JP2012063598A - Roll-state film base material - Google Patents

Abstract

The present invention relates to a roll-shaped film substrate having no dimensional deviation in and out of winding, a film substrate with a roll-shaped pattern having a pattern forming body formed with high dimensional accuracy, and the roll-shaped film substrate. The main object is to provide a method for producing a roll-shaped film substrate to be produced, a method for producing a pattern-formed body, an image display element having high dimensional accuracy, and a color filter.
In the present invention, when a film base material and a supporting member partially disposed on the film base material are used and the film base material is used as a base material of a pattern forming body, A roll-shaped film base material comprising a support member laminated film base material provided with a through-hole penetrating the film base material outside a pattern forming region where a film base material pattern is provided. By providing, the above-mentioned problems are solved.
[Selection] Figure 1

Description

  The present invention relates to a roll-shaped film substrate used for a pattern forming body that can be used for various applications such as a color filter and a wiring pattern.

  In recent years, liquid crystal display elements have been reduced in thickness and weight and improved in impact resistance. As a base material for constituting color filters, TFT arrays, etc., instead of the conventionally used glass substrate, flexibility has been achieved. Attempts have been made to use a roll-shaped film base material in which a film base material is wound. When a roll-shaped film base material is used for such a base material, there is a problem that it is difficult to obtain a color filter in which, for example, a colored layer and a black matrix are formed on the base material with a desired accuracy. . Specifically, in the process of forming a colored layer and a black matrix on a film substrate unwound from a roll-shaped film substrate, a pattern is formed using a fine processing means such as a photolithography method or an inkjet method. However, there is a problem that a dimensional shift occurs in the roll-shaped film substrate affected by heat, moisture, etc. during the process, and it is difficult to produce a color filter with high accuracy.

  On the other hand, for example, in Patent Document 1, after drying the substrate, the substrate is left in a high-temperature and high-humidity environment to absorb moisture so that the moisture content is within ± 10% of the moisture content in a predetermined temperature-humidity environment. A method of controlling the dimensions of the substrate by performing the above is disclosed.

  However, in this method, since the inside of the roll film substrate is difficult to absorb or dehydrate, it takes a long time to reach the desired moisture content, and the moisture content is uniform between the inside and outside of the roll. However, there is a problem that dimensional deviation occurs in and outside the roll film substrate.

  On the other hand, for example, in Patent Document 2, the time from the heat dehydration of the base material to the start of exposure is managed by the transport means, and the temperature and humidity are adjusted to control the dimensions of the base material with good reproducibility. A method is disclosed.

  However, this method requires precise time management, and there is a problem that the required time differs between the inside and outside of the roll-shaped film substrate.

JP 2003-66423 A JP 2003-177551 A

  The present invention has been made in view of the above problems, and a roll-shaped film substrate having no dimensional deviation in and outside the winding, a film substrate with a roll-shaped pattern having a pattern formed with high dimensional accuracy, The main object is to provide a roll film substrate production method for producing the roll film substrate, a pattern forming body production method, an image display device having high dimensional accuracy, and a color filter.

  The present invention has a film base material and a support member partially disposed on the film base material. When the film base material is used as a base material of a pattern forming body, the pattern of the film base material is used. Provided is a roll-shaped film base material in which a support member laminated film base material provided with a through-hole penetrating the film base material is provided outside a pattern forming region where the film base material is provided.

  According to the present invention, by arranging the support member, a space can be formed between the upper layer and the lower layer film substrate in the roll film substrate, and the penetration formed in the film substrate. Since the outside air can be vented from the hole to the space, it can be brought into contact with the outside air up to the inside of the roll-shaped film base material. It can be a material.

  In this invention, it is preferable that the said supporting member is arrange | positioned on the edge part area | region of the both ends of the said film base material at least. By disposing the support member on the end regions at both ends of the film base material, the support member is disposed in the pattern forming region where the pattern is formed when the roll-shaped film base material is used as the base material of the pattern forming body. Since it is possible to prevent the attachment of dust and the generation of fine scratches by arranging the support member, the surface of the film base can be stored in a good state.

  In the present invention, the support member is preferably a synthetic resin film of the same type as the film base material. Since the physical properties such as the elastic modulus, surface friction, thermal expansion, and humidity expansion of the film substrate and the support member can be made equivalent, when the support member laminated film substrate is wound into a roll-shaped film substrate In addition, it can be stably wound, and the roll-shaped film substrate can be hardly stretched, distorted, wrinkled, etc. even during storage.

  The present invention provides a film base material having a through hole, and a support member laminated film base material provided with a support member disposed at least at end regions of both ends of the film base material, and the through hole of the film base material. A patterned film base material having a pattern outside the through-hole forming region and the pattern provided outside the support member placement region where the support member on the film base material is placed is wound A film substrate with a roll pattern is provided.

  According to the present invention, by having the support member laminated film base material, it is possible to have a uniform moisture content regardless of whether the film base material is wound or unwound. It can be set as the film base material with a roll-shaped pattern in which the high-definition pattern without this was formed. In addition, when a new pattern is formed on the pattern, it is possible to form a pattern by stacking the patterns with high overlay accuracy. In addition, since the support member can be removed, when the image display element or the like is manufactured using the patterned film base material, the pattern forming process is not hindered, so that the process can be easily performed.

  The present invention has a film base material and a support member partially disposed on the film base material. When the film base material is used as a base material of a pattern forming body, the pattern of the film base material is used. A roll-shaped film base material preparation step for forming a roll-shaped film base material in which a support member laminated film base material in which a through-hole penetrating the film base material is provided outside the pattern forming region is provided; And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. A method for producing a roll film substrate is provided.

  According to the present invention, the roll-shaped film substrate having the support member and the through hole is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, so that it is uniform regardless of whether it is inside or outside the winding. A roll-shaped film substrate having a moisture content can be obtained.

  This invention provides the manufacturing method of the pattern formation body which has the pattern formation process which forms a pattern on the film base material unwound from the roll-shaped film base material mentioned above.

  According to the present invention, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

  The present invention is a film substrate and an image display element having a predetermined pattern provided on the film substrate, and outside the pattern formation region where the predetermined pattern of the film substrate is provided, Provided is an image display element characterized in that a through-hole penetrating a film substrate is provided.

Here, as described above, since the dimensional accuracy of the film substrate is influenced by the moisture content of the film substrate, the moisture content of the entire film substrate is preferably uniform. However, conventionally, when storing a film base material in a case where a plurality of film base materials are laminated and stored, or when a film base material is wound and stored in a roll, Since there are parts that are easy to contact and parts that are difficult to contact with the outside air, a part with a high water content and a part with a low water content are generated in the same film base material, and the water content of the entire film base material is made uniform. There was a problem that made it difficult to do.
On the other hand, since the film base material has through holes, when the film base material is laminated or rolled and stored, it is partially supported between the upper and lower film base materials. By forming a space by arranging the outside air, it is possible to take in outside air from the through holes between the film base materials, and the moisture content of the entire film base material can be made uniform. Thereby, since the dimensional accuracy of a film base material can be made uniform, it becomes possible to make a pattern formed on the said film base material a thing with a high dimensional accuracy. Therefore, according to the present invention, an image display element having a pattern with high dimensional accuracy can be obtained.

  In the present invention, when the length of the film base in the longitudinal direction is at least 50 cm or more and the dimensional accuracy of the pattern in any two regions in the image display element is compared, in one region When the dimension of the pattern is 1, it is preferable that the dimension of the pattern in the other region is within a range of 1.00000 ± 0.00033. Furthermore, in this invention, it is preferable that the said film base material arrange | positions a support member partially on the said film base material beforehand, and is wound by roll shape 2 times or more. When the length in the longitudinal direction of the film base is within the above-described range, the film base itself is usually wound into a roll and stored as a roll-shaped film base. As described above, the film substrate used in the present invention can make the dimensional accuracy of the entire film substrate uniform even when it is a roll-shaped film substrate. Therefore, in the present invention, since the film base is used, an image display element having a pattern with high dimensional accuracy can be obtained.

  The present invention provides a color filter, wherein the pattern described above is a pixel portion of the color filter.

  According to the present invention, a color filter having a pixel portion with high dimensional accuracy can be obtained.

  In this invention, there exists an effect that the roll-shaped film base material without the dimension shift | offset | difference in winding and unwinding can be obtained.

It is the schematic diagram and schematic sectional drawing which show an example of the roll-shaped film base material of this invention. It is a schematic plan view which shows an example of the film base material used for the roll-shaped film base material of this invention. It is a schematic plan view which shows an example of the supporting member laminated | multilayer film base material used for the roll-shaped film base material of this invention. It is a schematic plan view which shows another example of the supporting member laminated | multilayer film base material used for the roll-shaped film base material of this invention. It is a schematic plan view which shows another example of the supporting member laminated | multilayer film base material used for the roll-shaped film base material of this invention. It is a schematic plan view which shows another example of the supporting member laminated | multilayer film base material used for the roll-shaped film base material of this invention. It is a schematic sectional drawing which shows an example of the supporting member used for this invention. It is a schematic diagram which shows an example of the film base material with a roll-shaped pattern of this invention. It is process drawing which shows an example of the manufacturing method of the roll-shaped film base material of this invention. It is process drawing which shows an example of the manufacturing method of the pattern formation body of this invention. It is a schematic plan view which shows an example of the color filter of this invention. It is a schematic plan view which shows another example of the color filter of this invention. It is a graph which shows the correlation with the moisture content and dimensional change amount of the PET film used for an Example and a comparative example.

  Hereinafter, the roll-shaped film substrate of the present invention, the film substrate with a roll-shaped pattern, the production method of the roll-shaped film substrate, the production method of the pattern forming body, the image display element, and the color filter will be described in detail.

A. Roll-shaped film base material First, the roll-shaped film base material of this invention is demonstrated. When the roll-shaped film base material of the present invention has a film base material and a support member partially disposed on the film base material, when the film base material is used as a base material of a pattern forming body, A support member laminated film base material provided with a through-hole penetrating the film base material outside a pattern formation region where the film base material pattern is provided is wound.

  According to the present invention, by arranging the support member, a space can be formed between the upper layer and the lower layer film substrate in the roll-shaped film substrate, and the penetration provided in the film substrate. Since the outside air can be vented from the hole to the space, it can be brought into contact with the outside air up to the inside of the roll-shaped film base material. It can be a material.

Here, the “pattern forming region” refers to a region where a pattern is provided on the film substrate when the film substrate is used as the substrate of the pattern forming body. In addition, since the pattern here is demonstrated in the term of "B. Film base material with a roll-shaped pattern" mentioned later, description here is abbreviate | omitted.
Further, “outside pattern formation region” refers to a region obtained by removing the above-described pattern formation region from the entire surface of the film base material.

In addition, the support member is partially disposed on the film base means that the support member is partially disposed so as not to completely block the through-hole provided in the film base. When it is set as a base material, the upper layer film base material and the lower layer film base material refer to a state where they are partially arranged so as not to adhere to each other.
Further, when the plurality of support members are arranged at a predetermined interval in the width direction or the longitudinal direction of the film base material, one or more through holes are provided in the film base material between the adjacent support members. Thus, the state where the support member is arranged is indicated.

Moreover, in the roll-shaped film base material of the present invention, that the inside and outside of the roll have a uniform water content means that the water content of the film base in the outside of the roll is different from the water content of the film base in the inside of the roll. Is 0.05 wt% or less, preferably 0.02 wt% or less, particularly preferably 0.01 wt% or less. In addition, about the said moisture content, for example, a moisture meter (product name: RX-100, transmission type) manufactured by Kurabo Industries, a microwave on-line moisture meter (manufactured by Markham), an electric resistance type moisture meter (Yamazaki Seiki Laboratory Co., Ltd.) Etc.).
Further, the roll-out of the roll-shaped film substrate in the present invention refers to the outermost layer of the roll-shaped film substrate, and the roll-up of the roll-shaped film substrate means two or more turns from the roll-out of the roll-shaped film substrate. Refers to the inner layer.

Here, the roll-shaped film base material of this invention is demonstrated using figures. Fig.1 (a) is a schematic diagram which shows an example of the roll-shaped film base material of this invention, FIG.1 (b) is a schematic sectional drawing of an AA line. As shown in FIG. 1 (a), a roll-shaped film substrate 10 of the present invention has a film substrate 1 and a support member 2 partially disposed on the film substrate 1. Is used as the base material of the pattern forming body, the supporting member laminated film base material 11 in which the through-hole 3 penetrating the film base material 1 is provided outside the pattern forming region where the pattern of the film base material 1 is provided. It is wound. In FIG. 1, “outside the pattern formation region of the film substrate 1” means a pattern formation region t where a pattern is provided from the entire surface of the film substrate 1 when the film substrate 1 is used as the substrate of the pattern formation body. This refers to the area excluding. In FIG. 1, a pattern formation region t is a region surrounded by a dotted line.
FIG. 1 shows an example in which the support member 2 is disposed only on the end regions at both ends of the film substrate 1 and is not disposed in the pattern formation region t. In addition, since the edge part area | region of the both ends of a film base material is mentioned later, description here is abbreviate | omitted. Further, the direction indicated by X in FIG. 1 (a) indicates the longitudinal direction of the film substrate, and the direction indicated by Y indicates the width direction of the film substrate.

  In this invention, as shown in FIG.1 (b), in the roll-shaped film base material 10, the upper film base material 1 and the lower film base material 1 are arrange | positioned by arrange | positioning the support member 2 partially. Since a space is formed between the through holes 3 of the film substrate 1 and the outside air can be vented to the space, the film substrate can be in contact with the outside air even in the winding. 1 can also take in moisture to the same extent as the unwinding film substrate 1. Therefore, it becomes possible to set it as the roll-shaped film base material 10 which does not produce a difference in the moisture content in a winding and unwinding.

  As described above, the roll-shaped film substrate of the present invention can form a space between the upper layer and the lower layer film substrate of the roll-shaped film substrate by arranging the support member. Since the outside air can be ventilated from the through-hole provided in the film base material, it can be brought into contact with the outside air up to the inside of the winding, so that it has a uniform moisture content irrespective of the inside and outside of the winding. be able to.

  Hereinafter, the supporting member laminated film substrate used in the present invention will be described.

1. Support member laminated film base material The support member laminated film base material used in the present invention has a film base material and a support member partially disposed on the film base material, and the film base material is used as a pattern forming body. When used as the base material, a through-hole penetrating the film base material is provided outside the pattern forming region where the pattern of the film base material is provided.
Here, as a form of the support member laminated film base material, when a roll-shaped film base material is used, a space is formed between the upper layer and the lower layer film base material by the support member, and the outside air is ventilated by the through holes. It is not particularly limited as long as it can be made to be a form. Hereinafter, the form of such a support member laminated | multilayer film base material is demonstrated.

(1) Form of support member laminated film base The form of the support member laminated film base is determined by the formation position of the through hole and the arrangement position of the support member.

(A) Through-hole formation position First, the through-hole formation position will be described. The formation position of the through hole in the present invention is not particularly limited as long as it is outside the pattern formation region where the pattern of the film base material is provided when the film base material is used as the base material of the pattern forming body. . Hereinafter, the outside of the pattern formation region may be referred to as a through hole formation region.

  More specifically, the through hole forming region in the present invention refers to a region excluding the pattern forming region t in the film substrate 1 shown in FIG. FIG. 2 is a schematic plan view showing an example of a film substrate used in the present invention.

  Moreover, as a formation position of a through-hole, when it is set as a roll-shaped film base material, the moisture content inside and outside the roll of the roll-shaped film base material is made constant by contacting with the outside air up to the inside of the roll. If it can, it will not specifically limit, for example, as shown in FIG.1 (b), when setting it as a roll-shaped film base material, the formation position of the through-hole 3 provided in the upper film base material 1 and The formation position of the through hole 3 formed in the upper layer film base material may be formed so as to coincide with the formation position of the through hole 3 provided in the lower layer film base material 1. And may be formed so that the formation position of the through hole provided in the lower layer film base material does not match. Especially, it is preferable that it is formed so that the formation position of the through-hole formed in the upper film base material and the formation position of the through-hole provided in the lower film base material may not correspond. Thereby, it becomes possible to make air permeability into the roll of a roll-shaped film base material higher.

(B) Arrangement Position of Support Member Next, the arrangement position of the support member will be described. As the arrangement position of the support member in the present invention, it is possible to partially arrange the support member so as not to completely block the through hole provided in the film base material, and the roll-shaped film base material and In this case, the upper film base material and the lower film base material are not particularly limited as long as they can be partially arranged so as not to be in close contact with each other.
Further, when the plurality of support members are arranged at a predetermined interval in the width direction or the longitudinal direction of the film base material, one or more through holes are provided in the film base material between the adjacent support members. If it can arrange | position in this way, it will not specifically limit.

  Here, arranging the support member so as not to completely block the through-hole formed in the film substrate means that the support member is arranged so as not to completely block the through-hole in the film substrate. The state in which the support member is arranged in a part of the part where the through hole is formed in the film base material is indicated.

  Also, that one or more through holes are provided in the film base between adjacent support members means that one or more through holes are formed in the through hole forming region of the film base between adjacent support members. It means being. Further, in this case, the through hole includes not only those that are not blocked at all by the support member but also those that are partially blocked by the support member.

  As an arrangement of the support member, for example, as shown in FIG. 1, the support member 2 may be arranged on the end regions at both ends of the film substrate 1. Further, for example, as shown in FIG. 3 (a), the support member 2 may be arranged at a predetermined interval in the longitudinal direction X of the film substrate 1, or as shown in FIG. 3 (b), The support member 2 may be arranged at a predetermined interval in the width direction Y of the film base 1, or as shown in FIG. The support member 2 may be arranged at a predetermined interval in the acute angle direction. 3 (a), 3 (b), and 3 (c), one or more through holes are formed in the through hole forming region u of the film base 1 between the adjacent support members 2 respectively. It is. FIG. 3 is a schematic plan view showing an example of the support member laminated film substrate used in the present invention.

  Here, the roll-shaped film base material of the present invention is used as a base material of a pattern forming body such as a base material such as an image display element or a multi-sided substrate of an image display element. A predetermined pattern is provided on the surface. At this time, if dust or the like adheres to the film substrate in the pattern formation region where the predetermined pattern is provided, or if fine scratches are generated, it may cause defects in the formed image display element. . Therefore, in this invention, when a roll-shaped film base material is used for the base material of a pattern formation body, it is preferable that a support member is not arrange | positioned on the film base material of the said pattern formation area.

  Considering the above points, as the arrangement of the supporting members in the present invention, it is preferable that the supporting members are arranged at least on end regions at both ends of the film base material.

  Here, the “end regions at both ends of the film substrate” are regions existing at both ends in the width direction of the film substrate, and the roll-shaped film substrate of the present invention is used as the substrate of the pattern forming body. When used, this is a region where no pattern is provided. The end region may be provided with a through hole or may not be provided.

  More specifically, the end region of the film base means that the distance from the side in the width direction of the film base is 0.2 or less, where the length in the width direction of the film base is 1. However, it refers to a region of 0.1 or less, particularly 0.05 or less.

  From the above, in the present invention, the support member is disposed at least on the end regions at both ends on the film base, and the support member is disposed at least on the end regions at both ends of the above-described film base, And it points out that the supporting member is arrange | positioned out of the pattern formation area.

  Hereinafter, the arrangement of the supporting members on at least the end regions on both ends of the film substrate will be described in more detail. 4-6 is a schematic plan view which shows an example of the supporting member laminated | multilayer film base material used for this invention all. Moreover, since the reference numerals not described below in FIGS. 4 to 6 can be the same as those in FIG. 1, description thereof is omitted here.

In the present invention, for example, as shown in FIG. 1 and FIG. 4A, the support member 2 is disposed only on the end regions at both ends of the film substrate 1 and is not disposed in the pattern formation region t. Thus, the support member 2 can be arranged. In this case, one or more through holes are provided at an arbitrary position in the through hole forming region inside the support member 2 arranged in the end region s at both ends.
Specifically, as shown in FIG. 4B, the through hole 3 may be provided only in the end region s along the support member 2, or as shown in FIG. The through holes 3 may be provided only in the through hole forming regions u other than the end regions s at both ends of the film substrate 1, and although not shown, the through holes are formed in the end regions along the support member. And the through-hole may be provided in the through-hole formation area | region other than the edge part area | region of the both ends of the film base material mentioned above.

  In addition, as arrangement | positioning of the supporting member in the edge part area | region mentioned above, the close_contact | adherence of the film base material of an upper layer and a lower layer of a roll-shaped film base material is prevented, and the moisture content of the film base material in a winding and unwinding is made. There is no particular limitation as long as the arrangement can be uniform. Specifically, as shown in FIGS. 4 (a), (b), (c), and FIG. 5 (a), the support member 2 is arranged in a part of the end region s at both ends of the film base 1. Alternatively, as shown in FIG. 5B, the support member 2 may be disposed on the entire surface of the end region s at both ends of the film substrate 1. In addition, as shown in FIG.5 (b), when the supporting member 2 is arrange | positioned on the whole surface on the edge part area | region s of the both ends of the film base material 1, in film | membrane base material 1, other than edge part area | region s. A through hole is provided at an arbitrary position in the through hole forming region u. Moreover, although not shown in figure, about the outer edge of a supporting member, you may arrange | position beyond the edge of the width direction of a film base material.

  In the present invention, in consideration of problems such as positioning accuracy of the support member, usually, as shown in FIG. 5A, a part of the end region s at both ends of the film substrate 1, more preferably the end region. The support member 2 is disposed in the central portion of s.

  In the present invention, it is preferable that the supporting members are disposed at least on the end regions at both ends of the film base material, but among them, outside the pattern formation region of the region other than the end region at both ends of the film base material, It is preferable that a support member is also disposed on the through hole forming region. This is because it is possible to more effectively prevent the upper film base material and the lower film base material from coming into close contact with each other in the roll film base material.

  Specifically, as shown in FIGS. 6A and 6B, the support member 2 is arranged so that the support member 2 surrounds the pattern formation region t in addition to the end regions s at both ends of the film substrate 1. can do. In this case, as shown in FIG. 6A, the support member 2 may be arranged so as to surround the entire periphery of the pattern formation region t. As shown in FIG. The support member 2 may be arranged so as to surround except for a part of the periphery of the formation region t. 6A and 6B, the support member 2 has a through hole at an arbitrary position in the through hole formation region u between the portion where the support member 2 is disposed and the pattern formation region t. Is arranged.

  In any of the above-described support member arrangements, there is no support member in the pattern formation region of the film base material, which causes problems such as dust adhering to the pattern formation region or scratches. It can be prevented, and the surface of the film base in the pattern forming region can be kept in a good state.

(2) Configuration of Support Member Laminated Film Base Next, the through hole, the support member, and the film base included in the support member laminated film base will be described.

(A) Through hole The through hole in this invention penetrates a film base material, and when a film base material is used for the base material of a pattern formation body, it is provided out of a pattern formation area.

  The formation positions of the through holes have been described in the above-mentioned section “(1) Form of support member laminated film base material”, and thus description thereof is omitted here.

  As the shape of the through-hole, when a roll-shaped film substrate is used, the outside air can be ventilated to the inside of the roll, and the water content in the roll and the outside of the roll-shaped film base can be made uniform. The shape is not particularly limited, and examples thereof include a linear shape, a circular shape, an elliptical shape, a rectangular shape, and a polygonal shape.

As for the size of such a through-hole, when a roll-shaped film substrate is used, the outside air is vented to the inside of the winding, and the water content in the winding and the outside of the rolling-shaped film substrate is made uniform. if possible it is not particularly ^limited, in the range of 0.1 mm 2 to 20 mm ^2, preferably in the range of these of ^{1 mm} 2 to 10 mm ^2. If the size of the through hole is less than the above range, it may be difficult to ventilate the outside air sufficiently to the inside of the winding. If the size of the through hole exceeds the above range, the film This is because the strength of the base material is reduced, and the film base material may be deformed at the time of conveyance, winding time, or the like when the support member is wound.

Further, the number of the through holes formed is not particularly limited as long as the moisture content inside and outside the roll-shaped film substrate can be made uniform, and the roll-shaped film substrate is not particularly limited. The size is appropriately selected depending on the size, etc., but usually a plurality are formed. In this case, the plurality of through holes may be formed continuously or discontinuously, but are preferably formed continuously.
Here, that the plurality of through holes are continuously formed means that the plurality of through holes are continuously formed so as to have a predetermined pattern arrangement.

  In this case, the pattern arrangement of the through holes is not particularly limited as long as it can be formed with a predetermined interval so that adjacent through holes are not connected to each other. In the present invention, the arrangement is preferably such that the interval between adjacent through holes is within the range of one through hole to 30 through holes, and in particular, one through hole to 10 through holes. It is preferable that it is within the range of the number of pieces, particularly within the range of two through holes to five through holes. If the distance is less than the above range, the strength of the film substrate may be reduced. If the distance exceeds the above range, even if a through-hole is formed, the roll shape Since it is difficult to ventilate sufficient outside air into the film substrate roll, it may be difficult to make the moisture content inside and outside the roll film substrate uniform. It is.

  Further, when a plurality of through holes are formed continuously, as shown in FIGS. 4B and 4C, the plurality of through holes are formed so as to form a line in the longitudinal direction or the width direction. Such a row of through holes may be one row or two or more rows.

  The method for forming the through hole is not particularly limited as long as it is a method capable of forming a through hole having a desired shape and size on a film substrate. For example, punching, punching, embossing Etc. can be used. It can also be formed by laser processing or the like.

(B) Support member The support member used in the present invention is partially disposed on the film base material. In the roll-shaped film base material, the upper film base material and the lower film base material It is used to form a space between them. Moreover, a support member is arrange | positioned in the state which can be removed from a film base material.

The supporting member is not particularly limited as long as it has flexibility and can support the film base so that the upper and lower film bases of the roll-shaped film base do not adhere to each other. It is not a thing.
Further, the support member may be air permeable or may not be air permeable. In the following, description will be given separately.

(I) Air-permeable support member Specific examples of the air-permeable support member include a gap member. Since the gap member itself can ventilate the outside air, it is useful in that a large amount of the outside air can be ventilated in the roll of the roll-shaped film substrate.

  The gap member is flexible, has air permeability and moisture permeability so as not to cause a difference in moisture content between the roll and roll of the roll-shaped film base material, and has high releasability. If it is a thing, it will not specifically limit, For example, a porous sheet, a nonwoven fabric, a carrier tape for IC chip conveyance, a wipe, paper, a nylon film etc. can be mentioned.

  Here, the cross-sectional shape of the void member in the present invention may be, for example, an uneven void member having irregularities formed on at least one surface, or a porous void having a plurality of vent holes. It may be a member, or may be a gap member formed by processing one plate-like member into a wave shape.

  In particular, the void member in the present invention is more preferably a concavo-convex-shaped void member in which irregularities are formed on at least one surface. This is because the gap member having the above-described cross-sectional shape is excellent in air permeability and moisture permeability and is easily disposed on the film substrate.

Here, the uneven shape is not particularly limited as long as the gap formed by the uneven shape has desired air permeability and moisture permeability. For example, the height of the convex portion is within a range of 0.01 mm to 1.5 mm, and preferably within a range of 0.1 mm to 0.5 mm so that the convex portion is not crushed, and the distance between adjacent convex portions Is in the range of 0.01 mm to 4.0 mm, preferably in the range of 0.1 mm to 2.0 mm.
In addition, about the height of the said convex part and the distance of adjacent convex parts, if it is mm order, it can be measured using a caliper or a microscope. In the case of the μm order, it can be measured using a stylus type surface roughness meter (Mikasa Corporation, product name ET4000L-S).
The height of the convex portion is indicated by Q in the gap member 2 ′ shown in FIG. 7, and the distance between adjacent convex portions is the distance indicated by P in the gap member 2 ′ shown in FIG. Point to. FIG. 7 is a schematic cross-sectional view showing an example of a gap member (support member) used in the present invention.

  The shape of the surface of the convex portion that contacts the film substrate may be a flat surface or a curved surface, but is preferably a flat surface. It is because it is a shape which does not produce a damage | wound to a film base material.

The air permeability of the gap member in the present invention is not particularly limited as long as the air permeability is such that it does not cause a difference in moisture content between the inside and outside of the roll when placed on a roll-shaped film substrate. It is preferably 1.4 cm ³ / cm ² · sec or more. When the air permeability is smaller than the above numerical value, the air permeability and moisture permeability of the gap member are not sufficient, so that when used for a roll-shaped film substrate, the moisture content in and outside the winding can be made uniform. This is because it may be difficult.
The air permeability is measured by JIS L1096 8.27.1 A method (Fragile method).

  Moreover, as surface roughness (Ra) in case a space | gap member is a flat member, it is preferable that it is 1 micrometer or more, it is more preferable that it is 2 micrometers or more, and it is further more preferable that it is 5 micrometers or more. This is because when Ra is smaller than the above range, the gap member has less gaps, and the air permeability and moisture permeability cannot be increased. In addition, Ra of the space | gap member used for this invention is 10 micrometers or less normally. In addition, "surface roughness (Ra)" here is "arithmetic mean surface roughness", and is measured based on JIS-B0601.

  In consideration of the shape, air permeability, surface roughness (Ra), and the like of the above-described gap member, among the above-described specific examples, preferable gap members in the present invention include a porous sheet, a carrier tape for IC chip conveyance, A wipe, a nylon film, etc. can be mentioned, As a especially preferable space | gap member, a porous sheet, a carrier tape for IC chip conveyance, etc. can be mentioned.

  The thickness of the gap member used in the present invention is preferably in the range of 20 μm to 200 μm. When the thickness of the gap member is too thin than the above range, the gap is easily crushed when the support member laminated film substrate is wound. When the gap member is too thick, the winding of the support member laminated film substrate is It is because it becomes impossible.

  The width of the gap member used in the present invention is a width that allows the gap member to be partially arranged on the film base so that the moisture content inside and outside the roll film base is uniform. If it is, it will not specifically limit, According to the width | variety of a roll-shaped film base material, the magnitude | size of a pattern formation area, etc., it selects suitably.

In addition, when arrange | positioning a space | gap member at least on the edge part area | region of the both ends of a film base material, as the width | variety of the said space | gap member, it exists in the range of 5 mm-60 mm, especially the range of 5 mm-30 mm, especially the range of 5 mm-15 mm. It is preferable to be within. If the width of the gap member is too wide than the above range, the protruding part is wasted when placed on the roll film base, and if it is too narrow than the above range, it becomes difficult to support the film base, This is because, in the roll-shaped film substrate, the upper film substrate and the lower film substrate are in close contact with each other, and air permeability is impaired.
In addition, the width | variety of the space | gap member in said case points out the distance shown by v in FIG. 4 (a) and FIG. 6 (a).

(Ii) Supporting member that does not have air permeability Examples of the supporting member that does not have air permeability include synthetic resin films and metals.
More specifically, synthetic resin films such as polyethersulfone (PES), acrylic resin, and vinyl chloride resin, synthetic resin films used for film bases described later, and metals such as aluminum, copper, and stainless steel are used. . Especially, it is preferable that it is a synthetic resin film of the same kind as a film base material as said support member. Since the physical properties such as the elastic modulus, surface friction, thermal expansion, and humidity expansion of the film substrate and the support member can be made equivalent, when the support member laminated film substrate is wound into a roll-shaped film substrate In addition, it can be stably wound, and can be stored in a good condition since it can be hardly stretched, distorted, wrinkled, etc. in the roll-shaped film substrate even during storage. It becomes possible.

  The thickness of the support member that does not have air permeability is not particularly limited as long as the thickness is such that the upper layer and the lower layer film substrate of the roll-shaped film substrate do not adhere to each other. It is preferably in the range of 0.025 mm to 0.5 mm, and more preferably in the range of 0.05 mm to 0.3 mm. When the thickness is less than the above range, the volume of the space formed between the upper layer and the lower layer film substrate of the roll-shaped film substrate cannot be made sufficient, and the water content inside and outside the winding can be reduced. This is because it may be difficult to make the rate uniform, and when the thickness exceeds the above range, the stability when winding the support member laminated film substrate may be poor and the roll may collapse. Because. Moreover, since the volume of a roll-shaped film base material becomes large, it is because the handling may become difficult.

  Since the width of the support member that does not have air permeability can be the same as the width of the support member described above, description thereof is omitted here.

(Iii) Support member In the present invention, among the above-described support members, it is particularly preferable to use the same synthetic resin film as the film substrate. Since this reason was mentioned above, description here is abbreviate | omitted.

(C) Film base material The film base material used for this invention is wound and turns into a roll-shaped film base material. The film base material is not particularly limited as long as it is a flexible resin base material. A base material made of any resin material is used depending on the use of the roll-shaped film base material of the present invention. Can be used.
Examples of such a film base material include polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polycarbonate (PC), polyimide (PI), polyetheretherketone (PEEK), polyethylene (PE), and polypropylene. (PP), polyphenylene sulfide (PPS), polyetherimide (PEI), cellulose triacetate (CTA), cyclic polyolefin (COP), polymethyl methacrylate (PMMA), polysulfone (PSF), polyamideimide (PAI), norbornene resin And synthetic resins such as allyl ester resins, among which PEN and PET are preferable.

As the humidity expansion coefficient of the film substrate used in the present invention, it is preferably 2 × ¹⁰ -5 /% RH or less, more preferably less ^{RH 1 × 10 -5 /%,} 5 × More preferably, it is 10 ⁻⁶ /% RH or less. This is because the amount of dimensional change due to changes in humidity is small and handling is easy.

As the linear expansion coefficient of the film substrate used in the present invention, it is preferably 2 × 10 -5 ^/ ℃ or less, more preferably at most ^{1 × 10 -5 / ℃, 5} × 10 - More preferably, it is ⁶ / ° C. or less. This is because the amount of dimensional change due to temperature change is small and handling is easy.

  In addition, the thickness of the film substrate used in the present invention is preferably in the range of 1 μm to 1 mm, more preferably in the range of 10 μm to 500 μm, and in the range of 50 μm to 250 μm. Is more preferable. This is because if the thickness of the film substrate is too thick than the above range, the flexibility is impaired, making it difficult to produce a roll-shaped film substrate, and it is easy to break. On the other hand, when it is thinner than the above range, there is no strain and handling in each step becomes difficult.

  In addition, the width of the film substrate used in the present invention is not particularly limited as long as a roll-shaped film substrate can be prepared by winding in this step, but for example, 100 mm to 1000 mm It is preferably within the range, and more preferably within the range of 150 mm to 600 mm.

  In addition, the film base material used for this invention may be the structure which consists of a single layer, or may have the structure by which the several layer was laminated | stacked.

2. Roll-shaped film base material The use of the roll-shaped film base material of the present invention is not particularly limited as long as it can be used as a base material for a pattern forming body, but it is used as a base material for an image display element. It is preferable. As a base material of the image display element, for example, it can be used for a color filter forming substrate, a wiring pattern forming substrate, and the like. In the present invention, it is particularly preferably used as a color filter forming substrate.

Moreover, in FIG. 1, although the support member laminated | multilayer film base material 11 has shown about the roll-shaped film base material wound without using a core material etc., you may have a core material.
The core material can be the same as that used for a general roll-shaped film substrate, but those having an inner diameter in the range of 70 mm to 160 mm can be suitably used.

Moreover, the roll-shaped film base material of this invention does not produce a difference in the moisture content in a winding and unwinding by having the structure mentioned above. Such a roll-shaped film substrate can be formed by the same production method as a general roll-shaped film substrate. Moreover, in this invention, since it is preferable to arrange | position the supporting member mentioned above to the edge part area | region of the both ends of a film base material, it manufactures with the manufacturing method similar to the roll-shaped film base material in which general knurling is performed. It is more preferable. Specifically, the production method described in the section “C. Production method of roll-shaped film substrate” described later can be used.
In addition, knurling is a void layer at both end portions of the film base material so as not to cause a defect in the pattern formation region of the film base material due to stress generated when the film base material is wound into a roll shape. Or forming a concavo-convex pattern to increase the thickness of both end portions of the film substrate.

B. Next, the film substrate with a roll pattern of the present invention will be described. The roll-patterned film substrate of the present invention includes a film substrate having a through-hole, and a support member laminated film substrate including at least support members disposed in end regions at both ends of the film substrate, and the film With a pattern having a pattern provided outside the through hole forming region where the through hole is provided on the base material and outside the supporting member arrangement region where the supporting member is arranged on the film base material The film base material is wound.

In addition, about the through-hole formation area | region in this invention, since it is the same as that of the area | region demonstrated by the term of the "A. roll-shaped film base material" mentioned above, description here is abbreviate | omitted.
In addition, the support member arrangement region in the present invention is described in the above-mentioned section of “A. Roll-shaped film substrate”, and at least when the support member is arranged on the end region at both ends of the film substrate, It refers to the region where the support member is placed. More specifically, it refers to the region where the support member 2 is disposed in FIG. 1 and FIGS.

  The roll-patterned film substrate of the present invention will be described with reference to the drawings. FIG. 8 is a schematic view showing an example of a film substrate with a roll pattern of the present invention. As shown in FIG. 8, the roll-patterned film substrate 20 of the present invention includes a film substrate 1 having a through-hole 3 and support members 2 arranged in end regions at both ends of the film substrate 1. The supporting member laminated film base material 11 and the supporting member arrangement region where the supporting member 2 on the film base material 1 is arranged outside the through hole forming region where the through hole 3 of the film base material 1 is provided. A patterned film substrate 21 having a pattern 4 formed outside is wound.

According to the present invention, by having the support member laminated film base material, it is possible to have a uniform moisture content regardless of whether the film base material is wound or unwound. It can be set as the film base material with a roll-shaped pattern in which the high-definition pattern without this was formed. In addition, when a new pattern is formed on the pattern, it is possible to form a pattern by stacking the patterns with high overlay accuracy. In addition, since the support member can be removed, when the image display element or the like is manufactured using the patterned film base material, the pattern forming process is not hindered, so that the process can be easily performed.
Hereinafter, the patterned film substrate used in the present invention will be described.

1. Patterned film substrate The patterned film substrate used in the present invention is a support member laminated film base comprising a film substrate having a through-hole, and at least support members disposed at both end regions of the film substrate. The material and the pattern provided outside the through-hole forming area where the through-hole of the film base is provided and outside the support member arranging area where the supporting member on the film base is arranged It has.
In addition, about the support member laminated | multilayer film base material, it is the same as that which the support member demonstrated in the above-mentioned item of "A. Roll-shaped film base material" is arrange | positioned at the edge part area | region of the both ends of a film base material at least. Therefore, the description here is omitted. Hereinafter, the pattern will be described.

  The pattern used in the present invention is outside the through hole forming region where the through hole of the film base is provided and outside the supporting member placement region where the supporting member on the film base is placed. Specifically, it is provided in the pattern formation region t in the film substrate 1 shown in FIG.

  Moreover, a pattern will not be specifically limited if it can be formed in a predetermined pattern form on a film base material, However, It is preferable for an image display element. This is because, in an image display element, by using the film base material in place of a conventionally used glass substrate, it is possible to reduce the thickness and weight and to improve the impact resistance. The pattern for the image display element indicates an optical functional layer used for the image display element or the entire image display element.

When the said pattern points out the whole image display element, a color filter, a wiring pattern, etc. can be mentioned, for example.
Moreover, when the said pattern points out an optical function layer, the pixel part of a color filter, the pixel part of a wiring pattern, a hard-coat layer, an anti-glare layer, an anti-reflection layer, a polarizing layer etc. can be mentioned, for example.

  In the present invention, it is particularly preferable that the pattern is a color filter or a pixel portion of a color filter.

  Further, the pattern forming method is not particularly limited as long as it can be accurately formed in a desired pattern shape. For example, generally known methods such as a photolithography method and an ink jet method are used. Since it can do, description here is abbreviate | omitted.

  As said film base material with a pattern, it is used as a multi-sided board | substrate which has multiple image display elements mentioned above or an image display element.

2. Film substrate with roll pattern The film substrate with roll pattern of the present invention is formed by winding the above-described film substrate with pattern. About the manufacturing method of the said film base material with a pattern, it can manufacture by winding the said film base material with a pattern with a general winding method. Since the winding method will be described in the manufacturing method section of “C. Manufacturing method of roll-shaped film substrate” described later, description thereof is omitted here.

C. Next, the manufacturing method of the roll-shaped film base material of this invention is demonstrated. The manufacturing method of the roll-shaped film base material of this invention has the supporting member partially arrange | positioned on the film base material and the said film base material, The said film base material was used for the base material of a pattern formation body. In this case, a roll-shaped film substrate is formed by winding a support member laminated film substrate provided with a through-hole penetrating the film substrate outside the pattern formation region where the pattern of the film substrate is provided. And storing the roll-shaped film substrate in the temperature-humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature-humidity atmosphere. It is a manufacturing method characterized by having a process.

  The manufacturing method of the roll-shaped film base material of this invention is demonstrated referring a figure. FIG. 9 is a process diagram showing an example of a method for producing a roll film substrate of the present invention. Although not shown, first, a through hole is provided outside a pattern formation region where a pattern is formed when the film substrate is used as a substrate of a pattern forming body. Next, as shown in FIG. 9A, the support member laminated film base material 11 is produced by partially disposing the support member 2 on the film base material 1, and is shown in FIG. 9B. As shown, the support member laminated film substrate 11 is wound to form the roll film substrate 10 (roll film substrate preparation step). Next, the roll-shaped film base material 10 is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere (storage process). Thereby, the roll-shaped film base material 10 which reached the moisture content in predetermined | prescribed temperature-humidity atmosphere is obtained.

  According to the present invention, the roll-shaped film substrate having the support member and the through hole is stored until the moisture content reaches the moisture content in a predetermined temperature and humidity atmosphere, so that it is uniform regardless of whether it is inside or outside the winding. A roll-shaped film substrate having a moisture content can be obtained.

The manufacturing method of the roll-shaped film base material of this invention has a roll-shaped film base material preparatory process and a storage process at least, and may have another arbitrary processes as needed.
Hereinafter, each step will be described.

1. Roll-shaped film base material preparation step This step has a film base material and a support member partially disposed on the film base material, and when the film base material is used as a base material for a pattern forming body. The process of forming the roll-shaped film base material by which the support member laminated | multilayer film base material in which the through-hole which penetrates the said film base material is provided out of the pattern formation area | region in which the pattern of the said film base material is provided is wound It is.
In addition, about the support member laminated | multilayer film base material formed by this process, since it can be made to be the same as that of what was demonstrated by the term of "A. roll-shaped film base material" mentioned above, description here is abbreviate | omitted. .

  In this step, the support member laminated film base material is wound to prepare a roll-shaped film base material. The method for winding the support member laminated film substrate is particularly limited as long as it is possible to form a space between the upper layer and the lower layer film substrate of the roll-shaped film substrate by arranging the support member. The method of winding a support member laminated | multilayer film base material using a general well-known winding machine can be mentioned.

  It is preferable that the number of windings of the support member laminated film base material in this step is appropriately selected according to the use of the roll-shaped film base material manufactured according to the present invention.

  In addition, in FIG. 9, after arrange | positioning the supporting member 2 on the film base material 1 and making it the supporting member laminated | multilayer film base material 11, it illustrates about the method of winding and preparing the roll-shaped film base material 10. It is not limited to this. For example, it can be used in a method in which a support member is disposed at a predetermined position on a film substrate and simultaneously wound. According to this method, the support member can be fixed by the pressure generated by winding by sandwiching the support member between the upper layer film substrate and the lower layer film substrate during winding. Since the roll-shaped film base material manufactured by this invention does not arrange | position a supporting member on a film base material using an adhesive agent etc., use the formation method of the roll-shaped film base material mentioned above suitably. Can do.

  Moreover, in FIG. 9, after forming a through-hole in a film base material beforehand, it arrange | positions a supporting member and makes it a supporting member laminated | multilayer film base material, About the example which forms a roll-shaped film base material by winding this Although shown, it is not limited to this. For example, a roll-shaped film substrate can be formed by disposing a support member on a film substrate and winding it in a roll shape, and then providing a through-hole at a predetermined position of the film substrate.

2. Storage Step Next, the storage step in the present invention will be described. The storage step in the present invention is a step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere.

  By storing the roll-shaped film substrate having the support member and the through hole in this manner, a roll-shaped film substrate having a uniform moisture content is obtained without causing a difference in moisture content between the inside and outside of the winding. And the dimensions of the roll-shaped film substrate can be stabilized.

  In this step, the moisture content of the roll-shaped film substrate has reached the moisture content in a predetermined temperature and humidity atmosphere. If the moisture content of the roll-shaped film substrate can be measured, for example, manufactured by Kurabo Industries, Ltd. Moisture content measurement using a moisture meter (product name: RX-100, transmission type), microwave on-line moisture meter (manufactured by Markham), electric resistance moisture meter (manufactured by Yamazaki Seiki Laboratories), etc. Can be determined.

  In the present invention, the temperature and humidity atmosphere of this step is a temperature and humidity atmosphere when forming a pattern on a film substrate unwound from a roll-shaped film substrate that has reached a moisture content in a predetermined temperature and humidity atmosphere. It needs to be equal. Film base material unwound from a roll-like film base material having a moisture content in a predetermined temperature and humidity atmosphere without causing dimensional expansion / contraction of the roll-like film base material due to temperature difference and humidity difference between storage process and pattern formation This is because the pattern can be formed with high dimensional accuracy by forming the pattern with reference to the dimension.

Although it will not specifically limit if it is in the range which can obtain | require the dimension of the roll-shaped film base under desired temperature by calculation as a temperature in this process, For example, the range of 20 degreeC-30 degreeC It is preferable that the temperature is equal to that in the subsequent step (for example, an alignment bonding step with the counter substrate). This is because it is not necessary to form the pattern in consideration of the amount of dimensional expansion and contraction of the roll-shaped film substrate due to the temperature difference between the pattern formation and the subsequent process.
Moreover, as humidity in this process, if it is in the range which can obtain | require the dimension of the roll-shaped film base material under desired temperature and humidity by calculation, it will not specifically limit, For example, 30% RH- The humidity is preferably within the range of 60% RH, and the humidity is equal to the post-process (for example, when the film substrate is used as a substrate such as a color filter of an image display element, the alignment bonding step with the counter substrate). It is more preferable. This is because it is not necessary to form a pattern in consideration of the amount of dimensional expansion / contraction of the roll-shaped film substrate due to the humidity difference between the pattern formation and the subsequent process.

  Moreover, in this invention, if the moisture content of a roll-shaped film base material can reach the moisture content in predetermined | prescribed temperature / humidity atmosphere, the temperature / humidity atmosphere of this process may always be made constant, and this process is performed. Although the temperature and humidity atmosphere in this step may be changed every time, it is preferable that the temperature and humidity atmosphere is always constant from the viewpoint of the pattern forming apparatus. The temperature and humidity atmosphere of this process is always constant, and the film substrate size unrolled from the roll film substrate is maintained by keeping the moisture content of the roll film substrate in a predetermined temperature and humidity atmosphere constant. This is because the number of types of masks during pattern formation can be reduced.

  The storage location in this step is a sealed space, and is not particularly limited as long as the temperature and humidity atmosphere in the sealed space can be managed. For example, a clean room, a desiccator and Examples include storage such as a chamber. Moreover, it is preferable that the inside of the said storage place is a gas atmosphere which does not degrade a roll-shaped film base material.

  In addition, the storage time in this step is not particularly limited as long as the moisture content of the roll-shaped film substrate can reach the moisture content in a predetermined temperature and humidity atmosphere. It is appropriately selected depending on the temperature and humidity atmosphere and the storage location.

D. Next, the manufacturing method of the pattern formation body of this invention is demonstrated. The method for producing a pattern forming body of the present invention includes a pattern forming step of forming a pattern on the film base material unwound from the roll-shaped film base material described in the section “A. Roll-shaped film base material” described above. It is a manufacturing method characterized by having.

  In addition, the pattern formation body manufactured by this invention is demonstrated not only in what has the pattern formed on the film base material and the film base material but in the above-mentioned "B. Roll-patterned film base material" section. The film base material with a pattern and the film base material with a roll pattern which wound this were included.

  The manufacturing method of the pattern formation body of this invention is demonstrated using figures. FIG. 10 is a process diagram showing an example of a method for producing a pattern formed body of the present invention. As shown in FIG. 10, in the manufacturing method of the pattern formation body of this invention, the roll-shaped film base material 10 is prepared, and the pattern 4 is formed on the film base material 1 unwound from the roll-shaped film base material 10 (Pattern formation step). Thereby, the pattern formation body which has the predetermined pattern 4 formed on the film base material 1 and the film base material 1 can be obtained. In addition, in FIG. 10, although the example which removes and uses the supporting member 2 from the film base material 1 is demonstrated before a pattern formation process, although not shown in figure, the supporting member is arrange | positioned on the film base material. Also good. Moreover, since it can be set as the thing demonstrated in FIG. 9 mentioned above about the roll-shaped film base material 10 and its manufacturing method, description here is abbreviate | omitted.

  According to the present invention, by forming a pattern on a film substrate unwound from a roll-shaped film substrate having a uniform water content regardless of whether it is in-winding or unwinding, It is possible to obtain a pattern forming body on which a high-definition pattern having no dimensional deviation is formed.

The manufacturing method of the pattern formation body of this invention has a pattern formation process at least, and another arbitrary process may be used as needed.
Hereinafter, the manufacturing method of the pattern formation body of this invention is demonstrated for every process.

1. Pattern formation process This process is a process of forming a pattern on the film base material unwound from the roll-shaped film base material described in the above-mentioned section "A. Roll-shaped film base material". In addition, the roll-shaped film base material used for this process may have a supporting member, and does not need to have it.

  About the pattern formed in this process, since it is the same as that of what was demonstrated by the term of the above-mentioned "B. Film substrate with a roll-shaped pattern", description here is abbreviate | omitted.

  In this invention, when the roll-shaped film base material used for the manufacturing method of the pattern formation body of this invention has a support member, it is a support member from a film base material before the said pattern formation process or after the said pattern formation process. You may have the peeling process which peels. When the function of a pattern formation body is prevented by a support member, it is necessary to peel a support member from a film base material. Even when the function of the pattern forming body is not hindered by the support member, the pattern forming body can be made thinner by peeling the support member from the film substrate. The peeling method of the supporting member is not particularly limited as long as the supporting member can be peeled without damaging the film base material, and the supporting member may be broken or not broken. Good.

2. Other Steps The method for producing a pattern formed body of the present invention comprises a roll-shaped film substrate on which a pattern is formed after the above-described pattern forming step, which is an essential step, and the moisture content thereof in a predetermined temperature and humidity atmosphere. It can have a storage process that stores until the rate is reached. By applying the above storage process to the roll-shaped film substrate on which the pattern is formed, for each process of stacking the patterns in multiple layers, it is possible to form a layered pattern with high dimensional reproducibility and high overlay accuracy regardless of whether it is inside or outside the winding. You can get a body. The details of the storage step are the same as the storage step described in the above section “C. Method for producing roll-shaped film substrate”, and thus the description thereof is omitted here.

  In the present invention, the pattern formation step may be performed only once, or the pattern formation step and the storage step may be repeated. Every time the pattern is overlapped, the pattern forming body is wound up after the pattern forming process, and a storage process is performed on the wound pattern forming body, so that the roll-shaped film base material can be used regardless of the inside or outside of the winding. The dimensions can be controlled, and a pattern forming body with high overlay accuracy can be obtained through the pattern forming step.

  In addition, about the pattern formation body manufactured by this invention, since it can be made to be the same as that of what was demonstrated in the term of "B. Film base material with a roll-shaped pattern", description here is abbreviate | omitted.

E. Image Display Element Next, the image display element of the present invention will be described. The image display element of the present invention is a film base material and an image display element having a predetermined pattern provided on the film base material, wherein the predetermined pattern of the film base material is provided. Outside, a through-hole penetrating the film base material is provided.

Here, as described above, since the dimensional accuracy of the film substrate is influenced by the moisture content of the film substrate, the moisture content of the entire film substrate is preferably uniform. However, when storing a film base material, when a plurality of film base materials are laminated and stored, or when a film base material is wound and stored in a roll shape, it is in contact with the outside air even in the same film base material. Because there are easy-to-use parts and parts that are difficult to contact with the outside air, parts with a high water content and parts with a low water content are generated in the same film base material, and the water content of the entire film base material should be uniform. There was a problem that became difficult.
On the other hand, since the film base has a through hole, when the film base is laminated and stored, a support member is partially disposed between the upper and lower film bases to provide a space. By forming, it becomes possible to take in external air between the film bases through the through holes, and to make the moisture content of the entire film base uniform. As a result, the dimensional deviation due to the difference in moisture content in the film substrate can be eliminated, and the dimensional accuracy of the film substrate can be made uniform. Can have high dimensional accuracy. Therefore, according to the present invention, an image display element having a pattern with high dimensional accuracy can be obtained.

  In the present invention, when the length of the film base in the longitudinal direction is at least 50 cm or more and the dimensional accuracy of the pattern in any two regions in the image display element is compared, one region When the dimension of the pattern at 1 is 1, it is preferable that the dimension of the pattern in the other region is within the range of 1.00000 ± 0.00033.

  Here, in the present invention, “arbitrary two regions in the image display element” are regions having the same number of patterns of the same type. The “dimension of the pattern in any two regions in the image display element” is an average value of measured values of the dimensions of each pattern when the region has a plurality of patterns.

When the length in the longitudinal direction of the film base is within the above-described range, the film base itself is usually wound into a roll and stored as a roll-shaped film base. Since the inside of the roll of the conventional roll-shaped film substrate is difficult to absorb or dehydrate, there is a difference in moisture content from the outside of the roll. As a result, a dimensional deviation occurs between the inside and outside of the roll-shaped film substrate. There was a problem such as.
On the other hand, even when the film substrate used in the present invention is a roll-shaped film substrate, the dimensional accuracy of the entire film substrate can be made uniform as described above. Therefore, in this invention, it can be set as the image display element in which the pattern was formed with high dimensional accuracy by using the said film base material.

  The image display element of the present invention is a multi-sided substrate having a plurality of image display elements formed on a film base material as a pattern, or an image display element having an optical functional layer formed on a film base material as a pattern. Any of these are included.

The image display element of the present invention will be described with reference to the drawings. FIG. 11 is a schematic plan view showing an example of the image display element of the present invention, in which a multi-faced substrate of a color filter is taken as an example of the image display element. FIG. 12 is an enlarged view of each pattern (color filter 4 ′) formed in FIG.
As shown in FIG. 11, the image display element 40 of the present invention includes a film substrate 1 having a length in the predetermined longitudinal direction X, and a plurality of color filters 4 ′ (FIG. 9) formed on the film substrate 1. The color filter 4′a to 4′m) has a multi-faceted color filter in which a through hole 3 penetrating the film substrate 1 is provided outside the pattern formation region where the color filter 4 ′ is provided. It is a substrate.
Further, as shown in FIG. 12, each color filter 4 ′ includes a plurality of pixel portions 41 (in FIG. 12, a red pixel portion 41R, a green pixel portion 41G, and a blue pixel portion 41B) formed on a film base material. And a light-shielding portion 42 that partitions the pixel portion 41. The light shielding portion 42 is shown in white for explanation. Moreover, the direction shown by Y in FIG. 11 has shown the width direction of the film base material.

Further, in the image display element of the present invention, when the dimensions of the pattern in any two areas in the image display element are compared, when the dimension of the pattern in one area is 1, the other area It will be described with reference to the drawing that the dimension of the above pattern falls within the range of 1.00000 ± 0.00033.
For example, an arbitrary region in the color filter 4′a in the image display element 40 shown in FIG. 11 is defined as a region x1, an arbitrary region in the color filter 4′m is defined as a region x2, and the region x1 and the region x2 are defined. 12, when there are three pixel portions 41 as shown in FIG. 12, assuming that the average value of the measured values of the three pixel portions in the region x1 is 1, 3 in the region x2 It shows that the average value of the measured values of the dimensions of the two pixel portions 41 falls within the numerical range described above.
In FIG. 12, for the sake of explanation, the region x1 of the color filter 4′a and the region x2 of the color filter 4′m are illustrated in the same color filter 4 ′.

  In the image display element 40 of FIG. 11, for example, the dimensions of the color filter 4'a and the color filter 4'm can be compared.

  Moreover, although the above-mentioned description has shown about the case where the image display element of this invention is a multi-sided board | substrate, when the image display element of this invention is one image display element, it is similarly in an image display element. When the dimensions of the patterns in any two regions are compared, the dimensions of the patterns in the two regions have the above-described relationship.

As described above, according to the present invention, it is possible to obtain an image display element in which a pattern with high dimensional accuracy is formed by using a film base material having no difference in dimensional accuracy of the entire film base material.
Hereinafter, each member used in the present invention will be described.

1. Image display element The image display element of this invention has a predetermined pattern formed in the said film base material.

The image display element is not particularly limited as long as it has a predetermined pattern, but when comparing the dimensions of the pattern in any two regions in the image display element, When the size of the pattern in one region is 1, the size of the pattern in the other region is preferably in the range of 1.00000 ± 0.00033. From the viewpoint of image display displacement, 1 More preferably, it is within the range of 0.00000 ± 0.00017.
Here, when the dimensional accuracy of the pattern when the two regions are compared is within the numerical range, it is possible to match the positions of the two opposing patterns in the image display element. It can be set as an image display element. As a specific example, since the positions of the color filter pattern and the TFT element pattern can be matched, the color filter is displaced with respect to the TFT element when the pixel is turned on / off by the TFT element. Therefore, a good image display can be performed without color shift.
On the other hand, when the dimensional accuracy of the pattern exceeds the numerical range, it is difficult to match the positions of the two opposing patterns on the image display element. More specifically, since the positions of the color filter pattern and the TFT element pattern are shifted, colors that should be displayed cannot be displayed, white spots (light leaks from gaps where the color filters are shifted), and color mixing. There is a possibility that problems such as (mixing colors of other adjacent pixels) may occur.

Here, in the present invention, “when the dimensions of the pattern in any two regions in the image display element are compared, the size of the pattern in one region is 1, and the size in the other region is More specifically, when the pattern dimensions in the two regions are compared, the difference between the pattern dimensions is 100 mm. It is within the range of 33 μm per area, preferably within the range of 3.3 μm per 100 mm, and particularly preferably within the range of 1.7 μm per 100 mm.
The measurement of the pattern dimension is not particularly limited as long as it is a device that can measure the distance between measurements, but it is generally preferable to use a length measuring device. Among the length measuring instruments, a precision measuring instrument capable of measuring the distance to the micrometer unit is preferable. For example, a super precision automatic two-dimensional coordinate measuring machine manufactured by SOKKIA or a CNC image measuring system manufactured by Nikon Instruments Company can be used. .

The pattern compared in the present invention is an optical functional layer existing in any two regions in the image display element when the image display element of the present invention is one image display element.
On the other hand, the pattern compared in the present invention may be any two image display elements when the image display element of the present invention is a multi-sided substrate having a plurality of image display elements. It may be an optical functional layer existing in an arbitrary region in the two image display elements.

  The image display element and the optical functional layer used in the present invention can be the same as those described in the above-mentioned section “B. Roll-patterned film base material”, so the description here is as follows. Omitted.

2. Film base material The film base material of the present invention has a through hole penetrating the film base material in a region where the above-described pattern is not formed.

About the form of the film base material used for this invention, it selects suitably by the use of the image display element of this invention. Especially, as a film base material used for this invention, it is preferable that the length of a longitudinal direction is at least 50 cm or more.
As described above, the film base having the length in the longitudinal direction described above is usually wound in a roll shape and stored as a roll film base. Since the film substrate used in the present invention can prevent the difference in dimensional accuracy between the inside and outside of the roll even when stored as a roll-like film substrate, the conventional roll-like film base is used. An image display element having high dimensional accuracy, which has been difficult to achieve in an image display element using a material, can be obtained. The upper limit of the length of the film base in the longitudinal direction is not particularly limited, but can be about 1000 m in consideration of ease of processing. This is because a film substrate exceeding the above value is usually difficult to handle as a substrate of an image display element.

  Furthermore, in this case, the film substrate is not particularly limited as long as the length in the longitudinal direction is not less than the above-described numerical value, but the support member is previously placed on the end regions at both ends of the film substrate. It is preferable that they are arranged and wound in a roll shape two or more times. When the film base having a length in the longitudinal direction equal to or greater than the above-mentioned value is wound around a commonly used core material or the like, it becomes more than two rounds. Therefore, the effect of the shape of the film base material in the present invention can be further increased. Moreover, it is preferable that the support member is disposed and wound from the viewpoint of preventing generation of defects in the film substrate due to stress generated when the film substrate is wound in a roll shape.

More specifically, the film base material is preferably one that has been unwound from the roll-shaped film base material described in the section “A. Roll-shaped film base material” described above.
In the image display element using the conventional roll-shaped film substrate, the above-described film substrate does not cause a difference in moisture content between the inside and outside of the winding even when it is wound two or more times. It can be set as the image display element which has the high dimensional accuracy which was difficult to achieve.

  The film base material having the length in the longitudinal direction described above is usually wound around a core material having a predetermined inner diameter. Such a core material can be the same as that described in the section of “A. Rolled film base material”, and thus the description thereof is omitted here.

  About the said film base material and the through-hole formed in the said film base material, since it can be made to be the same as that of what was demonstrated by the term of the "A. roll-shaped film base material" mentioned above, description here is abbreviate | omitted. To do.

F. Color filter The color filter of the present invention is characterized in that the pattern of the image display element described in the above section “F. Image display element” is a pixel portion of the color filter.

  Note that the drawing showing the color filter of the present invention can be the same as FIG. 11 and FIG. 12 described in the section “E. Image display element” described above, so the description thereof is omitted here.

As described above in the section “E. Image display element”, in the present invention, a film base material having a uniform moisture content in the entire film base material is used, so that a color having a pixel portion with high dimensional accuracy is used. A filter can be obtained.
Hereinafter, each member in the color filter of the present invention will be described.

1. Pixel unit The pixel unit used in the present invention is formed on a film substrate, and usually has a red pixel unit, a green pixel unit, and a blue pixel unit. You may have.

In addition, the shape, size, and the like of the pixel portion are appropriately selected depending on the use of the color filter.
In addition, the pixel portion can be the same as that used for a general color filter, and a description thereof is omitted here.

2. Film Base The film base used in the present invention can be the same as that described in the above-mentioned section “E. Image Display Element”, and thus description thereof is omitted here.

3. Others The color filter of the present invention is not particularly limited as long as it has the pixel portion and the film base described above, and other necessary members can be appropriately selected and added. Examples of such a member include a light shielding portion and a columnar spacer. Since these members can be the same as those used in general color filters, description thereof is omitted here.

  Since the color filter of the present invention uses the above-described film base material, it is possible to have high dimensional accuracy not only for the pixel portion but also for other members, and those having a laminated structure are high. It is possible to have overlay accuracy.

  The present invention is not limited to the above embodiment. The above-described embodiment is an exemplification, and the present invention has any configuration that has substantially the same configuration as the technical idea described in the claims of the present invention and exhibits the same function and effect. Are included in the technical scope.

  Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples.

[Example]
A PET film (product name: A4100 manufactured by Toyobo Co., Ltd.) having a length of 10 m, a width of 300 mm, and a thickness of 0.125 mm was used as the film substrate. On the film substrate, through holes having a diameter of 5 mm were formed by punching over the entire length of 10 m at intervals of 50 mm at positions 50 mm inside both end faces in the longitudinal direction. Next, a 30 mm wide narrow film (supporting member) prepared using a PET film made of the same material as the film substrate was prepared. Next, the narrow film was placed on the film base so that the center of the narrow film was placed at a position 20 mm from the edge in the width direction of the film base and wound into a roll.
In addition, the outer diameter of the obtained roll-shaped film base material was 10.4 cm.

[Comparative example]
A roll-shaped film substrate was produced in the same manner as in the example except that the through hole and the support member were not used. In addition, the outer diameter of the obtained roll-shaped film base material was 9.6 cm.

  The moisture content immediately after formation of the roll-shaped film base material of an Example and a comparative example was measured. Next, after the roll-shaped film bases of Examples and Comparative Examples were stored after standing for 1 week in an environment of 25 ° C. and 40% RH, the moisture content before and after storage was measured. Thus, the behavior of the moisture content before and after storage was examined. Note that. A moisture meter manufactured by Kurabo Industries Co., Ltd. (product name: RX-100, transmission type) was used for the measurement of the moisture content. The results are shown in Table 1. In addition, the moisture content in the dry state of the used film base material is 0.09 wt%, and the moisture content in a normal temperature normal humidity equilibrium state is 0.33%.

Further, when the correlation between the moisture content and dimensions of the film substrate was examined by the measurement method shown below, when the moisture content of the film substrate was reduced by 0.01 wt% from the normal temperature and normal humidity equilibrium state, the dimensions of the film substrate were Was 1.8 μm / 100 mm smaller than the dimension (design dimension) in the normal temperature and normal humidity equilibrium state, and it was found that a dimensional deviation occurred.
Table 2 shows the result of conversion of the dimensional change amount with respect to the design dimension from the moisture content shown in Table 1 using numerical values indicating the correlation between the moisture content and the dimension of the film base material.

(Measurement of correlation between moisture content of film substrate and dimensions of film substrate)
The PET film used in Examples and Comparative Examples was prepared in a predetermined size, the moisture content and dimensions of the PET film at a certain temperature and humidity were measured, and the dimensions were used as a reference. Next, the amount of change in dimension from the reference was measured by measuring the dimension when the moisture content of the PET film was changed. A graph with the water content on the horizontal axis and the dimensional change on the vertical axis was formed, and the above-described numerical values were obtained from the slope of the approximate curve. The measurement results are shown in Table 3, and the graph and approximate curve are shown in FIG.

In the roll-shaped film base material of the example, the moisture content of the entire film base material could be made substantially constant, but in the comparative example, the water content progressed at the center of the roll-shaped film base material and the core side. In other words, the moisture content of the entire film substrate was not uniform.
Also, with respect to the dimensions of the film substrate, in the examples, the dimensional change of the entire film substrate could be made small, but in the comparative example, the outer side, the center, and the core of the film substrate Each side had different dimensions.
In addition, the winding outside in a table | surface refers to the position of 0.5 m in the longitudinal direction from the winding outside edge part of the film base outside a roll-shaped film base material, and 150 mm (width center part) in the width direction, The center refers to the position of 5 m in the longitudinal direction and 150 mm in the width direction (center portion in the width direction), and the core side refers to the position of 9.5 m in the longitudinal direction and 150 mm in the width direction (center portion in the width direction). Pointing.

DESCRIPTION OF SYMBOLS 1 ... Film base material 2 ... Support member 3 ... Through-hole 4 ... Pattern 4 '... Color filter 10 ... Roll-shaped film base material 11 ... Support member laminated | stacked film base material 20 ... Roll-shaped pattern film base material 21 ... Film with pattern Base material 40 ... Image display element 41 ... Pixel part X ... Longitudinal direction of film base material Y ... Width direction of film base material

Claims (10)

A film substrate, and a support member partially disposed on the film substrate;
When the film base material is used as a base material of a pattern forming body, a support member laminated film base in which a through-hole penetrating the film base material is provided outside a pattern forming region where the pattern of the film base material is provided. A roll-shaped film base material in which a material is wound.   The roll-shaped film substrate according to claim 1, wherein the support member is disposed at least on end regions of both ends of the film substrate.   The roll-shaped film base material according to claim 1, wherein the support member is a synthetic resin film of the same type as the film base material. A film base material having a through-hole, and a support member laminated film base material provided with a support member disposed at least at end regions of both ends of the film base material;
A pattern provided outside the through-hole forming region where the through-hole of the film base material is provided and outside the support member placement region where the support member on the film base material is placed. A film substrate with a roll pattern, wherein the film substrate with a pattern is wound. A pattern having a film base material and a support member partially disposed on the film base material, wherein the film base material pattern is provided when the film base material is used as a base material of a pattern forming body. A roll-shaped film base material preparation step for forming a roll-shaped film base material in which a support member laminated film base material provided with a through-hole penetrating the film base material is formed outside the formation region;
And a storage step of storing the roll-shaped film substrate in the temperature and humidity atmosphere until the moisture content of the roll-shaped film substrate reaches a moisture content in a predetermined temperature and humidity atmosphere. Of manufacturing a film-like film substrate.   It has a pattern formation process which forms a pattern on the film base material unwound from the roll-shaped film base material in any one of Claims 1-3, The manufacture of the pattern formation body characterized by the above-mentioned Method. An image display element having a film base and a predetermined pattern provided on the film base,
An image display element, wherein a through-hole penetrating the film base material is provided outside a pattern forming region in which the predetermined pattern of the film base material is provided.   When the length of the film base in the longitudinal direction is at least 50 cm or more and the dimensional accuracy of the pattern in any two regions in the image display element is compared, the dimension of the pattern in one region is The image display element according to claim 7, wherein when 1, the dimension of the pattern in the other region is within a range of 1.00000 ± 0.00033.   The said film base material arrange | positions a support member partially on the said film base material beforehand, and is wound two or more times in roll shape, The Claim 7 and Claim 8 characterized by the above-mentioned. Image display element.   10. A color filter, wherein the pattern according to claim 7 is a pixel portion of the color filter.

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