layer has a binder polymer and an ethylenically unsaturated bond.
- a photosensitive compound containing a polymerizable compound and a photopolymerization initiator wherein the thickness T of the photosensitive layer and the absorbance A at 365 nm of the layer made of the photosensitive resin composition satisfy a relationship represented by the following formula (I): Provide an element. 0.001 ⁇ A / T ⁇ 0.020 (I)
- the cross section of the resist pattern having a line width of 10 ⁇ m or less tends to have an extremely inverted trapezoidal shape because the absorbance of the photosensitive layer is high. For this reason, the cross section of the wiring pattern produced using such a resist pattern becomes an extremely inverted trapezoid, and there is a limit to increasing the density of the printed wiring board.
- the present inventors pay attention to the support film, and adopt a support film that sufficiently reduces the haze and has a sufficiently small total number of particles having a diameter of 5 ⁇ m or more and aggregates having a diameter of 5 ⁇ m or more contained in the film.
- a support film that sufficiently reduces the haze and has a sufficiently small total number of particles having a diameter of 5 ⁇ m or more and aggregates having a diameter of 5 ⁇ m or more contained in the film.
- the present inventors have found that the cross-sectional shape of the resist pattern can be made closer to a rectangle, and further the substrate surface roughness (Ra ) was found to be sufficient even when a substrate of less than 300 nm was used, and the present invention was completed.
- the photopolymerization initiator contains a 2,4,5-triarylimidazole dimer, so that the adhesion and resolution are further improved while maintaining high photosensitivity, An extremely fine-line resist pattern can be formed.
- the photopolymerization initiator contains a pyrazoline compound represented by the following general formula (XI) or (XII).
- R independently represents a linear or branched alkyl group having 1 to 12 carbon atoms, a linear or branched alkoxy group having 1 to 10 carbon atoms, or a halogen atom, and a, b and c are each independently Represents an integer of 0 to 5, and the sum of a, b and c is 1 to 6, and when the sum of a, b and c is 2 or more, a plurality of R may be the same or different from each other Good.
- At least one of R in the formulas (XI) and (XII) is an isopropyl group, a methoxy group, or an ethoxy group.
- the photopolymerizable compound contains a compound represented by the following general formula (II), a good balance of adhesion, resolution and chemical resistance is obtained, and an extremely fine-line resist pattern is formed. It becomes possible.
- R 5 and R 6 each independently represent a hydrogen atom or a methyl group
- Y represents an alkylene group having 2 to 6 carbon atoms
- n 1 and n 2 each independently represent a positive integer
- n 1 + N 2 is 4 to 40, and when n 1 + n 2 is 4 or more, a plurality of Y may be the same or different from each other.
- the binder polymer has a divalent group represented by the following general formulas (III), (IV), and (V), the balance between adhesion, resolution, and peelability is obtained. As a result, it becomes possible to form a very thin resist pattern.
- R 7 , R 8 and R 10 each independently represent a hydrogen atom or a methyl group
- R 9 represents an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, a hydroxyl group or a halogen atom
- R 11 represents an alkyl group having 1 to 6 carbon atoms
- p represents an integer of 0 to 5
- a plurality of R 9 may be the same or different from each other.
- the binder polymer further has a divalent group represented by the following general formula (VI) together with the divalent group represented by the above general formulas (III), (IV) and (V), The balance of adhesion, resolution and peelability can be further improved.
- R 12 represents a hydrogen atom or a methyl group
- R 13 represents an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, a hydroxyl group, or a halogen atom.
- q represents an integer of 0 to 5, and when q is 2 or more, a plurality of R 13 may be the same or different from each other.
- the present invention provides a lamination process in which the photosensitive element is laminated on a circuit-forming substrate in the order of a photosensitive layer and a support film, and a predetermined portion of the photosensitive layer is irradiated with actinic rays through the support film.
- a resist pattern forming method including an exposure step for forming a photocured portion and a developing step for removing a photosensitive layer other than the photocured portion.
- the present invention also provides a method for manufacturing a printed wiring board, in which etching or plating is performed on a circuit forming substrate on which a resist pattern is formed.
- a method for manufacturing a printed wiring board of the present invention since the resist pattern forming method using the photosensitive element of the present invention is employed, a high-density printed wiring board having an ultrafine wiring pattern is obtained. It is done.
- a photosensitive element comprising a layer made of a photosensitive resin composition
- the adhesion and resolution are good, and the resist has small defects.
- a photosensitive element capable of forming a resist pattern having a cross-sectional shape closer to a rectangle and a method for forming a resist pattern using the photosensitive element can be provided.
- FIG. 1 is a schematic cross-sectional view showing a preferred embodiment of the photosensitive element of the present invention.
- the photosensitive element 1 shown in FIG. 1 includes a support film 10 and a photosensitive layer 20.
- the photosensitive layer 20 is provided on the first main surface 12 of the support film 10.
- the support film 10 has a second main surface 14 on the side opposite to the first main surface 12.
- the support film 10 has a haze of 0.01 to 1.5%, and the total number of particles and aggregates (hereinafter simply referred to as “particles”) having a diameter of 5 ⁇ m or more contained in the support film 10 is 5 particles / mm. 2 or less.
- the particles having a diameter of 5 ⁇ m or more included in the support film 10 include both those protruding from the main surface of the support film and those existing inside the film.
- particles having a diameter of 5 ⁇ m or more include aggregates of primary particles having a diameter of 5 ⁇ m or more and primary particles having a diameter of less than 5 ⁇ m.
- the haze of the support film 10 is 0.01 to 1.5%, preferably 0.01 to 1.3%, more preferably 0.01 to 1.0%, More preferably, it is ⁇ 0.5%. If this haze is less than 0.01%, the production of the support film itself tends to be difficult, and if it exceeds 1.5%, the sensitivity and resolution tend to decrease.
- “haze” means haze.
- the haze in the present invention refers to a value measured using a commercially available haze meter (turbidimeter) in accordance with the method defined in JIS K 7105. The haze can be measured with a commercially available turbidimeter such as NDH-1001DP (trade name, manufactured by Nippon Denshoku Industries Co., Ltd.).
- the diameter 5 ⁇ m or more particles like are five / mm 2 or less, preferably 3 / mm 2 or less, more preferably 1 / mm 2 or less.
- partial defect (resist minute defect) of the resist after exposure and development tends to occur.
- a photosensitive element when used for a printed wiring board, it becomes a cause of the open defect at the time of an etching, and the short defect generation
- the support film 10 contains a large number of particles having a diameter of less than 5 ⁇ m, the influence on light scattering is not great.
- the photocuring reaction of the photosensitive layer is not only in the light irradiation part, but in a lateral direction where light is not directly irradiated (relative to the light irradiation direction). It also proceeds in the vertical direction. For this reason, when the particle size is small, the photocuring reaction directly under the particle proceeds sufficiently. However, as the particle size increases, the photocuring reaction directly under the particle does not proceed sufficiently, resulting in resist microdefects. I think that.
- the particles having a diameter of 5 ⁇ m or more included in the support film 10 include components constituting the support film, for example, a polymer gel, a raw material monomer, a catalyst used in production, and as necessary. Resulting from aggregates formed by agglomeration of inorganic or organic fine particles during film production, swelling due to lubricant and adhesive generated when a lubricant-containing layer is applied on the film, particles having a diameter of 5 ⁇ m or more contained in the film, etc. This is what happened. In order to reduce the number of particles having a diameter of 5 ⁇ m or more to 5 particles / mm 2 or less, among these particles, particles having a small particle diameter or excellent dispersibility may be selectively used.
- the number of particles having a diameter of 5 ⁇ m or more can be measured using a polarizing microscope.
- the aggregate formed by aggregating primary particles having a diameter of 5 ⁇ m or more and primary particles having a diameter of less than 5 ⁇ m is counted as one.
- FIG. 2 is a polarization micrograph observing the surface of the support film having particles having a diameter of 5 ⁇ m or more.
- a portion surrounded by a circle indicates an example of a portion corresponding to a particle having a diameter of 5 ⁇ m or more.
- FIG. 3 is a scanning photomicrograph of a resist pattern formed using a photosensitive element having a photosensitive layer on a support film having a large number of particles having a diameter of 5 ⁇ m or more. Thus, if there are a large number of particles having a diameter of 5 ⁇ m or more on the surface of the support film, a resist defect occurs.
- the material of the support film 10 is not particularly limited as long as particles having a diameter of 5 ⁇ m or more are 5 particles / mm 2 or less.
- Examples of the support film 10 include a film containing at least one resin material selected from the group consisting of polyesters such as polyethylene terephthalate (hereinafter referred to as “PET”), polyolefins such as polypropylene and polyethylene.
- the support film 10 may be a single layer or a multilayer.
- a two-layer support film consisting of two layers a two-layer film obtained by laminating a resin layer containing fine particles on one surface of a biaxially oriented polyester film is used as the support film, and contains the fine particles.
- the photosensitive layer is preferably formed on the surface opposite to the surface on which the resin layer is formed.
- a multilayer support film composed of three layers for example, A layer / B layer / A layer
- the configuration of the multilayer support film is not particularly limited, but the outermost layer (A layer in the case of the above-mentioned three layers) is preferably a resin layer containing fine particles from the standpoint of film slipperiness and the like.
- the conventional two-layer support film is manufactured by applying a resin layer having fine particles to a biaxially oriented polyester film, the resin layer containing the fine particles is easily peeled off when the photosensitive film is laminated. It may adhere to the photosensitive resin layer and cause defects. Therefore, in this invention, it is preferable to use the multilayer support film which consists of the resin layer which has microparticles
- the haze of the support film 10 is 0.01 to 1.5%, and particles having a diameter of 5 ⁇ m or more and the like contained in the support film 10 are adjusted to 5 particles / mm 2 or less, and at the same time, A multilayer support film provided with a resin layer containing fine particles is particularly suitable. Thereby, the slipperiness of the film is improved, and the suppression of light scattering at the time of exposure can be achieved in a balanced manner at a higher level.
- the average particle diameter of the fine particles is preferably 0.1 to 10 times the thickness of the resin layer containing the fine particles, and more preferably 0.2 to 5 times. If the average particle size is less than 0.1 times, the slipping property tends to be inferior, and if it exceeds 10 times, the photosensitive layer tends to be particularly uneven.
- the above fine particles are preferably contained in an amount of 0.01 to 50% by mass in the resin layer containing the fine particles.
- the fine particles include fine particles generated during polymerization with various nucleating agents, aggregates, silicon dioxide fine particles (aggregated silica, etc.), inorganic fine particles such as calcium carbonate fine particles, alumina fine particles, titanium oxide fine particles, and barium sulfate fine particles, Organic fine particles such as crosslinked polystyrene fine particles, acrylic fine particles, and imide fine particles, or a mixture thereof can be used.
- the one or more intermediate layers sandwiched between the outermost layers containing fine particles may or may not contain the fine particles, but from the viewpoint of resolution Preferably does not contain the fine particles.
- the content in the intermediate layer is preferably 1/3 or less of the content of the outermost layer, and more preferably 1/5 or less.
- the thickness of the resin layer containing the fine particles is preferably 0.01 to 5 ⁇ m, more preferably 0.05 to 3 ⁇ m, and more preferably 0.1 to 2 ⁇ m. Is particularly preferred.
- middle layer of outermost layer has a static friction coefficient of 1.2 or less. If the coefficient of static friction exceeds 1.2, wrinkles tend to occur during film production and photosensitive element production, and dust tends to adhere because it tends to generate static electricity.
- the static friction coefficient can be measured according to ASTM D1894.
- the particle size of the fine particle which the resin layer containing fine particle contains is less than 5 micrometers. Is preferred. In order to further reduce light scattering during exposure, it is preferable to appropriately adjust the thickness of the resin layer containing fine particles in accordance with the particle size of the fine particles.
- the support film 10 may contain an antistatic agent or the like as necessary as long as the photosensitive characteristics are not impaired.
- the thickness of the support film 10 is preferably 5 to 40 ⁇ m, more preferably 8 to 35 ⁇ m, still more preferably 10 to 30 ⁇ m, and particularly preferably 12 to 25 ⁇ m.
- the thickness is less than 5 ⁇ m, the support film 10 tends to be easily broken when the support film 10 is peeled from the photosensitive element 1.
- the thickness exceeds 40 ⁇ m, the resolution tends to decrease and the cost is inferior.
- the support film 10 may be obtained by using a commercially available general industrial film that can be used as a support film for the photosensitive element 1 and appropriately processing it.
- Examples of commercially available general industrial films that can be used as the support film 10 include “FB-40” (trade name, manufactured by Toray Industries, Inc.), which is a three-layer PET film whose outermost layer contains fine particles.
- the photosensitive layer 20 is a layer (derived from the photosensitive resin composition) formed using the photosensitive resin composition.
- the thickness T of the photosensitive layer and the absorbance A at 365 nm of the photosensitive layer satisfy the relationship represented by the following formula (I). 0.001 ⁇ A / T ⁇ 0.020 (I)
- the absorbance of the photosensitive layer can be measured using a UV spectrophotometer (trade name “U-3310” manufactured by Hitachi, Ltd.). Absorbance can be measured continuously from 550 to 300 nm in an absorbance mode by placing a photosensitive element comprising a support film and a photosensitive layer on the measurement side of the apparatus and placing only the support film on the reference side.
- a UV spectrophotometer trade name “U-3310” manufactured by Hitachi, Ltd.
- a / T (hereinafter referred to as “Y value”), which is the ratio between the absorbance A at 365 nm of the photosensitive layer and the thickness T of the photosensitive layer, is 0.001 to 0.020, and is 0.005 to 0.00. 020 is preferable, 0.010 to 0.020 is more preferable, 0.012 to 0.018 is still more preferable, and 0.014 to 0.016 is particularly preferable. If this Y value is less than 0.001, light is hardly absorbed by the photosensitive layer, so that the sensitivity tends to decrease, and the productivity of the printed wiring board tends to decrease, and the amount of light reflected from the substrate increases. Therefore, the resolution due to the halation effect tends to decrease.
- the Y value exceeds 0.020, the amount of light absorbed at the top of the exposed area increases, and the photocuring reaction at the bottom of the exposed area does not proceed sufficiently, so the resist shape after development is reversed. It becomes a trapezoid, the adhesiveness decreases, and the tenting property tends to deteriorate.
- the fall of adhesiveness will express more notably.
- a substrate having a substrate surface roughness (Ra) of less than 300 nm the adhesiveness is more significantly reduced.
- the substrate surface roughness (Ra) can be measured using a surface roughness measuring instrument (trade name “SE-30D” manufactured by Kosaka Laboratory Ltd.).
- the photosensitive resin composition constituting the photosensitive layer 20 includes (a) a binder polymer (hereinafter referred to as “component (a)”), (b) a photopolymerizable compound having an ethylenically unsaturated bond (hereinafter referred to as “(b ) Component ”) and (c) a photopolymerization initiator (hereinafter referred to as“ component (c) ”).
- component (a) a binder polymer
- component (b ) Component ) a photopolymerizable compound having an ethylenically unsaturated bond
- component (c) a photopolymerization initiator
- the binder polymer as component (a) is not particularly limited as long as it is used in conventional photosensitive resin compositions.
- acrylic resin, styrene resin, epoxy resin, amide resin, amide epoxy resin , Alkyd resins and phenol resins are used.
- an acrylic resin is preferable from the viewpoint of alkali developability. These are used singly or in combination of two or more.
- the binder polymer can be produced by radical polymerization of a polymerizable monomer.
- polymerizable monomers include polymerizable styrene derivatives such as styrene and vinyltoluene, p-methylstyrene, p-chlorostyrene, ⁇ -methylstyrene and ⁇ -methylstyrene derivatives, acrylamide, acrylonitrile, vinyl-n-butyl.
- esters of vinyl alcohol such as esters, (meth) acrylic acid alkyl esters, (meth) acrylic acid benzyl esters, (meth) acrylic acid tetrahydrofurfuryl esters, (meth) acrylic acid dimethylaminoethyl esters, (meth) acrylic acid Diethylaminoethyl ester, (meth) acrylic acid glycidyl ester, 2,2,2-trifluoroethyl (meth) acrylate, 2,2,3,3-tetrafluoropropyl (meth) acrylate, (meth) acrylic acid, ⁇ - Bromo (meth) a Rylic acid, ⁇ -chloro (meth) acrylic acid, ⁇ -furyl (meth) acrylic acid, ⁇ -styryl (meth) acrylic acid, maleic acid, maleic anhydride, monomethyl maleate, monoethyl maleate, monoisopropyl maleate And maleic acid monoesters such as fumaric acid
- the binder polymer preferably contains a carboxyl group in the molecule from the viewpoint of alkali developability.
- the binder polymer having a carboxyl group can be produced by radical polymerization of a polymerizable monomer having a carboxyl group and another polymerizable monomer.
- the binder polymer preferably contains a divalent group represented by the following general formulas (III), (IV) and (V) as a structural unit from the viewpoint of the balance between developer resistance and peelability. Note that the adhesion and resolution tend to be improved due to the improvement in developer resistance.
- R 7 , R 8 and R 10 each independently represent a hydrogen atom or a methyl group
- R 9 represents an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, a hydroxyl group or a halogen atom
- R 11 represents an alkyl group having 1 to 6 carbon atoms
- p represents an integer of 0 to 5
- a plurality of R 9 may be the same or different from each other.
- the content ratio of the structural unit represented by the general formula (III) is preferably 10 to 50% by mass, and preferably 15 to 40% by mass based on the total solid content of the copolymer (a) binder polymer. % Is more preferable, and 20 to 35% by mass is even more preferable.
- this ratio is less than 10% by mass, the resistance to an alkaline aqueous solution generally used in a developer and a stripping solution is improved, and development and peeling tend to be difficult.
- this ratio exceeds 50% by mass, There is a tendency for the developer resistance to deteriorate and the adhesion and resolution to decrease.
- the term “styrene derivative” and “ ⁇ -methylstyrene derivative” mean that the hydrogen atom in the benzene ring of styrene and ⁇ -methylstyrene is a substituent R 9 (an alkyl group having 1 to 4 carbon atoms, 1 to 3 alkoxy group, OH group, halogen atom).
- styrene derivative examples include methyl styrene, ethyl styrene, tert-butyl styrene, methoxy styrene, ethoxy styrene, hydroxy styrene, and chlorostyrene, and are structural units in which R 9 is substituted at the p-position. More preferred.
- ⁇ -methylstyrene derivative include those in which the hydrogen atom at the ⁇ -position of the vinyl group is substituted with a methyl group in the above styrene derivative.
- the content of the structural unit represented by the general formula (IV) is preferably 3 to 60% by mass based on the total solid content of the (a) binder polymer that is a copolymer, and is preferably 10 to 55% by mass. % Is more preferable, 15 to 50% by mass is more preferable, and 20 to 45% by mass is particularly preferable. If this content is less than 3% by mass, the adhesion and resolution tend to decrease, and if it exceeds 60% by mass, the exfoliation piece tends to be large, the exfoliation time tends to be long, and the flexibility of the resist after curing is further increased. There is a tendency to decrease.
- the structural unit represented by the general formula (V) is a structural unit based on (meth) acrylic acid alkyl ester.
- examples of the (meth) acrylic acid alkyl ester include those in which R 11 is an alkyl group having 1 to 12 carbon atoms in the general formula (V).
- the alkyl group having 1 to 12 carbon atoms may be linear or branched and may have a substituent such as a hydroxyl group, an epoxy group, or a halogen atom.
- Such (meth) acrylic acid alkyl esters include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, isopropyl (meth) acrylate, butyl (meth) acrylate, (meth) ) Tert-butyl acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, heptyl (meth) acrylate, octyl (meth) acrylate and 2-ethylhexyl (meth) acrylate, and structural isomers thereof Is mentioned.
- R 11 is preferably an alkyl group having 1 to 6 carbon atoms, more preferably an alkyl group having 1 to 6 carbon atoms having no substituent. Preferably, it is a methyl group.
- the content of the structural unit represented by the general formula (V) is preferably 1 to 60% by mass based on the total solid content of the copolymer (a) binder polymer, and preferably 2 to 55% by mass. %, More preferably 4 to 50% by mass, still more preferably 5 to 50% by mass. If this content is less than 1% by mass, the resist releasability tends to decrease, and if it exceeds 60% by mass, the resolution tends to decrease.
- the binder polymer can further contain a divalent group represented by the following general formula (VI) as a structural unit from the viewpoint of the balance between adhesion, resolution, and peelability.
- VI a divalent group represented by the following general formula (VI) as a structural unit from the viewpoint of the balance between adhesion, resolution, and peelability.
- R 12 represents a hydrogen atom or a methyl group
- R 13 represents an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 3 carbon atoms, a hydroxyl group, or a halogen atom.
- q represents an integer of 0 to 5, and when q is 2 or more, a plurality of R 13 may be the same or different from each other.
- the structural unit represented by the general formula (VI) is a structural unit based on benzyl (meth) acrylate or a benzyl (meth) acrylate derivative.
- the benzyl (meth) acrylate derivative include 4-methylbenzyl (meth) acrylate, 4-ethylbenzyl (meth) acrylate, 4-tertbutylbenzyl (meth) acrylate, 4-methoxybenzyl (meth) acrylate, 4- Mention may be made of ethoxybenzyl (meth) acrylate, 4-hydroxylbenzyl (meth) acrylate and 4-chlorobenzyl (meth) acrylate.
- a structural unit is preferred.
- the content of the structural unit represented by the general formula (VI) is preferably 5 to 60% by mass based on the total solid content of the copolymer (a) binder polymer, and preferably 10 to 55% by mass. More preferably, it is 15 to 50% by mass, more preferably 20 to 45% by mass. If this content is less than 5% by mass, the adhesion tends to decrease. If it exceeds 60% by mass, the peeling time tends to be long, and the flexibility of the resist after UV curing tends to decrease.
- the weight average molecular weight of the binder polymer is preferably 30,000 to 100,000, more preferably 35,000 to 80,000, still more preferably 40,000 to 60,000. If the weight average molecular weight is less than 30000, the photosensitive layer tends to be brittle, and if it exceeds 100000, a residual thread development occurs and the resolution tends to decrease.
- the weight average molecular weight is measured by gel permeation chromatography (hereinafter referred to as “GPC”), and a value converted to standard polystyrene is used.
- the acid value of the binder polymer is preferably 30 to 300 mgKOH / g, and more preferably 50 to 200 mgKOH / g.
- the acid value is less than 30 mgKOH / g, the development time tends to be long, and when it exceeds 300 mgKOH / g, the acidity of the photocured resist with respect to the alkaline developer tends to decrease.
- binder polymers are used singly or in combination of two or more.
- combinations of binder polymers in the case of using two or more in combination include, for example, two or more binder polymers composed of different copolymerization components (including different repeating units as constituent components), and two or more types of different weight average molecular weights. And two or more types of binder polymers having different degrees of dispersion.
- a polymer having a multimode molecular weight distribution described in JP-A No. 11-327137 can also be used.
- the binder polymer may have a photosensitive group as needed.
- the photopolymerizable compound having an ethylenically unsaturated bond as the component (b) preferably includes a compound having 4 to 40 carbon atoms of an oxyalkylene unit (alkylene glycol unit) having 2 to 6 carbon atoms.
- a compound having 4 to 40 carbon atoms of an oxyalkylene unit (alkylene glycol unit) having 2 to 6 carbon atoms By containing such a compound as component (b), compatibility with (a) the binder polymer can be improved.
- the photopolymerizable compound having an ethylenically unsaturated bond as the component (b) has the following general formula ( It is preferable that the bisphenol A type (meth) acrylate compound represented by II) is included.
- R 5 and R 6 each independently represent a hydrogen atom or a methyl group, and preferably a methyl group.
- Y represents an alkylene group having 2 to 6 carbon atoms.
- n 1 and n 2 each represent a positive integer, and n 1 + n 2 is an integer of 2 to 40, preferably an integer of 6 to 34, more preferably an integer of 8 to 30, It is more preferably an integer of ⁇ 28, particularly preferably an integer of 8-20, very preferably an integer of 8-16, and most preferably an integer of 8-12.
- n 1 + n 2 When the value of n 1 + n 2 is less than 2, the compatibility with the binder polymer decreases, and when the photosensitive element is laminated on the circuit forming substrate, it tends to be peeled off. When the value of n 1 + n 2 exceeds 40, The hydrophilicity increases, the resist tends to peel off during development, and the plating resistance tends to decrease.
- a plurality of Y present in the molecule may be the same as or different from each other.
- alkylene group having 2 to 6 carbon atoms examples include ethylene group, propylene group, isopropylene group, butylene group, pentylene group and hexylene group.
- an ethylene group or an isopropylene group is preferable, and an ethylene group is more preferable.
- the aromatic ring in the general formula (II) may have a substituent.
- substituents include a halogen atom, an alkyl group having 1 to 20 carbon atoms, a cycloalkyl group having 3 to 10 carbon atoms, an aryl group having 6 to 18 carbon atoms, a phenacyl group, an amino group, and 1 to 10 carbon atoms.
- An alkylcarbonyl group having 2 to 10 carbon atoms, an alkenyl group having 2 to 10 carbon atoms, an N-alkylcarbamoyl group having 2 to 10 carbon atoms, or a complex Groups containing, or an aryl group substituted with these substituents include.
- the above substituents may form a condensed ring, and a hydrogen atom in these substituents may be substituted with the above substituent such as a halogen atom.
- the number of substituents is 2 or more, the two or more substituents may be the same or different.
- Examples of the compound represented by the general formula (II) include 2,2-bis (4-((meth) acryloxypolyethoxy) phenyl) propane, 2,2-bis (4-((meth) acrylic). Loxypolypropoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxypolybutoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxypolyethoxypolypropoxy) phenyl) Examples thereof include bisphenol A-based (meth) acrylate compounds such as propane.
- 2,2-bis (4-((meth) acryloxypolyethoxy) phenyl) propane examples include 2,2-bis (4-((meth) acryloxydiethoxy) phenyl) propane, 2,2- Bis (4-((meth) acryloxytriethoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxytetraethoxy) phenyl) propane, 2,2-bis (4-((meth)) Acryloxypentaethoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxyhexaethoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxyheptaethoxy) phenyl) propane 2,2-bis (4-((meth) acryloxyoctaethoxy) phenyl) propane, 2,2-bis (4-((meth) acryloxynonato) C) phenyl) propane, 2,2-bis (4-((meth) acryloxydeca
- 2,2-bis (4- (methacryloxydiethoxy) phenyl) propane is preferred, and is commercially available as BPE-200 (trade name, manufactured by Shin-Nakamura Chemical Co., Ltd.). Further, 2,2-bis (4- (methacryloxypentaethoxy) phenyl) propane is more preferable, and is commercially available as BPE-500 (trade name, manufactured by Shin-Nakamura Chemical Co., Ltd.). 2,2-bis (4- (methacryloxypentadecaethoxy) phenyl) propane is commercially available as BPE-1300 (trade name, manufactured by Shin-Nakamura Chemical Co., Ltd.). These are used singly or in combination of two or more.
- Examples of 2,2-bis (4-((meth) acryloxypolyethoxypolypropoxy) phenyl) propane include 2,2-bis (4-((meth) acryloxydiethoxyoctapropoxy) phenyl) propane, Examples include 2,2-bis (4-((meth) acryloxytetraethoxytetrapropoxy) phenyl) propane and 2,2-bis (4-((meth) acryloxyhexaethoxyhexapropoxy) phenyl) propane. These are used singly or in combination of two or more.
- polyalkylene glycol di (meth) acrylate can also be preferably used.
- polyalkylene glycol di (meth) acrylate for example, a compound represented by the following general formula (VII), (VIII) or (IX) is preferable.
- R 14 and R 15 each independently represent a hydrogen atom or a methyl group
- EO represents an oxyethylene group
- PO represents a propyleneoxy group
- S 1 represents an integer of 1 to 30
- r 1 represents an integer of 0 to 30, and r 1 + r 2 (average value) is an integer of 1 to 30.
- R 16 and R 17 each independently represent a hydrogen atom or a methyl group.
- EO represents an oxyethylene group
- PO represents an oxypropylene group
- r 3 represents an integer of 1 to 30
- s 2 and s 3 each represents an integer of 0 to 30, and s 2 + s 3 (average value) Is an integer from 1 to 30.
- each of R 18 and R 19 independently represents a hydrogen atom or a methyl group, and is preferably a methyl group.
- EO represents an oxyethylene group
- PO represents an oxypropylene group.
- r 4 represents an integer of 1 to 30, and s 4 represents an integer of 1 to 30.
- the secondary carbon of the propylene group may be bonded to the oxygen atom, or the primary carbon may be bonded to the oxygen atom.
- the total number of repeating oxyethylene units (r 1 + r 2 , r 3 and r 4 ) in the general formulas (VII), (VIII) and (IX) is preferably an integer of 1 to 30 each independently, More preferably, it is an integer of 1 to 10, more preferably an integer of 4 to 9, and particularly preferably an integer of 5 to 8. If the number of repetitions exceeds 30, the tent reliability and the resist shape tend to deteriorate.
- the total number of repeating oxypropylene units (s 1 , s 2 + s 3 and s 4 ) in the general formulas (VII), (VIII) and (IX) is preferably independently an integer of 1 to 30, An integer of 5 to 20 is more preferable, an integer of 8 to 16 is still more preferable, and an integer of 10 to 14 is particularly preferable. If the number of repetitions exceeds 30, the resolution decreases and sludge tends to be generated during development.
- Compound manufactured by Hitachi Chemical Co., Ltd., trade name: FA-023M) and the like.
- the component (b) may further contain a photopolymerizable compound having one ethylenically unsaturated bond from the viewpoint of improving developability such as adhesion and resolution and releasability.
- a photopolymerizable compound having one ethylenically unsaturated bond it is preferable to contain a compound represented by the following general formula (X).
- R 20 represents a hydrogen atom or a methyl group, and is preferably a hydrogen atom.
- Z is synonymous with Y in the general formula (II) described above, and is preferably an ethylene group.
- k represents a positive integer of 4 to 20, and from the viewpoint of developability, it is preferably an integer of 5 to 18, more preferably an integer of 6 to 12, and an integer of 6 to 10. Further preferred.
- aromatic ring in the general formula (X) may have a substituent, and examples of the substituent include the same substituents as the aromatic ring in the general formula (II) described above.
- nonylphenoxypolyethyleneoxy (meth) acrylate examples include nonylphenoxytetraethyleneoxy (meth) acrylate, nonylphenoxypentaethyleneoxy (meth) acrylate, nonylphenoxyhexaethyleneoxy (meth) acrylate, nonylphenoxyheptaethyleneoxy ( (Meth) acrylate, nonylphenoxyoctaethyleneoxy (meth) acrylate, nonylphenoxynonaethyleneoxy (meth) acrylate, nonylphenoxydecaethyleneoxy (meth) acrylate, nonylphenoxyundecaethyleneoxy (meth) acrylate and nonylphenoxide decaethyleneoxy (Meth) acrylate is mentioned.
- butylphenoxypolyethyleneoxy (meth) acrylate examples include butylphenoxytetraethyleneoxy (meth) acrylate, butylphenoxypentaethyleneoxy (meth) acrylate, butylphenoxyhexaethyleneoxy (meth) acrylate, butylphenoxyheptaethyleneoxy ( Examples include meth) acrylate, butylphenoxyoctaethyleneoxy (meth) acrylate, butylphenoxynonaethyleneoxy (meth) acrylate, butylphenoxydecaethyleneoxy (meth) acrylate, and butylphenoxyundecaethyleneoxy (meth) acrylate. In addition, these are used individually by 1 type or in combination of 2 or more types.
- a urethane monomer such as a (meth) acrylate compound having a urethane bond may be contained from the viewpoint of improving tenting properties and the like.
- the urethane monomer examples include a (meth) acrylic monomer having a hydroxyl group at the ⁇ -position and a diisocyanate compound such as isophorone diisocyanate, 2,6-toluene diisocyanate, 2,4-toluene diisocyanate, and 1,6-hexamethylene diisocyanate.
- a diisocyanate compound such as isophorone diisocyanate, 2,6-toluene diisocyanate, 2,4-toluene diisocyanate, and 1,6-hexamethylene diisocyanate.
- examples include addition reaction products, tris ((meth) acryloxytetraethylene glycol isocyanate) hexamethylene isocyanurate, EO-modified urethane di (meth) acrylate, and EO, PO-modified urethane di (meth) acrylate.
- EO represents ethylene oxide
- PO represents propylene oxide
- PO-modified compound has a block structure of propylene oxide groups.
- examples of the EO-modified urethane di (meth) acrylate include the product name “UA-11” manufactured by Shin-Nakamura Chemical Co., Ltd.
- Examples of the EO and PO-modified urethane di (meth) acrylates include trade name “UA-13” manufactured by Shin-Nakamura Chemical Co., Ltd. These are used individually by 1 type or in combination of 2 or more types.
- the component (b) may contain a photopolymerizable compound having an ethylenically unsaturated bond other than those described above.
- Other (b) photopolymerizable compounds include, for example, compounds obtained by reacting an ⁇ , ⁇ -unsaturated carboxylic acid with a polyhydric alcohol, and reacting an ⁇ , ⁇ -unsaturated carboxylic acid with a glycidyl group-containing compound.
- the compound obtained by this, a phthalic acid type compound, (meth) acrylic-acid alkylester, etc. are mentioned. These are used individually by 1 type or in combination of 2 or more types.
- Examples of the compound obtained by reacting the polyhydric alcohol with an ⁇ , ⁇ -unsaturated carboxylic acid include, for example, trimethylolpropane di (meth) acrylate, trimethylolpropane tri (meth) acrylate, EO-modified trimethylolpropane tri ( Examples include meth) acrylate, PO-modified trimethylolpropane tri (meth) acrylate, EO, PO-modified trimethylolpropane tri (meth) acrylate, dipentaerythritol penta (meth) acrylate and dipentaerythritol hexa (meth) acrylate. These are used individually by 1 type or in combination of 2 or more types.
- phthalic acid compounds examples include ⁇ -chloro- ⁇ -hydroxypropyl- ⁇ ′-(meth) acryloyloxyethyl-o-phthalate and ⁇ -hydroxyalkyl- ⁇ ′-(meth) acryloloxyalkyl-o. -Phthalates. These may be used alone or in any combination of two or more.
- the concentration of ethylenically unsaturated bonds (also referred to as “vinyl group concentration”) contained in the photosensitive layer is preferably 0.8 mmol / g to 1.6 mmol / g, and 0.9 mmol / g to 1.5 mmol / g. g is more preferable, 1.0 mmol / g to 1.4 mmol / g is further preferable, and 1.1 mmol / g to 1.3 mmol / g is most preferable.
- concentration of the ethylenically unsaturated bond is less than 0.8 mmol / g, the crosslink density of the photosensitive layer after exposure is reduced, and the adhesion and chemical resistance are reduced.
- the photopolymerization initiator as component (c) preferably contains 2,4,5-triarylimidazole dimer.
- 2,4,5-triarylimidazole dimers include 2- (o-chlorophenyl) -4,5-diphenylimidazole dimer, 2- (o-chlorophenyl) -4,5-di (methoxy).
- Phenyl) imidazole dimer 2- (o-fluorophenyl) -4,5-diphenylimidazole dimer, 2- (o-methoxyphenyl) -4,5-diphenylimidazole dimer, 2- (p- And methoxyphenyl) -4,5-diphenylimidazole dimer and 2,2′-bis (o-chlorophenyl) -4,5,4 ′, 5′-tetraphenylimidazole dimer.
- 2- (o-chlorophenyl) -4,5-diphenylimidazole dimer is preferable from the viewpoint of further improving adhesion and sensitivity.
- the aryl group substituents of the two 2,4,5-triarylimidazoles may give the same and symmetrical compounds, or differently asymmetric Such compounds may be provided.
- the content ratio of the 2,4,5-triarylimidazole dimer when the component (c) includes a 2,4,5-triarylimidazole dimer is based on the total amount of the component (c). It is preferably 70 to 100% by mass, more preferably 85 to 100% by mass, still more preferably 90 to 100% by mass, and particularly preferably 93 to 100% by mass.
- the photosensitive element of the present invention has better adhesion and sensitivity.
- the photopolymerizable compound as component (c) preferably contains a pyrazoline compound represented by the following general formula (XI) or (XII) together with the 2,4,5-triarylimidazole dimer.
- a pyrazoline compound represented by the following general formula (XI) or (XII) together with the 2,4,5-triarylimidazole dimer.
- each R independently represents a linear or branched alkyl group having 1 to 12 carbon atoms, a linear or branched alkoxy group having 1 to 10 carbon atoms, or a halogen atom.
- A, b and c each independently represent an integer of 0 to 5, and the sum of a, b and c is 1 to 6.
- a plurality of R may be the same or different from each other.
- at least one of R is a linear or branched alkyl group having 1 to 12 carbon atoms or a linear or branched alkoxy group having 1 to 10 carbon atoms.
- R is a linear or branched alkyl group having 1 to 12 carbon atoms or a linear or branched alkoxy group having 1 to 10 carbon atoms.
- a linear or branched alkyl group having 1 to 4 carbon atoms or a linear or branched alkoxy group having 1 to 4 carbon atoms such as a tert-butyl group, isopropyl group, methoxy group, More preferably, it is a group or an ethoxy group.
- pyrazoline compound represented by the formula (XI) examples include 1- (4-methoxyphenyl) -3-styryl-5-phenyl-pyrazoline, 1-phenyl-3- (4-methoxystyryl)- 5- (4-methoxyphenyl) -pyrazoline, 1-phenyl-3- (4-methoxystyryl) -5- (4-tert-butyl-phenyl) -pyrazoline, 1,5-bis- (4-methoxyphenyl) -3- (4-methoxystyryl) -pyrazoline, 1- (4-isopropylphenyl) -3-styryl-5-phenyl-pyrazoline, 1-phenyl-3- (4-isopropylstyryl) -5- (4-isopropyl Phenyl) -pyrazoline, 1,5-bis- (4-isopropylphenyl) -3- (4-isopropylstyryl) -pyrazoline, 1- (4-(2-
- 1-phenyl-3- (4-methoxystyryl) -5- (4-methoxyphenyl) is provided in that a light-sensitive resin composition excellent in resist shape is prepared by adjusting the absorbance with respect to the thickness of the photosensitive layer.
- Examples of the pyrazoline compound represented by the formula (XII) include 1-phenyl-3-phenyl-5- (4-isopropylphenyl) pyrazoline, 1- (4-tert-butyl-phenyl) -3,5-diphenyl.
- 1-phenyl-3-phenyl-5- (4-isopropylphenyl) pyrazoline is included from the viewpoint of adjusting the absorbance with respect to the thickness of the photosensitive layer and providing a photosensitive resin composition having an excellent resist shape. Is preferred.
- pyrazoline compounds can be obtained as commercial products from Nippon Chemical Industry Co., Ltd., and can be synthesized by the methods described in Japanese Patent No. 2931893, Japanese Patent No. 2757528, Japanese Patent No. 2972373, Japanese Patent No. 3215718, Japanese Patent No. 3312756, etc. it can.
- the content is the total amount of the component (c).
- it is preferably 0.5 to 6.0% by mass, more preferably 1.0 to 5.0% by mass, and further preferably 1.0 to 4.0% by mass.
- photopolymerization initiators may be used as the photopolymerization initiator as component (c).
- Other photopolymerization initiators include, for example, aromatic ketones, p-aminophenyl ketones, quinones, benzoin ether compounds, benzoin compounds, benzyl derivatives, acridine derivatives, coumarin compounds, oxime esters, N-aryls - ⁇ -amino acid compounds, aliphatic polyfunctional thiol compounds, acylphosphine oxides, thioxanthones, tertiary amine compounds, and the like, and these compounds may be used in combination.
- the photopolymerization initiator preferably contains the above aromatic ketones in addition to the 2,4,5-triarylimidazole dimer or the pyrazoline compound, and among them, N, N′-tetraethyl-4 4,4′-diaminobenzophenone (Michler ketone) is preferably contained.
- the blending amount of the binder polymer as component (a) is preferably 40 to 70 parts by weight, and 45 to 65 parts by weight based on 100 parts by weight of the total amount of components (a) and (b). Is more preferably 50 to 60 parts by mass. If the blending amount is less than 40 parts by mass, the photocured product tends to be brittle, and if it exceeds 70 parts by mass, the resolution and photosensitivity tend to be insufficient.
- the amount of the photopolymerizable compound having an ethylenically unsaturated bond as the component (b) is preferably 30 to 60 parts by mass based on 100 parts by mass of the total amount of the components (a) and (b). 35 to 55 parts by mass is more preferable, and 40 to 50 parts by mass is even more preferable. If the blending amount is less than 30 parts by mass, the resolution and photosensitivity tend to be insufficient, and if it exceeds 60 parts by mass, the photocured product tends to be brittle.
- the blending amount of the photopolymerization initiator as the component (c) is preferably 0.1 to 20 parts by mass with respect to 100 parts by mass of the total amount of the components (a) and (b), 0.2 to The amount is more preferably 10 parts by mass, and particularly preferably 0.5 to 5 parts by mass. If the blending amount is less than 0.1 parts by mass, the photosensitivity tends to be insufficient, and if it exceeds 20 parts by mass, the light absorption on the surface of the photosensitive resin composition increases during the exposure, and the internal There is a tendency for photocuring to be insufficient.
- the photosensitive resin composition includes a photopolymerizable compound (oxetane compound or the like) having at least one cationically polymerizable cyclic ether group in the molecule, a cationic polymerization initiator, a dye such as malachite green, as necessary.
- a photopolymerizable compound oxetane compound or the like
- a cationic polymerization initiator a dye such as malachite green
- Photochromic agents such as tribromophenylsulfone and leucocrystal violet, thermochromic inhibitors, plasticizers such as p-toluenesulfonamide, pigments, fillers, antifoaming agents, flame retardants, stabilizers, inhibitors, leveling agents
- additives such as a peeling accelerator, an antioxidant, a fragrance, an imaging agent, and a thermal crosslinking agent may be contained. These are used singly or in combination of two or more. These additives may be contained in an amount of about 0.0001 to 20 parts by mass based on 100 parts by mass of the total amount of the components (a) and (b) as long as the object of the present invention is not impaired.
- the photosensitive resin composition is dissolved in a solvent such as methanol, ethanol, acetone, methyl ethyl ketone, methyl cellosolve, ethyl cellosolve, toluene, N, N-dimethylformamide and propylene glycol monomethyl ether, or a mixed solvent thereof, as necessary.
- a solvent such as methanol, ethanol, acetone, methyl ethyl ketone, methyl cellosolve, ethyl cellosolve, toluene, N, N-dimethylformamide and propylene glycol monomethyl ether, or a mixed solvent thereof, as necessary.
- a solvent such as methanol, ethanol, acetone, methyl ethyl ketone, methyl cellosolve, ethyl cellosolve, toluene, N, N-dimethylformamide and propylene glycol monomethyl ether, or a mixed solvent thereof, as necessary.
- the photosensitive layer 20 in the photosensitive element 1 of the present invention can be formed by applying the above-described photosensitive resin composition on the support film 10 and removing the solvent.
- a coating method for example, a known method such as roll coating, comma coating, gravure coating, air knife coating, die coating, or bar coating can be employed.
- the removal of the solvent can be performed, for example, by treating at a temperature of 70 to 150 ° C. for about 5 to 30 minutes.
- the amount of the remaining organic solvent in the photosensitive layer 20 is preferably 2% by mass or less from the viewpoint of preventing the organic solvent from diffusing in a later step.
- the thickness (T) of the photosensitive layer 20 thus formed is preferably 2 to 30 ⁇ m, more preferably 5 to 25 ⁇ m, and more preferably 7 to 20 ⁇ m after drying. More preferred is 10 to 20 ⁇ m. If this thickness is less than 2 ⁇ m, problems occur when the photosensitive layer is laminated on the circuit forming substrate, or the tenting property is inferior, the resist is damaged during the development and etching processes, and open defects are caused. There is a possibility that the manufacturing yield of the printed wiring board tends to decrease.
- the thickness exceeds 30 ⁇ m, the resolution of the photosensitive layer 20 is lowered or the circumference of the etching solution is deteriorated, so that the influence of side etching becomes large, and it becomes difficult to manufacture a high-density printed wiring board. Tend.
- the absorbance (a) at 365 nm of the photosensitive layer 20 is preferably 0.01 to 0.60, more preferably 0.05 to 0.55, and more preferably 0.10 to 0.50. Further preferred. If the absorbance is less than 0.01, sufficient sensitivity cannot be obtained and it becomes difficult to form a resist pattern. If the absorbance exceeds 0.60, the amount of light absorbed at the top of the exposed portion increases, and at the bottom of the exposed portion. Since the photocuring reaction does not proceed sufficiently, the resist shape after development tends to be an inverted trapezoid.
- the photosensitive element 1 may include a protective film (not shown) on the main surface of the photosensitive layer 20 opposite to the first main surface 12 in contact with the support film 10.
- a protective film it is preferable to use a film in which the adhesive force between the photosensitive layer 20 and the protective film is smaller than the adhesive force between the photosensitive layer 20 and the support film 10. It is preferable to use the film. Specific examples include inert polyolefin films such as polyethylene and polypropylene. From the viewpoint of peelability from the photosensitive layer 20, a polyethylene film is preferable.
- the thickness of the protective film varies depending on the use, but is preferably about 1 to 100 ⁇ m.
- the photosensitive element 1 may further include an intermediate layer or a protective layer such as a cushion layer, an adhesive layer, a light absorption layer, and a gas barrier layer in addition to the support film 10, the photosensitive layer 20, and the protective film.
- a protective layer such as a cushion layer, an adhesive layer, a light absorption layer, and a gas barrier layer in addition to the support film 10, the photosensitive layer 20, and the protective film.
- the photosensitive element 1 of the present embodiment may be stored, for example, as it is or in a state where a protective film further laminated on the photosensitive layer 20 is wound around a cylindrical core. At this time, it is preferable that the support film 10 is wound into a roll shape so as to become a re-outer layer. Moreover, it is preferable to install an end face separator on the end face of the photosensitive element 1 wound up in a roll shape from the viewpoint of end face protection, and it is preferable to install a moisture-proof end face separator from the viewpoint of edge fusion resistance. Further, as a packing method, it is preferable to wrap and package in a black sheet with low moisture permeability.
- the core material examples include plastics such as polyethylene resin, polypropylene resin, polystyrene resin, polyvinyl chloride resin, and ABS resin (acrylonitrile-butadiene-styrene copolymer).
- the photosensitive element 1 is laminated on the circuit forming substrate in the order of the photosensitive layer 20 and the support film 10, and the active light is passed through the support film 10 to the photosensitive layer.
- 20 is a method including an exposure step of irradiating a predetermined portion 20 to form a photocured portion on the photosensitive layer 20 and a developing step of removing a portion of the photosensitive layer 20 other than the photocured portion.
- the laminating step as a method of laminating the photosensitive layer 20 on the circuit forming substrate, when a protective film is present on the photosensitive layer 20, the photosensitive layer 20 is removed after the protective film has been removed.
- a method of laminating by heating to about 130 ° C. with pressure of about 0.1 to 1 MPa on a circuit forming substrate may be used.
- lamination can also be performed under reduced pressure.
- the surface on which the circuit forming substrate is laminated is usually a metal surface, but is not particularly limited. Further, in order to further improve the stackability, a pre-heat treatment of the circuit forming substrate may be performed.
- a photomask having a negative or positive mask pattern is aligned and brought into close contact with the second main surface 14 of the support film 10 with respect to the photosensitive layer 20 that has been laminated in the laminating step.
- the photosensitive layer 20 is irradiated with an actinic ray in an image form through the support film 10, and a photocured portion is formed on the photosensitive layer 20.
- the light source of the actinic light a known light source such as a carbon arc lamp, a mercury vapor arc lamp, a high pressure mercury lamp, a xenon lamp, or the like that effectively emits ultraviolet rays or visible light is used.
- a photocuring part can also be formed in the photosensitive layer 20 using a laser direct drawing exposure method.
- the photomask is peeled off from the support film 10. Further, the support film 10 is peeled off from the photosensitive layer 20.
- the unexposed portion (unphotocured portion) of the photosensitive layer 20 is removed and developed by wet development using a developer such as an alkaline aqueous solution, an aqueous developer, an organic solvent, dry development, etc. Can be manufactured.
- Examples of the alkaline aqueous solution include a dilute solution of 0.1 to 5% by mass sodium carbonate, a dilute solution of 0.1 to 5% by mass potassium carbonate, and a dilute solution of 0.1 to 5% by mass sodium hydroxide.
- the pH of the alkaline aqueous solution is preferably in the range of 9 to 11, and the temperature is adjusted according to the developability of the photosensitive layer 20.
- a surfactant, an antifoaming agent, an organic solvent, or the like may be mixed in the alkaline aqueous solution.
- Examples of the development method include a dip method, a spray method, brushing, and slapping.
- the resist pattern may be further cured by performing heating at a temperature of about 60 to 250 ° C. or an exposure amount of about 0.2 to 10 J / cm 2 as necessary. .
- the printed wiring board manufacturing method of the present embodiment is performed by etching or plating the circuit forming substrate on which the resist pattern is formed by the resist pattern forming method.
- etching or plating of the circuit forming substrate is performed by etching or plating the surface of the circuit forming substrate by a known method using the developed resist pattern as a mask.
- etching solution used for etching for example, a cupric chloride solution, a ferric chloride solution, an alkaline etching solution, or the like can be used.
- plating examples include copper plating, solder plating, nickel plating, and gold plating.
- the resist pattern can be peeled off with a stronger alkaline aqueous solution than the alkaline aqueous solution used for development, for example.
- a stronger alkaline aqueous solution for example, a 1 to 10% by mass sodium hydroxide aqueous solution, a 1 to 10% by mass potassium hydroxide aqueous solution and the like are used.
- a peeling system an immersion system, a spray system, etc. are mentioned, for example.
- the printed wiring board on which the resist pattern is formed may be a multilayer printed wiring board or may have a small diameter through hole.
- the photosensitive element 1 of the present invention can also be used for a package substrate including a rigid substrate and an insulating film formed on the rigid substrate.
- the photocured portion of the photosensitive layer may be used as the insulating film.
- a high pressure mercury lamp is used for the purpose of improving solder heat resistance, chemical resistance, etc. It is preferable to perform ultraviolet irradiation or heating. In the case of irradiating with ultraviolet rays, the irradiation amount can be adjusted as necessary.
- irradiation can be performed at an irradiation amount of about 0.2 to 10 J / cm 2 .
- the resist pattern when it is heated, it is preferably performed in the range of about 100 to 170 ° C. for about 15 to 90 minutes.
- ultraviolet irradiation and heating can be performed at the same time, and after either one is performed, the other can be performed. When ultraviolet irradiation and heating are performed simultaneously, heating to 60 to 150 ° C. is more preferable from the viewpoint of effectively imparting solder heat resistance, chemical resistance, and the like.
- This solder resist is effective as a permanent mask for semiconductor packages because it also serves as a protective film for wiring after soldering to the substrate and has excellent physical properties such as tensile strength and elongation and thermal shock resistance. .
- the package substrate provided with the resist pattern in this manner is then mounted with semiconductor elements (for example, wire bonding, solder connection) and then mounted on an electronic device such as a personal computer.
- semiconductor elements for example, wire bonding, solder connection
- the solution a was added dropwise to the above blend of toluene and methyl cellosolve having a mass ratio of 6: 4 and heated to 80 ° C. over 4 hours. Thereafter, the dropping funnel was washed with 40 g of a mixture of toluene and methyl cellosolve having a mass ratio of 6: 4, added to the flask, and kept at 80 ° C. with stirring for 2 hours. Furthermore, a solution in which 1.0 g of azobisisobutyronitrile was dissolved in 40 g of a mixture of methyl cellosolve and toluene having a mass ratio of 6: 4 was dropped into the flask over 30 minutes.
- the dropping funnel was washed with 120 g of a mixture of toluene and methyl cellosolve having a mass ratio of 6: 4 and added to the flask.
- the solution after dropping was kept at 80 ° C. for 3 hours with stirring, and then heated to 90 ° C. over 30 minutes.
- the mixture was kept at 90 ° C. for 2 hours and then cooled to obtain a binder polymer solution as component (a).
- Toluene was added to this binder polymer solution to prepare a nonvolatile component concentration (solid content concentration) of 40% by mass.
- the weight average molecular weight of the binder polymer was 45,000.
- the acid value was 107 mmg KOH.
- each component was blended in the blending amounts (g) shown in Tables 2 to 4 below to prepare solutions of photosensitive resin compositions of Examples and Comparative Examples.
- the numerical value in () shows solid content.
- b-1 FA-321M (EO-modified bisphenol A dimethacrylate, total number of EO (average value) 10, manufactured by Hitachi Chemical Co., Ltd., trade name)
- b-2 BPE-200 (EO-modified bisphenol A dimethacrylate, EO total number (average value) 10, Shin-Nakamura Kogyo Co., Ltd., trade name)
- b-3 FA-MECH ( ⁇ -chloro-2-hydroxypropyl- ⁇ ′-methacryloyloxyeryl-o-phthalate, manufactured by Hitachi Chemical Co., Ltd., trade name)
- b-4 BPE-100 (EO-modified bisphenol A dimethacrylate, total number of EO (average value) 2.6, manufactured by Shin-Nakamura Kogyo Co., Ltd., trade name)
- b-5 BPE-900 (EO-modified bisphenol A dimethacrylate, total number of EO (average value) 17, manufactured by Shin-Nakamura Kogyo Co.,
- the number of particles and the like is a value obtained by measuring the number of particles and the like having a size of 5 ⁇ m or more existing in 1 mm 2 units using a polarizing microscope. In this case, the n number was 5.
- the haze is a value measured according to JIS K 7105. All of these support films had a thickness of 16 ⁇ m.
- the solution of the photosensitive resin composition was applied on each PET film so as to have a uniform thickness, and the solvent was removed by drying with a hot air convection dryer at 100 ° C. for 5 minutes. After drying, the photosensitive layer was covered with a protective film made of polyethylene (manufactured by Tamapoly, trade name “NF-15”, thickness 20 ⁇ m) to obtain a photosensitive element. The coating amount of the photosensitive resin composition solution was adjusted so that the thickness of the photosensitive layer after drying would be the thickness T shown in Tables 5-7.
- Non-adhesive two-layer plating method FPC base material Metaroyal PI-38N-CCS-E (trade name, polyimide: Kapton 150EN (manufactured by Toray DuPont), polyimide thickness: 38 ⁇ m, copper plating layer: none)
- the copper surface of the copper foil was washed with water and then dried with an air flow.
- the obtained FPC base material was heated to 80 ° C., and the photosensitive element was laminated so that the photosensitive layer was in contact with the copper surface while peeling off the protective film.
- a laminate was obtained in which the FPC substrate, the photosensitive layer, and the support film were laminated in this order.
- Lamination was performed using a 120 ° C. heat roll at a pressure of 0.4 MPa and a roll speed of 1.5 m / min. These laminates were used as test pieces in the following tests.
- the resolution is the smallest width (unit: ⁇ m) of the space width between the line widths where the unexposed areas could be completely removed when the resist pattern was observed using an optical microscope after the development process. It was evaluated by doing. Note that the smaller the numerical value, the better the evaluation of resolution. The results are shown in Tables 5-7.
- the number of remaining step steps after development of the 41-step tablet is 11 using an exposure machine (trade name “EXM-1201”, manufactured by Oak Co., Ltd.) having a high-pressure mercury lamp lamp in close contact with the tool on the support film of the test piece. Exposure was performed with an irradiation energy amount of 0.0. Next, the support film was peeled off, and a 1% by mass aqueous sodium carbonate solution was spray-developed at 30 ° C.
- the adhesion is such that the unexposed part can be removed cleanly by the development process, and when the resist pattern is observed using an optical microscope after the development process, it is the smallest line width among the remaining line widths without peeling or twisting. Evaluation was made by measuring (unit: ⁇ m). In addition, evaluation of adhesiveness is a favorable value, so that a numerical value is small. The results are shown in Tables 5-7.
- the difference in line width is less than 0.3 ⁇ m.
- B Line width difference is 0.3 to 0.6 ⁇ m.
- C The difference in line width exceeds 0.6 to 0.9 ⁇ m.
- D The difference in line width exceeds 0.9 ⁇ m.
- a photosensitive element comprising a layer made of a photosensitive resin composition
- the adhesion and resolution are good, and the resist has small defects.
- a photosensitive element capable of forming a resist pattern having a cross-sectional shape closer to a rectangle and a method for forming a resist pattern using the photosensitive element can be provided.
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Abstract
Description
0.001≦A/T≦0.020 (I)
支持フィルム10は、ヘーズが0.01~1.5%であり、かつ支持フィルム10に含まれる直径5μm以上の粒子及び凝集物(以下、単に「粒子等」という)の総数が5個/mm2以下のものである。ここで、支持フィルム10に含まれる直径5μm以上の粒子等には、支持フィルムの主面から突出しているもの及びフィルム内部に存在するものの両方が含まれる。また、直径5μm以上の粒子等には、直径5μm以上の一次粒子及び直径5μm未満の一次粒子の凝集物が含まれる。
これにより、フィルムの滑り性が良くなると共に、露光時の光散乱の抑制をバランスよく、より高いレベルで成し遂げることができる。微粒子の平均粒子径は、微粒子を含有する樹脂層の層厚の0.1~10倍であることが好ましく、0.2~5倍であることがより好ましい。平均粒子径が0.1倍未満では滑り性が劣る傾向があり、10倍を超えると感光層に特に凹凸が生じ易い傾向がある。
感光層20は感光性樹脂組成物を用いて形成される(感光性樹脂組成物に由来する)層である。感光層の厚さTと感光層の365nmにおける吸光度Aとは、下記式(I)で表される関係を満足する。
0.001≦A/T≦0.020 (I)
本実施形態のレジストパターンの形成方法は、上記感光性エレメント1を、感光層20、支持フィルム10の順に回路形成用基板上に積層する積層工程と、活性光線を、上記支持フィルム10を通して感光層20の所定部分に照射して、感光層20に光硬化部を形成させる露光工程と、上記光硬化部以外の感光層20の部分を除去する現像工程と、を含む方法である。
本実施形態のプリント配線板の製造方法は、上記レジストパターンの形成方法によりレジストパターンの形成された回路形成用基板に対し、エッチング又はめっきすることによって行われる。ここで、回路形成用基板のエッチング又はめっきは、現像されたレジストパターンをマスクとして、回路形成用基板の表面を公知の方法によりエッチング又はめっきすることによって行われる。
本発明の感光性エレメント1は、リジット基板と、そのリジット基板上に形成された絶縁膜とを備えるパッケージ基板に用いることもできる。この場合、感光層の光硬化部を絶縁膜として用いればよい。感光層の光硬化部を、例えば半導体パッケージ用のソルダーレジストとして用いる場合は、上述のレジストパターンの形成方法における現像終了後、はんだ耐熱性、耐薬品性等を向上させる目的で、高圧水銀ランプによる紫外線照射や加熱を行うことが好ましい。紫外線を照射させる場合は必要に応じてその照射量を調整することができ、例えば0.2~10J/cm2程度の照射量で照射を行うこともできる。また、レジストパターンを加熱する場合は、100~170℃程度の範囲で15~90分程行われることが好ましい。さらに紫外線照射と加熱とを同時に行うこともでき、いずれか一方を実施した後、他方を実施することもできる。紫外線の照射と加熱とを同時に行う場合、はんだ耐熱性、耐薬品性等を効果的に付与する観点から、60~150℃に加熱することがより好ましい。
まず、表1に示す組成のバインダーポリマーを下記合成例にしたがって合成した。
撹拌機、還流冷却器、温度計、滴下ロート及び窒素ガス導入管を備えたフラスコに、質量比6:4であるトルエン及びメチルセロソルブの配合物420gを加え、窒素ガスを吹き込みながら撹拌して、80℃まで加熱した。一方、共重合単量体としてメタクリル酸162g、メタクリル酸メチル30g、スチレン270g及びメタクリル酸ベンジル270gと、アゾビスイソブチロニトリル4.4gとを混合した溶液(以下、「溶液a」という)を用意し、80℃に加熱された質量比6:4であるトルエン及びメチルセロソルブの上記配合物に溶液aを4時間かけて滴下した。その後、質量比6:4であるトルエン及びメチルセロソルブの配合物40gを用い滴下ロートを洗浄し、フラスコ内に加え、80℃で撹拌しながら2時間保温した。さらに、質量比6:4であるメチルセロソルブ及びトルエンの配合物40gにアゾビスイソブチロニトリル1.0gを溶解した溶液を、30分かけてフラスコ内に滴下した。そして、質量比6:4であるトルエン及びメチルセロソルブの配合物120gを用い滴下ロートを洗浄し、フラスコ内に加えた。滴下後の溶液を撹拌しながら80℃で3時間保温した後、30分間かけて90℃に加温した。90℃で2時間保温した後、冷却して(a)成分であるバインダーポリマー溶液を得た。このバインダーポリマー溶液に、トルエンを加えて不揮発成分濃度(固形分濃度)が40質量%になるように調製した。バインダーポリマーの重量平均分子量は、バインダーポリマーの重量平均分子量は、45000であった。なお、ゲルパーミエーションクロマトグラフィー(GPC)法によって測定し、標準ポリスチレンの検量線を用いて換算することにより算出した。
GPCの条件を以下に示す。また、バインダーポリマーの酸価を下記測定手順に従い測定した結果、酸価は107mmgKOHであった。
共重合単量体としてメタクリル酸150g、メタクリル酸メチル300g及びスチレン150gと、アゾビスイソブチロニトリル4.4gとを混合した溶液(以下、「溶液b」という)を用意した以外は、合成例1と同様の操作をして(a)成分であるバインダーポリマー溶液を得た。このバインダーポリマー溶液に、トルエンを加えて不揮発成分濃度(固形分濃度)が40質量%になるように調製した。バインダーポリマーの重量平均分子量は、バインダーポリマーの重量平均分子量は、45000であった。また、バインダーポリマーの酸価は121mmgKOHであった。
ポンプ:日立 L-6000型(日立製作所社製、商品名)
カラム:Gelpack GL-R420+Gelpack GL-R430+Gelpack GL-R440(計3本)(以上、日立化成工業社製、商品名)
溶離液:テトラヒドロフラン
測定温度:40℃
流量:2.05mL/分
検出器:日立 L-3300型RI(日立製作所社製、商品名)
三角フラスコに合成したバインダーポリマーを秤量し、混合溶剤(質量比:トルエン/メタノール=70/30)を加え溶解後、指示薬としてフェノールフタレイン溶液を添加し、N/10水酸化カリウムアルコール溶液で滴定し、酸価を測定した。
b-2:BPE-200(EO変性ビスフェノールAジメタクリレート、EO総数(平均値)10、新中村工業社製、商品名)
b-3:FA-MECH(γ-クロロ-2-ヒロドキシプロピル-β’-メタクリロイルオキシエリル-o-フタレート、日立化成工業社製、商品名)
b-4:BPE-100(EO変性ビスフェノールAジメタクリレート、EO総数(平均値)2.6、新中村工業社製、商品名)
b-5:BPE-900(EO変性ビスフェノールAジメタクリレート、EO総数(平均値)17、新中村工業社製、商品名)
b-6:BPE-1300N(EO変性ビスフェノールAジメタクリレート、EO総数(平均値)30、新中村工業社製、商品名)
b-7:NP-4EA(ノニルフェノキシポリエチレングリコールアクリレート、EO総数(平均値)4、共栄社化学製、商品名)
b-8:NP-8EA(ノニルフェノキシポリエチレングリコールアクリレート、EO総数(平均値)8、共栄社化学製、商品名)
b-9:SR-454(EO変性トリメチロールプロパントリアクリレート、EO総数(平均値)3、化薬サトーマー製、商品名)
b-10:FA-024M(PO変性エチレングリコールジメタクリレート、日立化成工業製、商品名)
c-1:2-(o-クロロフェニル)-4,5-ジフェニルイミダゾール二量体
c-2:1-フェニル-3-(4-メトキシスチリル)-5-(4-メトキシフェニル)ピラゾリン
c-3:1-フェニル-3-(4-メトキシフェニル)-5-(4-t-ブチルフェニル)ピラゾリン
c-4:1-フェニル-3-フェニル-5-(4-イソプロピルフェニル)ピラゾリン c-5:N,N’-テトラエチル-4,4’-ジアミノベンゾフェノン
感光性エレメントの支持フィルムとして、下記PETフィルムを用意した。各PETフィルムに含まれる5μm以上の粒子等の個数及びヘーズを測定した結果を表5~7に示す。
<支持フィルム>
微粒子を含有する層を表裏に有する3層構造の二軸配向PETフィルム:FB40(東レ社製、商品名)
微粒子が片側にのみ存在する2層構造の二軸配向PETフィルム:A-1517(東洋紡績製、商品名)
微粒子を含有する層を表裏に有する3層構造の二軸配向PETフィルム:HTR-02(帝人デュポン社製、商品名)
上記試験片を125mm×200mmのサイズにカットし、支持フィルムを剥離した後、30℃の1質量%炭酸ナトリウム水溶液を用いて、未露光状態の感光層をスプレー現像し、未露光部が完全に除去される時間を測定し、最少現像時間とした。測定結果を表5~7に示す。
試験片の支持フィルム上に、ネガとして41段ステップタブレット(日立化成工業社製)を載置し、高圧水銀灯ランプを有する露光機(オーク社製、商品名「EXM-1201」)及びi線バンドバスフィルターを用いて、現像後のレジスト硬化段数が11段になる所定の照射エネルギー量となるように感光層を露光した。次に、支持フィルムを剥離し、30℃の1質量%炭酸ナトリウム水溶液を最少現像時間の2倍の時間でスプレー現像し、未露光部分を除去して現像を行った。そして、銅張積層板上に形成された光硬化膜のステップタブレットの段数が11段になっていることを確認し、このときの露光量を各感光層の所定の照射エネルギー量とした。結果を表5~7に示す。
解像度を調べるため、41段ステップタブレットを有するフォトツールと、解像度評価用ネガとしてライン幅/スペース幅が2/2~30/30(単位:μm)の配線パターンを有するガラスクロムタイプのフォトツールとを試験片の支持フィルム上に密着させ、高圧水銀灯ランプを有する露光機(オーク社製、商品名「EXM-1201」)及びi線バンドパスフィルターを用いて、41段ステップタブレットの現像後の残存ステップ段数が11段となる照射エネルギー量で露光を行った。次に、支持フィルムを剥離し、30℃で1質量%炭酸ナトリウム水溶液を最少現像時間の2倍の時間でスプレー現像し、未露光部分を除去して現像を行った。ここで、解像度は、現像処理後に光学顕微鏡を用いてレジストパターンを観察したとき、未露光部を完全に除去することができたライン幅間のスペース幅の最も小さい幅(単位:μm)を測定することにより評価した。なお、解像度の評価は数値が小さいほど良好な値である。結果を表5~7に示す。
密着性を調べるため、41段ステップタブレットを有するフォトツールと、密着性評価用ネガとしてライン幅/スペース幅が2/6~30/90(単位:μm)の配線パターンを有するガラスクロムタイプのフォトツールとを試験片の支持フィルム上に密着させ、高圧水銀灯ランプを有する露光機(オーク社製、商品名「EXM-1201」)を用いて、41段ステップタブレットの現像後の残存ステップ段数が11.0となる照射エネルギー量で露光を行った。次に、支持フィルムを剥離し、30℃で1質量%炭酸ナトリウム水溶液を最少現像時間の2倍の時間でスプレー現像し、未露光部分を除去して現像を行った。ここで、密着性は、現像処理によって未露光部をきれいに除去することができ、現像処理後に光学顕微鏡を用いてレジストパターンを観察したとき、剥がれ及びよれがなく残ったライン幅のうち最も小さい幅(単位:μm)を測定することにより評価した。なお、密着性の評価は数値が小さいほど良好な値である。結果を表5~7に示す。
上記解像度測定試験で評価した基板において、ライン幅/スペース幅がx/x(単位:μm)の指定箇所の配線パターンのレジストラインの断面形状を観察した。観察手法として、タングステンを用いてレジストの保護膜を形成した後、集束イオンビーム加工観察装置(日立製作所社製、商品名「FB-2000A」、イオン種:Gaイオン、加速電圧:30kV、観察条件:ビームアパーチャーφ500μm)を用い、レジストパターン中心部のレジスト断面を露出させた。次いで、走査型電子顕微鏡(日立製作所社製、商品名「FE-SEM S-4700」)により観察し、レジスト上面とレジスト底面の線幅の差を測定し、以下のように評価した。結果を表5~7に示す。
A:線幅の差が1.0μm未満である。
B:線幅の差が1.0~1.5μmである。
C:線幅の差が1.5μmを超える。
A:線幅の差が0.3μm未満である。
B:線幅の差が0.3~0.6μmである。
C:線幅の差が0.6~0.9μmを超える。
D:線幅の差が0.9μmを超える。
上記解像度測定試験で評価した基板において、レジストラインの側面形状を走査型電子顕微鏡(日立製作所社製、商品名「SU-1500」)により観察し、以下のように評価した。結果を表5~7に示す。
A:滑らかな形状
B:やや粗い形状
C:粗い形状
レジストの微小欠損部発生性を調べるため、41段ステップタブレットを有するフォトツールと、ライン幅/スペース幅が10/30(単位:μm)の配線パターンを有するガラスクロムタイプのフォトツールとを試験片の支持フィルム上に密着させ、高圧水銀灯ランプを有する露光機及びi線バンドパスフィルターを用いて、41段ステップタブレットの現像後の残存ステップ段数が8.0となる照射エネルギー量で露光を行った。次に、支持フィルムを剥離し、30℃の1質量%炭酸ナトリウム水溶液を最少現像時間の4倍の時間スプレーし、未露光部分を除去した。次いで、顕微鏡を用いて、レジスト欠損部の個数を数えた。ライン長さが1mmでライン本数が10本を観察単位とし、n数を5とした時の平均値をレジスト微小欠損部発生数とした。その結果を表5~7に示す。
Claims (10)
- 支持フィルムと、該支持フィルム上に形成された感光性樹脂組成物に由来する感光層と、を備える感光性エレメントであって、
前記支持フィルムのヘーズが、0.01~1.5%であり、かつ、該支持フィルムに含まれる直径5μm以上の粒子及び直径5μm以上の凝集物の総数が5個/mm2以下であり、
前記感光層が、バインダーポリマー、エチレン性不飽和結合を有する光重合性化合物及び光重合開始剤を含有し、
前記感光層の厚さTと前記感光層の365nmにおける吸光度Aとが、下記式(I)で表される関係を満足する、感光性エレメント。
0.001≦A/T≦0.020 (I) - 前記光重合開始剤が、2,4,5-トリアリールイミダゾール二量体を含有する、請求項1記載の感光性エレメント。
- 前記Rのうち少なくとも一つがイソプロピル基である、請求項3記載の感光性エレメント。
- 前記Rのうち少なくとも一つがメトキシ基又はエトキシ基である、請求項3記載の感光性エレメント。
- 請求項1~8のいずれか一項に記載の感光性エレメントを、前記感光層、前記支持フィルムの順に回路形成用基板上に積層する積層工程と、
活性光線を、前記支持フィルムを通して前記感光層の所定部分に照射して、前記感光層に光硬化部を形成させる露光工程と、
前記光硬化部以外の前記感光層を除去する現像工程と、
を含む、レジストパターンの形成方法。 - 請求項9記載のレジストパターンの形成方法によりレジストパターンが形成された回路形成用基板に対し、エッチング又はめっきを施す、プリント配線板の製造方法。
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US10520816B2 (en) | 2014-05-23 | 2019-12-31 | Hitachi Chemical Company, Ltd. | Method for forming resist pattern, method for manufacturing printed wiring board, photosensitive resin composition for projection exposure and photosensitive element |
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JPWO2022065049A1 (ja) * | 2020-09-28 | 2022-03-31 | ||
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JP7416969B2 (ja) | 2020-09-28 | 2024-01-17 | 富士フイルム株式会社 | 転写フィルム、積層体の製造方法、回路配線の製造方法 |
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JPWO2012081680A1 (ja) | 2014-05-22 |
MY161035A (en) | 2017-04-14 |
KR20130073978A (ko) | 2013-07-03 |
CN107422606A (zh) | 2017-12-01 |
CN103261966A (zh) | 2013-08-21 |
TWI514082B (zh) | 2015-12-21 |
TW201241568A (en) | 2012-10-16 |
JP5573961B2 (ja) | 2014-08-20 |
KR101444044B1 (ko) | 2014-09-23 |
CN107367903A (zh) | 2017-11-21 |
US9439291B2 (en) | 2016-09-06 |
US20130266900A1 (en) | 2013-10-10 |
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