Function transfer product, functional layer transfer method, packed product, and function transfer film roll

Patent metadata

Field	Value
Publication number	US-10239279-B2
Application number	US-201314407332-A
Country	US
Kind code	B2
Filing date	Jun 10, 2013
Priority date	Jun 13, 2012
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

A function transfer product ( 14 ) is provided with a carrier ( 10 ) having a concavo-convex structure ( 11 ) of nanostructure, and a functional layer ( 12 ) provided on the concavo-convex structure ( 11 ). The functional layer ( 12 ) is beforehand provided on the surface of the concavo-convex structure ( 11 ), and is directly brought into contact with one main surface of a target object ( 20 ), and then the carrier ( 10 ) is removed from the functional layer ( 12 ) to transfer the functional layer ( 12 ) to the target object ( 20 ). An average pitch of the concavo-convex structure ( 11 ) ranges from 1 nm to 1500 nm, the functional layer ( 12 ) contains a resin, and a ratio (Ra/lor) between surface roughness (Ra) on the exposed surface side of the functional layer ( 12 ) and a distance between a top position of a convex-portion of the concavo-convex structure ( 11 ) and the exposed surface of the functional layer ( 12 ) is 1.2 or less. Further, the functional layer ( 12 ) is arranged inside concave portions ( 11 a ), and the exposed surface thereof is in a non-liquid state at a temperature of 20° C. under light shielding. It is possible to add the function onto the target object ( 20 ) with high accuracy.

First claim

The invention claimed is:

1. A function transfer product for transferring a functional layer onto a target object, the function transfer product comprising:
a carrier provided with a concavo-convex structure on a main surface thereof; and
at least one functional layer or more provided on the concavo-convex structure, wherein
an average pitch of the concavo-convex structure ranges from 1 nm to 1500 nm,
the functional layer comprises a resin containing a photocurable monomer,
a ratio (Ra/lor) between surface roughness (Ra) on an exposed surface side that is on an opposite side of the functional layer with respect to the carrier and a distance (lor) between a top position of a convex-portion of the concavo-convex structure and the exposed surface of the functional layer is in a range from 0.002 to 1.2,
a mass average molecular weight of the resin ranges from 1,000 to 60,000,
the surface roughness (Ra) ranges from 2 nm to 300 nm,
the exposed surface side that is on an opposite side of the functional layer with respect to the carrier is in a non-liquid state at 20° C. under light shielding, and
in a temperature range of exceeding 20° C. to 300° C., the exposed surface side that is on an opposite side of the functional layer with respect to the carrier of the function transfer product exhibits tackiness, or tackiness of the exposed surface is increased.

2. The function transfer product according to claim 1 , wherein the resin contains a polar group.

3. The function transfer product according to claim 2 , wherein the polar group contains at least one polar group or more selected from the group consisting of an epoxy group, a hydroxyl group, an acryloyl group, a methacryloyl group, a vinyl group, a carboxyl group, and a carbonyl group.

4. The function transfer product according to claim 2 , wherein the functional layer contains a photocurable substance.

5. The function transfer product according to claim 2 , wherein the ratio (Ra/lor) is 0.75 or less.

6. The function transfer product according to claim 5 , wherein an average aspect (A) of the concavo-convex structure ranges from 0.1 to 5.0.

7. The function transfer product according to claim 6 , wherein the ratio (Ra/lor) is 0.25 or less.

8. The function transfer product according to claim 1 , wherein the carrier is provided with a concavo-convex structure A on a part or whole of the surface, in the concavo-convex structure A a ratio (Mcv/Mcc) between a top width of a convex-portion (Mcv) and an opening width of a concave-portion (Mcc) and a ratio (Sh/Scm) between an opening portion area (Sh) existing in a region of a unit area (Scm) of the concavo-convex structure A and the unit area (Scm) meet following equation (1),
the ratio (Sh/Scm) meets following equation (2), the ratio (Mcv/Mcc) meets following equation (3), and the average aspect (A) of the concavo-convex structure A meets following equation (4),
[Mathematical Expression 1]
√{square root over (0.5/( Sh/Scm ))}−1≤ Mcv/Mcc ≤√{square root over (1.1/( Sh/Scm ))}−1  Eq. (1)

0.23<( Sh/Scm )≤0.99  Eq. (2)

0.01≤( Mcv/Mcc )<1.0  Eq. (3)

0.1≤ A≤ 5.  Eq. (4)

9. The function transfer product according to claim 1 , wherein the resin contains a cyclic portion.

10. The function transfer product according to claim 9 , wherein the cyclic portion is comprised of at least one or more elements selected from the group consisting of a 4-membered ring, a 5-membered ring and a 6-membered ring.

11. The function transfer product according to claim 9 , wherein the functional layer contains the resin and a monomer.

12. The function transfer product according to claim 9 , wherein the functional layer contains a photocurable resin or a photocurable monomer.

13. The function transfer product according to claim 1 , wherein the concavo-convex structure contains at least one or more elements selected from the group consisting of a fluorine element, a methyl group and a siloxane bond.

14. The function transfer product according to claim 13 , wherein a ratio (Es/Eb) between a surface layer fluorine element concentration (Es) on the functional layer surface side of the concavo-convex structure and an average fluorine element concentration (Eb) of the concavo-convex structure exceeds 1 and is 30000 or less.

15. The function transfer product according to claim 1 , wherein the carrier is in the shape of a film, and a width of the carrier is 3 inches or more.

16. A functional layer transfer method including:
a step of directly bringing the functional layer of the function transfer product according to claim 1 into contact with one main surface of a target object; and
a step of removing the carrier from the functional layer, in this order.

17. A packed product, wherein the function transfer product according to claim 1 is packed in a resin-made case.

18. A function transfer film roll, wherein the function transfer product according to claim 1 is in the shape of a film, one end portion of the function transfer product is connected to a core, and the function transfer product is wound around the core.

Assignees

• Asahi Chemical Ind

Inventors

• Koike Jun
• Yamaguchi Fujito

Classifications

• G03F7/0002

  Lithographic processes using patterning methods other than those involving the exposure to radiation, e.g. by stamping · CPC title

• Y10T428/24355

  Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] · CPC title

• B32B2457/18

  Fuel cells · CPC title

• B32B3/30 Primary

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title

• H01L2933/0083

  Electricity · mapped topic