Process for forming a hydrophilic coating and hydrophilic coating, and process for forming an ink jet recording head and ink jet recording head

A process for forming a hydrophilic coating and a hydrophilic coating, the process including the steps of: (1) forming, on a substrate, a first coating resin layer including a first cationic polymerization resin and a first photoacid generator; (2) laminating, on the first coating resin layer, a second coating resin layer including a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain, and a second photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light; (3) forming a coating by curing the first coating resin layer and the second coating resin layer through exposure of the first coating resin layer and the second coating resin layer to the active energy ray to conduct development; and (4) forming a hydrophilic coating by hydrophilizing a surface of the coating through heat treatment of the coating.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a process for forming a hydrophilic coating and a hydrophilic coating formed by such process, and a process for forming an ink jet recording head including the hydrophilic coating and an ink jet recording head formed by such process.

2. Description of the Related Art

A technology for performing patterning by processing a resin composition by photolithography is applied in a variety of fields. Examples of the technology include a process for forming an ink jet recording head.

An ink jet recording head for performing recording by ejecting ink onto a recording medium generally includes multiple fine ink ejection orifices, ink flow paths, and energy generating elements for generating energy necessary for ejecting ink to be provided in parts of the ink flow paths.

Japanese Patent Publication No. H06-045242 describes a process of producing such ink jet recording head. First, an ink flow path pattern is formed with a soluble resin on a substrate having energy generating elements formed thereon. Next, a coating resin layer including a cationic polymerization resin and a photoacid generator is formed on the ink flow path pattern, and ink ejection orifices are formed above the energy generating elements by photolithography. Finally, the soluble resin is dissolved and the coating resin layer is then cured to form an ink flow path member.

In general, in order to achieve high printing quality and constantly provide a stable printing effect in an ink jet printer, it is necessary that ink to be ejected from ink ejection orifices be constantly ejected in a vertical direction with respect to an ink ejection orifice surface. When a non-uniform ink pool is present in the ink ejection orifice surface at the time of ejection or the pool is formed during the ejection, ink to be ejected is attracted into the ink pool, and the flying direction of each of ink droplets deviates from the normal direction, with the result that normal ejection is not achieved in some cases. Further, when the array density of ink ejection orifices is increased in order to improve printing quality, an array distance between the ink ejection orifices becomes shorter depending on the increase, and hence the ejection is more liable to be affected by the non-uniform ink pool in the ink ejection orifice surface.

In view of the foregoing, there have been reported a large number of proposals concerning solving the above-mentioned problems by subjecting an ink ejection orifice surface to water-repellent treatment for repelling ink, thereby providing stable ink droplets. Further, in contrast, there has also been reported a proposal concerning ensuring uniform wetness in an ink ejection orifice surface by subjecting the ink ejection orifice surface to hydrophilic treatment for wetting the surface with ink.

Japanese Patent Application Laid-Open No. H06-122210 describes those surface treatment processes. For example, examples of the process for subjecting an ink ejection orifice surface to water-repellent treatment include a process including applying a fluorine-based water repellent. Meanwhile, examples of the process for subjecting an ink ejection orifice surface to hydrophilic treatment include a process including performing hydrophilization by generating a polar group in the ink ejection orifice surface by acid treatment, plasma treatment, or the like.

As described above, the conventional processes each require an apparatus exclusively used for acid treatment, plasma treatment, or the like in the formation of a hydrophilic coating, and the hydrophilic coating cannot be formed with a photolithography apparatus alone, with the result that a large burden is imposed in some cases.

As described above, even in the case where an ink jet recording head is formed by photolithography, a process including applying a fluorine-based water repellent or the like has only to be employed in order to subject an ink ejection orifice surface to water-repellent treatment, and a conventional apparatus may be used. However, an apparatus exclusively used for acid treatment, plasma treatment, or the like is required for subjecting the ink ejection orifice surface to the hydrophilic treatment, and the hydrophilic coating cannot be formed with the conventional apparatus alone, with the result that a large burden is imposed on a forming step in some cases.

An object of the present invention is to provide a process for forming a hydrophilic coating easily by photolithography without requiring an apparatus exclusively used for hydrophilic treatment and a hydrophilic coating formed by the process. Another object of the present invention is to provide a process for forming an ink jet recording head including the hydrophilic coating and an ink jet recording head formed by the process.

SUMMARY OF THE INVENTION

According to the present invention, there is provided a process for forming a hydrophilic coating, which is a coating having a hydrophilized surface, the process including the steps of:

(1) forming, on a substrate, a first coating resin layer including a first cationic polymerization resin and a first photoacid generator;

(2) laminating, on the first coating resin layer, a second coating resin layer including a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain, and a second photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light;
(3) forming a coating by curing the first coating resin layer and the second coating resin layer through exposure of the first coating resin layer and the second coating resin layer to the active energy ray to conduct development; and
(4) forming a hydrophilic coating by hydrophilizing a surface of the coating obtained in the step (3) through heat treatment of the coating.

In addition, the present invention is a hydrophilic coating which is obtained by the process for forming a hydrophilic coating, in which a surface of the hydrophilic coating has a polar group generated by cleavage of the second cationic polymerization resin, and the surface has a static contact angle with pure water of 20° or less.

In addition, the present invention is a process for forming an ink jet recording head including: an ink flow path member which forms ejection orifices for ejecting ink and an ink flow path communicating with the ejection orifices and holding ink and is hydrophilized in its surface having the ejection orifices; and a substrate having energy generating elements formed thereon for generating energy necessary for ejecting ink, the process including the steps of:

(I) forming a first coating resin layer including a first cationic polymerization resin and a first photoacid generator on the substrate having formed thereon the energy generating elements;

(II) laminating, on the first coating resin layer, a second coating resin layer including a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain, and a second photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light;
(III) producing a coating having the ejection orifices formed therein by curing the first coating resin layer and the second coating resin layer through exposure of the first coating resin layer and the second coating resin layer to the active energy ray to conduct development; and
(IV) forming the ink flow path member by hydrophilizing a surface having the ejection orifices of the coating obtained in the step (III) through heat treatment of the coating.

In addition, the present invention is an ink jet recording head formed by the process for forming an ink jet recording head, in which a surface having the ejection orifices of the ink jet recording head has a polar group generated by cleavage of the second cationic polymerization resin, and the surface having the ejection orifices has a static contact angle with pure water of 20° or less.

DESCRIPTION OF THE EMBODIMENTS

The inventor of the present invention has made intensive studies in order to solve the above-mentioned problems. As a result, the inventor has found a process for forming a hydrophilic coating by generating a polar group in a surface of a coating resin layer including a specific cationic polymerization resin and a specific photoacid generator by photolithography. It should be noted that the “hydrophilic coating” as used herein refers to a coating having a static contact angle with pure water of 20° or less. According to the present invention, the hydrophilic coating can be formed easily by conventional photolithography without requiring any apparatus exclusively used for hydrophilic treatment. The process for forming a hydrophilic coating according to the present invention is applicable to a process for forming a semiconductor, an MEMS field, and the like as well as a process for forming an ink jet recording head.

Hereinafter, the present invention is specifically described with reference to drawings. It should be noted that in the following description, a construction having the same function is provided with the same numeral in the drawings, and its description may be omitted.

A process for forming a hydrophilic coating according to the present invention includes the steps of:

(1) forming, on a substrate, a first coating resin layer including a first cationic polymerization resin and a first photoacid generator;

(2) laminating, on the first coating resin layer, a second coating resin layer including a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain, and a second photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light;
(3) forming a coating by curing the first coating resin layer and the second coating resin layer through exposure of the first coating resin layer and the second coating resin layer to the active energy ray to conduct development; and
(4) forming a hydrophilic coating by hydrophilizing a surface of the coating obtained in the step (3) through heat treatment of the coating.

FIG. 1illustrates an example of a hydrophilic coating formed by the process for forming a hydrophilic coating according to the present invention. A substrate is represented by reference numeral1and a coating having a hydrophilized surface (hydrophilic coating) is represented by reference numeral14. The hydrophilic coating14has a first coating2b, a second coating3b, and a hydrophilic layer3con its surface. It should be noted that the first coating2bis formed by curing a first coating resin layer2aillustrated in each ofFIGS. 2A to 2C. Further, the second coating3bis formed by curing a second coating resin layer3a. In addition, the hydrophilic layer3cis formed by hydrophilizing a coating surface, i.e., a surface of the second coating3b, through heat treatment of those coatings.

Hereinafter, a process for forming the hydrophilic coating ofFIG. 1is described with reference toFIGS. 2A to 2E. However, the present invention is not limited thereto.

First, a first coating resin layer2aincluding a first cationic polymerization resin and a first photoacid generator is formed on a substrate1(FIG. 2A). It should be noted that the first coating resin layer2amay be formed directly on a surface of the substrate1, and alternatively, any other layer (for example, positive photosensitive resin layer) may be provided between the substrate1and the coating resin layer2a.

Examples of the first cationic polymerization resin include an epoxy-based resin, an oxetane-based resin, and a vinyl ether-based resin. Of those, an epoxy-based resin or an oxetane-based resin is preferably used in consideration of a small curing shrinkage, satisfactory adherence, and the like. In addition, it is more preferred to use, as the first cationic polymerization resin, a compound free of an acid-cleavable linkage such as an ether linkage or an ester linkage in its main chain.

A cationic polymerization resin including an ether linkage or an ester linkage in its main chain is, for example, a compound represented by each of the following formula 1-a to the following formula 1-i. In contrast, a cationic polymerization resin represented, for example, by each of the following formula 2-a to the following formula 2-e has an ether linkage but is defined as being free of an ether linkage in its main chain in the present invention.

That is, here, it is preferred to use, as the first cationic polymerization resin, such cationic polymerization resin as represented, for example, by each of the formula 2-a to the formula 2-e. It should be noted that the “main chain” means a chain which serves as a backbone in a carbon skeleton of a chain compound and has the maximum number of carbon atoms.

In the above-mentioned formula 1-a, l, m, and n each independently represent an integer of 1 or more.

In the formula 2-a to the formula 2-e, n represents an integer of 1 or more.

When a cationic polymerization resin which is free of an acid-cleavable linkage in its main chain (compound represented, for example, by each of the formula 2-a to the formula 2-e) is used as the first cationic polymerization resin, the first photoacid generator may be selected from known photoacid generators and used without any particular limitation. However, when a cationic polymerization resin which includes an acid-cleavable linkage in its main chain (compound represented, for example, by each of the formula 1-a to the formula 1-i) is used as the first cationic polymerization resin, it is preferred to use the following photoacid generator as the first photoacid generator. That is, the photoacid generator is a photoacid generator which generates antimonic acid or an acid having a weaker acid strength than that of antimonic acid. The reason for the foregoing is described later.

That is, such a first photoacid generator that generates antimonic acid or the like by irradiation with light, more specifically an active energy ray including ultraviolet light, can be used even when any of the cationic polymerization resins is used as the first cationic polymerization resin. The photoacid generator which generates antimonic acid has a structure represented by the following formula 3 as an anion moiety.
SbF6—  Formula 3

Specific examples of the photoacid generator which generates antimonic acid are represented by the following formula 4-a to the following formula 4-j, respectively.

In addition, when a cationic polymerization resin which includes an acid-cleavable linkage in its main chain (compound represented, for example, by each of the formula 1-a to the formula 1-i) is used as the first cationic polymerization resin, the following photoacid generator can also be used as the first photoacid generator. That is, there may also be used, for example, a compound which generates an acid having a weaker acid strength than that of antimonic acid obtained by changing the anion moiety (SbF6−) of the compound represented by each of the above-mentioned formula 4-a to formula 4-j to PF6−or CH3COO−.

A process for forming the first coating resin layer2ais, for example, the following process. That is, the process is a process including applying a solution which is obtained by appropriately dissolving materials for the first coating resin layer2a(including a first cationic polymerization resin and a first photoacid generator) in a solvent, onto the substrate1by a spin coating process. It should be noted that the materials for the first coating resin layer2amay also be applied onto the substrate1without using any solvent, but in the case of using a solvent, the solvent is appropriately selected from solvents which do not dissolve the substrate1and used.

It should be noted that the first coating resin layer2amay include a functionality-imparting material such as an ultraviolet absorber or a silane coupling agent in addition to the foregoing. It should be noted that the content of the first cationic polymerization resin in the coating resin layer2ais preferably 50 mass % or more with respect to the total amount in the case of using a solvent from the viewpoint of coating property. Further, the content of the first photoacid generator in the coating resin layer2ais preferably about 1 mass % with respect to the resin from the viewpoint of reactivity.

Next, a second coating resin layer3aincluding a second cationic polymerization resin and a second photoacid generator is laminated on the first coating resin layer2a(FIG. 2B).

The second cationic polymerization resin may be any cationic polymerization resin having an acid-cleavable linkage in its main chain, and examples thereof include such cationic polymerization resin having an ether linkage or an ester linkage in its main chain as represented by each of the formula 1-a to the formula 1-i.

Further, the second photoacid generator may be any photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light. The photoacid generator which generates methide acid has a structure represented by the following formula 5 as an anion moiety.

Specific examples of the photoacid generator which generates methide acid are represented by the following formula 6-a to the following formula 6-j, respectively.

A process for forming the second coating resin layer3ais, for example, the following process. That is, the process is a process including applying a solution which is obtained by appropriately dissolving materials for the second coating resin layer3a(including a second cationic polymerization resin and a second photoacid generator) in a solvent, onto the first coating resin layer2aby a spin coating process. The materials for the second coating resin layer3amay also be applied onto the first coating resin layer2awithout using any solvent, but in the case of using a solvent, the solvent is appropriately selected from solvents which do not dissolve the coating resin layer2aand used.

It should be noted that the second coating resin layer3amay include a functionality-imparting material such as an ultraviolet absorber or a silane coupling agent in addition to the foregoing. It should be noted that the content of the second cationic polymerization resin in the coating resin layer3ais preferably 50 mass % or more with respect to the total amount in the case of using a solvent from the viewpoint of coating property. Further, the content of the second photoacid generator in the coating resin layer3ais preferably about 1 mass % with respect to the resin from the viewpoint of reactivity.

The thickness of the second coating resin layer3ais not particularly limited as long as the cationic polymerization resin is not completely decomposed by an acid generated from the photoacid generator in the step (4) to be described later, but is desirably 5 μm or more in terms of a thickness on the first coating resin layer2a.

Next, a coating is formed by curing the first coating resin layer2aand the second coating resin layer3athrough exposure of the first coating resin layer2aand the second coating resin layer3ato an active energy ray including ultraviolet light (arrows ofFIG. 2C) to conduct development (FIGS. 2C and 2D). It should be noted that the coating is formed of a first coating2band a second coating3bas illustrated inFIG. 2D.

Next, a hydrophilic layer3cis formed on a surface of the coating, i.e., a surface layer of the second coating3b, through heat treatment of the coating (FIG. 2E). It should be noted that the “surface layer of the second coating3b” means a surface on which the hydrophilic layer is formed. The heat treatment may be carried out in an oven or on a hot plate. The heat treatment may be carried out at any temperature as long as methide acid generated from the second photoacid generator in the second coating resin layer3acan cause acid cleavage of an ether linkage or ester linkage group present in the main chain of the second cationic polymerization resin to generate a polar group, hydrophilize the surface layer, and form the hydrophilic layer3c.

Here, in order to grasp a correlation between the heat treatment temperatures in the step (4) and the remaining ether ratios in the hydrophilic layer3c, measurement was carried out under the following conditions. Specifically, a second coating resin layer including the second cationic polymerization resin which includes an ether linkage as an acid-cleavable linkage in its main chain and the second photoacid generator each described in Table 1 was formed directly on the substrate1without providing the first coating resin layer2a. Then, the coating resin layer was subjected to exposure, development, and heat treatment, and the number of remaining ethers in the surface layer of the coating resin layer, i.e., the hydrophilic layer3c, was measured.FIG. 3shows a graph showing a correlation between the heat treatment temperatures and the remaining ether ratios in the hydrophilic layer3cunder the conditions. It should be noted that the number of ethers is expressed as a ratio of an ether-derived peak intensity when measured with a Fourier transform infrared spectrophotometer (FT-IR) to a peak intensity as a reference. It should be noted that the peak intensity as a reference used here is that of a CH group.

As seen fromFIG. 3, in the following combination, the number of remaining ethers in the hydrophilic layer3cincluding the second cationic polymerization resin decreases depending on the heat treatment temperature. That is, the combination is a combination of No. 1 described in Table 1, and is a combination including a cationic polymerization resin (1-a), which has an acid-cleavable linkage in its main chain, as the second cationic polymerization resin and a photoacid generator (6-a), which generates methide acid, as the second photoacid generator in the second coating resin layer3a. This indicates that methide acid generated from the photoacid generator (6-a) causes acid cleavage of an ether linkage in the main chain of the cationic polymerization resin (1-a) through heat treatment to generate a polar group (cause a polar group to be present).

It should be noted that a similar tendency is expected to be observed even in the case of using a second cationic polymerization resin including an acid-cleavable linkage other than the ether linkage.

It should be noted that it is understood that No. 3 of Table 1, i.e., a combination including the cationic polymerization resin (1-a) and a photoacid generator (4-a), which generates antimonic acid, in the second coating resin layer3adoes not show a decrease in number of ethers in the hydrophilic layer3cdue to heat treatment. That is, this indicates that even the cationic polymerization resin which includes an acid-cleavable linkage in its main chain does not undergo acid cleavage by antimonic acid. This is based on the acid strength of the acid generated from the photoacid generator.

Here, the acid strength of the acid generated from the photoacid generator is described with reference to Table 2 below. Table 2 is an example showing photoacid generators and the order of the acid strengths of acids generated from the photoacid generators. It should be noted that the strength of the acid generated from the photoacid generator may be measured by the following process. That is, the strength may be measured by using resin compositions including the same kind of cationic polymerization resin and the same addition amount (molar number) of photoacid generators, and comparing exposure amounts required for forming a certain pattern. It can be said that the smaller exposure amount indicates that the photoacid generator generates an acid having a stronger acid strength. Thus, the order of the acid strengths is the order of methide acid>antimonic acid>phosphoric acid>acetic acid.

That is, it is understood that the standard for the acid strength necessary for the acid cleavage of the cationic polymerization resin which includes an acid-cleavable linkage in its main chain is methide acid. In other words, the second cationic polymerization resin needs to be cleavable by methide acid.

Next, as is the case withFIG. 3,FIG. 4shows a correlation between the heat treatment temperatures and the static contact angles with pure water of surfaces of hydrophilic coatings, the hydrophilic coatings being each obtained by directly forming, on a substrate, the second coating resin layer including the second cationic polymerization resin and the second photoacid generator each described in Table 1 and subjecting the layer to exposure and heat treatment. As seen fromFIGS. 3 and 4, the contact angle decreases depending on a decrease in number of remaining ethers in the hydrophilic layer3c. It should be noted that the static contact angle with pure water of the hydrophilic coating surface was measured using a contact angle meter (trade name: “FACE CA-XA150” manufactured by Kyowa Interface Science Co., Ltd.). The measurement limit of the method of measuring the contact angle carried out here is 20° or less.

That is, as demonstrated inFIGS. 3 and 4, in the following combination, the surface layer of the second coating3bincluding the second cationic polymerization resin is easily hydrophilized at a heat treatment temperature of 160° C. or more. The combination is a combination including the cationic polymerization resin (1-a), which has an acid-cleavable linkage in its main chain, and the photoacid generator (6-a), which generates methide acid, in the second coating resin layer3a.

Next, as is the case withFIGS. 3 and 4,FIG. 5shows a correlation between the heat treatment temperatures and the thicknesses after heat treatment of the hydrophilic coatings formed with the combinations described in Table 1 without forming the first coating resin layer. It should be noted that the thickness of the second coating resin layer before heat treatment was 20 μm. As seen fromFIGS. 3 and 5, the resin thickness after heat treatment decreases depending on a decrease in number of remaining ethers in the hydrophilic layer3c. That is, this indicates that not only the ether linkage in the surface layer of the resin but also the ether linkage in the resin is cleaved. In this case, there is a risk of a reduction in reliability of the resin layer such as a reduction in adherence between the resin layer and the substrate. That is, it is preferred to use a compound free of an acid-cleavable linkage as the first cationic polymerization resin in the resin layer (first coating resin layer in the present invention) in close contact with the substrate.

In order to easily hydrophilize the surface layer of the second coating resin layer without impairing the reliability of the resin layer as described above, the following procedure is preferably employed. That is, during the formation of the first coating resin layer2aon the substrate1, such a cationic polymerization resin which is free of an acid-cleavable linkage in its main chain as represented, for example, by each of the formula 2-a to the formula 2-e is used as the first cationic polymerization resin. Next, the second coating resin layer3aincluding such a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain as represented, for example, by each of the formula 1-a to the formula 1-i, and such a second photoacid generator which generates methide acid as represented, for example, by each of the formula 6-a to the formula 6-j, is laminated on the layer2a. Then, it is necessary to hydrophilize the surface layer of the second coating resin layer3a.

Further, the upper limit of the heat treatment temperature in the step (4) is preferably 250° C. or less in consideration of heat decomposition of the coating obtained in the step (3).

Next, an example of the process for forming an ink jet recording head is described below. In the steps in the process, the step of easily hydrophilizing a surface having ink ejection orifices (ejection orifice surface) is described by way of an example of the process for forming a hydrophilic coating of the present invention.

A process for forming an ink jet recording head according to the present invention is a process for forming an ink jet recording head including an ink flow path member and a substrate having energy generating elements formed thereon for generating energy necessary for ejecting ink. It should be noted that the ink flow path member forms ejection orifices for ejecting ink and an ink flow path communicating with the ejection orifices and holding ink, and is hydrophilized in its surface having the ejection orifices. In addition, the forming process of the present invention includes the steps of:

(I) forming a first coating resin layer including a first cationic polymerization resin and a first photoacid generator on the substrate having formed thereon the energy generating elements;

(II) laminating, on the first coating resin layer, a second coating resin layer including a second cationic polymerization resin which includes an acid-cleavable linkage in its main chain, and a second photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light;
(III) producing a coating having the ejection orifices formed therein by curing the first coating resin layer and the second coating resin layer through exposure of the first coating resin layer and the second coating resin layer to the active energy ray to conduct development; and
(IV) forming the ink flow path member by hydrophilizing a surface having the ejection orifices of the coating obtained in the step (III) through heat treatment of the coating.

FIG. 6illustrates an example of an ink jet recording head formed by the process for forming an ink jet recording head according to the present invention.

The ink jet recording head illustrated inFIG. 6has an ink flow path member15having a hydrophilized surface layer, i.e., a hydrophilic coating, on a substrate4having thereon multiple energy generating elements5for generating energy necessary for ejecting ink. It should be noted that, as illustrated inFIG. 7, the ink flow path member15has a first coating7b, a second coating8b, and a hydrophilic layer8cas a surface layer. In addition, the ink flow path member15forms ink ejection orifices10for ejecting ink and an ink flow path6bcommunicating with the ink ejection orifices10and holding ink. Further, the substrate4is provided with an ink supply port11for supplying ink to the ink flow path6b. Further,FIG. 7is a view illustrating a cross-section taken along the line7-7ofFIG. 6of an ink jet recording head having an ink supply member12bonded to the back surface of the substrate4in the ink jet recording head ofFIG. 6.

Hereinafter, an exemplary embodiment of the present invention is described in detail. However, the present invention is not limited thereto.

As illustrated inFIG. 8A, the multiple energy generating elements5are arranged on the substrate4in two arrays at a given pitch. It should be noted that a control signal input electrode (not shown) for driving the energy generating elements5is connected to the elements.

Hereinafter, the embodiment is described with reference toFIGS. 8B to 8Hand7.FIGS. 8B to 8Hare step-by-step cross-sectional views each corresponding to the cross-section taken along the line7-7ofFIG. 6.

First, a positive photosensitive resin layer (not shown) including a positive photosensitive resin is formed on the substrate4having the energy generating elements5formed thereon. An ink flow path pattern6amay be formed by patterning the positive photosensitive resin layer as necessary like a step (a2) to be described later.

The positive photosensitive resin included in the positive photosensitive resin layer is not particularly limited, but preferred is a material having a low absorbance for ultraviolet light used for exposure of a first coating resin layer7aand a second coating resin layer8ato be described later. Also preferred is a material sensitive to an active energy ray having a shorter wavelength than that of the ultraviolet light to be used, for example, excimer laser such as ArF laser or KrF laser, or Deep UV light. Examples of the material include polymethyl isopropenyl ketone, which can be exposed to Deep UV light.

A process for forming the positive photosensitive resin layer is, for example, the following process. First, the positive photosensitive resin is appropriately dissolved in a solvent and applied by a spin coating process. After that, the resultant may be subjected to prebaking to form the positive photosensitive resin layer.

The thickness of the positive photosensitive resin layer may be appropriately selected depending on a desired ink flow path height without any particular limitation, but is preferably 5 μm or more and 20 μm or less.

Next, the ink flow path pattern6ais formed by patterning the positive photosensitive resin layer (FIG. 8B).

A process for patterning the positive photosensitive resin layer is, for example, the following process. First, the positive photosensitive resin layer is irradiated via a mask with an active energy ray capable of photosensitizing the positive photosensitive resin to perform pattern exposure. After that, the layer may be developed with, for example, a solvent capable of dissolving the positive photosensitive resin and subjected to rinsing treatment to form the ink flow path pattern6a.

Step (a3): Corresponding to Step (I)

Next, the first coating resin layer7aincluding a first cationic polymerization resin and a first photoacid generator is formed on the ink flow path pattern6aand the substrate4(FIG. 8C).

It should be noted that examples of the first cationic polymerization resin include an epoxy-based resin, an oxetane-based resin, and a vinyl ether-based resin. Of those, an epoxy-based resin or an oxetane-based resin is preferably used in consideration of a small curing shrinkage, satisfactory adherence, and the like. In addition, it is more preferred to use, as the first cationic polymerization resin, a compound free of an acid-cleavable linkage such as an ether linkage or an ester linkage in its main chain. As described above, examples of the compound which is free of an acid-cleavable linkage include compounds represented by the formula 2-a to the formula 2-e.

Further, the first photoacid generator may be selected as necessary from known photoacid generators without any particular limitation in the case of using the cationic polymerization resin which is free of an acid-cleavable linkage in its main chain (compound represented, for example, by each of the formula 2-a to the formula 2-e) as the first cationic polymerization resin. However, in the case of using the cationic polymerization resin which includes an acid-cleavable linkage in its main chain (compound represented, for example, by each of the formula 1-a to the formula 1-i) as the first cationic polymerization resin, it is preferred to use, as the first photoacid generator, a photoacid generator which generates an acid having a weaker acid strength than that of methide acid. This is because there is a risk of cleavage of the main chain of the cationic polymerization resin in the case of using the photoacid generator which generates methide acid.

Examples of the photoacid generator which generates an acid having a weaker acid strength than that of methide acid include compounds represented by the formula 4-a to the formula 4-j as described above.

A process for forming the first coating resin layer7ais, for example, the following process. That is, the process is a process including applying a solution, which is obtained by appropriately dissolving materials for the first coating resin layer7ain a solvent, onto the ink flow path pattern6aand the substrate4by a spin coating process. It should be noted that the solvent for dissolving the materials for the coating resin layer7amay be appropriately selected from solvents which do not dissolve the ink flow path pattern6aand used.

The thickness of the first coating resin layer7ais preferably 3 μm or more in terms of a thickness on the ink flow path pattern6a(distance from the surface of the first coating resin layer7ato the ink flow path pattern6a) in consideration of the strength of the resin layer. Further, the upper limit of the thickness is not particularly limited as long as the developability at an ink ejection orifice portion is not impaired, but is preferably 50 μm or less in terms of a thickness on the ink flow path pattern6a.

Step (a4): Corresponding to Step (II)

Next, the second coating resin layer8aincluding a second cationic polymerization resin and a second photoacid generator is laminated on the first coating resin layer7a(FIG. 8D).

The second cationic polymerization resin may be any cationic polymerization resin having an acid-cleavable linkage in its main chain, and examples thereof include such compounds as represented by the formula 1-a to the formula 1-i as described above.

The second photoacid generator may be any photoacid generator which generates methide acid by irradiation with an active energy ray including ultraviolet light, and examples thereof include such compounds as represented by the formula 6-a to the formula 6-j as described above.

A process for forming the second coating resin layer8ais, for example, the following process. That is, the process is a process including applying a solution which is obtained by appropriately dissolving materials for the second coating resin layer8ain a solvent, onto the first coating resin layer7aby a spin coating process.

The thickness of the second coating resin layer8ais not particularly limited as long as the cationic polymerization resin is not completely decomposed by methide acid generated from the photoacid generator in the step (a7) to be described later, but is desirably 5 μm or more in terms of a thickness on the first coating resin layer7a.

Step (a5): Corresponding to Step (III)

Next, the first coating resin layer7aand the second coating resin layer8aare cured through exposure of the first coating resin layer7aand the second coating resin layer8ato an active energy ray including ultraviolet light (arrows ofFIG. 2C) to conduct development. Thus, a coating having the ink ejection orifices10formed therein is produced (FIGS. 8E and 8F). It should be noted that the coating is formed of a first coating7band a second coating8b.

A process for forming the ink ejection orifices is, for example, the following process. First, the first coating resin layer7aand the second coating resin layer8aare irradiated with the i-line as an active energy ray via a mask9corresponding to the shape of each of the ink ejection orifices10. After that, the first coating7band the second coating8bare formed by curing the first coating resin layer7aand the second coating resin layer8athrough heating, development, and rinsing treatment of the layers, respectively. Thus, the coating having formed therein the ink ejection orifices10can be produced.

The width of each of the ink ejection orifices10may be appropriately set depending on the size of each of ink droplets to be ejected.

Next, an ink supply port11is formed by etching. In addition, the ink flow path pattern6ais removed to form an ink flow path6b(FIG. 8G).

A process for removing the ink flow path pattern6ais, for example, a process including removing the ink flow path pattern6aby immersing the substrate in a solvent capable of dissolving the ink flow path pattern. Further, as necessary, the ink flow path pattern6amay be exposed to an active energy ray capable of photosensitizing the ink flow path pattern to enhance the solubility.

Step (a7): Corresponding to Step (IV)

Next, a hydrophilic layer8cis formed on a surface of the coating, i.e., a surface layer of the second coating8bthrough heat treatment (FIG. 8H).

The heat treatment may be carried out at any temperature as long as an acid generated from the second photoacid generator in the second coating8bcan cause acid cleavage of an ether group or ester group present in the second cationic polymerization resin to generate a polar group and hydrophilize the surface layer. The temperature is preferably 160° C. or more as described above. Further, the temperature is preferably 250° C. or less in consideration of physical properties of the coating resin layer as described above.

It should be noted that the ink flow path surface preferably has a contact angle with pure water of 50° or more.

The “ink flow path surface” as used herein refers to a surface on the ink flow path6bside of the first coating7b, and the contact angle at this site may be measured as a static contact angle with pure water by peeling the first coating7bfrom the substrate4, for example.

The contact angle with pure water is preferably 50° or more and preferably 70° or less in consideration of the efficient refilling of ink and the stability of meniscus oscillation of ink after the refilling.

After that, the energy generating elements5are electrically joined in order to drive the elements. In addition, an ink supply member12for supplying ink and the like are connected. Thus, an ink jet recording head is completed (FIG. 7).

The ink jet recording head according to the present invention is mountable to apparatuses such as a printer, a copier, a facsimile having a communication system, and a word processor having a printer unit, and industrial recording apparatuses integrally combined with various processing apparatuses. Further, the use of the ink jet recording head of the present invention allows recording in a variety of recording media made of paper, yarn, fiber, leather, metal, plastic, glass, wood, ceramic, and the like.

EXAMPLES

Production of Ink Jet Recording Head

Hereinafter, the present invention is further specifically described by way of examples. However, the present invention is not limited to these examples.

Evaluation of Contact Angle

A surface having ink ejection orifices (ink ejection orifice surface: reference numeral13ofFIG. 8H) of an ink jet recording head produced in each of Examples was measured for its static contact angle with pure water using a contact angle meter (trade name: “FACE CA-XA150” manufactured by Kyowa Interface Science Co., Ltd.).

First, as illustrated inFIG. 8A, polymethyl isopropenyl ketone (trade name: “ODUR-1010” manufactured by TOKYO OHKA KOGYO CO., LTD.) as a positive photosensitive resin was applied onto a silicon substrate4having electrothermal transducing elements5formed thereon as energy generating elements by spin coating. Next, the silicon substrate was subjected to prebaking at 120° C. for 6 minutes. Then, pattern exposure of an ink flow path pattern6a(exposure amount: 14 J/cm2) was carried out with a Deep UV exposing machine (trade name: “UX-3000” manufactured by Ushio Inc.). After that, the resultant was developed with methyl isobutyl ketone and subjected to rinsing treatment with isopropyl alcohol (IPA). Thus, the ink flow path pattern6awas formed (FIG. 8B). It should be noted that the ink flow path pattern6ahad a thickness of 10 μm.

Next, the following resin composition 1 was dissolved at a concentration of 50 mass % in a mixed solvent of methyl isobutyl ketone and diethylene glycol monomethyl ether. The solution was applied onto the ink flow path pattern6aand the silicon substrate4by spin coating, thereby forming a first coating resin layer7a(FIG. 8C). It should be noted that the thickness of the first coating resin layer7aon the ink flow path pattern6a(distance from the surface of the first coating resin layer7ato the ink flow path pattern6a) was 10 μm.

First Cationic Polymerization Resin

“157S70” (trade name: manufactured by Japan Epoxy Resin Co., Ltd., compound represented by the formula 2-a): 100 parts by mass

(In the formula 2-a, n represents an integer of 1 or more.)
First Photoacid Generator
Compound represented by the formula 4-a: 1.5 parts by mass

Next, the following resin composition 2 was dissolved at a concentration of 50 mass % in a mixed solvent of methyl isobutyl ketone and diethylene glycol monomethyl ether. Next, the solution was applied onto the first coating resin layer7aby spin coating, thereby forming a second coating resin layer8a(FIG. 8D). It should be noted that the thickness of the second coating resin layer8aon the first coating resin layer7awas 8 μm.

Second Cationic Polymerization Resin

“EHPE-3150” (trade name: manufactured by Daicel Chemical Industries Limited, compound represented by the formula 1-a): 100 parts by mass

(In the formula 1-a, l, m, and n each independently represent an integer of 1 or more.)
Second Photoacid Generator
“GSID26-1” (trade name, manufactured by Ciba Japan K.K., compound represented by the formula 6-a): 1.5 parts by mass

Next, the first coating resin layer7aand the second coating resin layer8awere exposed (exposure amount: 4,000 J/m2) via a mask9corresponding to the shape of each of ink ejection orifices10using an i-line stepper exposing machine (i5 manufactured by Canon Inc.) (FIG. 8E).

Next, the layers were subjected to post-exposure baking (PEB) at 90° C. for 4 minutes, development with methyl isobutyl ketone, and rinsing treatment with IPA. Thus, the first coating resin layer7aand the second coating resin layer8awere cured to produce a coating (first coating7band second coating8b) having formed therein the ink ejection orifices10(FIG. 8F). It should be noted that any of the ink ejection orifices10had a diameter of 10 μm.

Next, the resultant coating was subjected to etching in tetramethylammonium hydroxide (TMAH) to form an ink supply port11. Then, in order to enhance the solubility of the ink flow path pattern6a, the coating was exposed (exposure amount: 27 J/cm2) again with the Deep UV exposing apparatus (trade name: “UX-3000” manufactured by Ushio Inc.) used in forming the ink flow path pattern6a. After that, the resultant was immersed in methyl lactate while being irradiated with an ultrasound to dissolve the remaining ink flow path pattern6a(FIG. 8G).

Next, hydrophilization was carried out by generating a polar group derived from the second cationic polymerization resin in the surface layer of the second coating8bby heating at 200° C. for 1 hour (FIG. 8H).

Finally, an ink supply member12was bonded to the back surface of the silicon substrate4having formed therein the ink supply port11. Thus, an ink jet recording head was completed (FIG. 7).

Table 3 shows the evaluation results of the contact angle of the ink ejection orifice surface of the ink jet recording head.

An ink jet recording head was produced and evaluated in the same manner as in Example 1 except that the following resin composition 3 was used in place of the resin composition 2. Table 3 shows the evaluation results.

Second Cationic Polymerization Resin

“XA8040” (trade name: manufactured by Japan Epoxy Resin Co., Ltd., compound represented by the formula 1-e): 100 parts by mass

Second Photoacid Generator
“GSID26-1” (trade name, manufactured by Ciba Japan K.K., compound represented by the formula 6-a): 1.5 parts by mass

Comparative Example 1

An ink jet recording head was produced and evaluated in the same manner as in Example 1 except that the following resin composition 4 was used in place of the resin composition 2. Table 4 shows the evaluation results. It should be noted that the cationic polymerization resin (compound represented by the formula 2-a) in the resin composition 4 is free of an acid-cleavable linkage, and does not comply with requirements of the second cationic polymerization resin to be used in the present invention.

Cationic Polymerization Resin

“157S70” (trade name: manufactured by Japan Epoxy Resin Co., Ltd., compound represented by the formula 2-a): 100 parts by mass

“GSID26-1” (trade name, manufactured by Ciba Japan K.K., compound represented by the formula 6-a): 1.5 parts by mass

Comparative Example 2

An ink jet recording head was produced and evaluated in the same manner as Example 1 except that the following resin composition 5 was used in place of the resin composition 1 and the resin composition 4 was used in place of the resin composition 2. Table 4 shows the evaluation results.

Cationic Polymerization Resin

“EHPE-3150” (trade name: manufactured by Daicel Chemical Industries Limited, compound represented by the formula 1-a): 100 parts by mass

Compound represented by the formula 4-a: 1.5 parts by mass

Comparative Example 3

An ink jet recording head was produced and evaluated in the same manner as Example 1 except that the resin composition 2 was used in place of the resin composition 1 and the resin composition 5 was used in place of the resin composition 2. Table 4 shows the evaluation results. It should be noted that the photoacid generator in the resin composition 5 is a photoacid generator which generates antimonic acid, and does not comply with requirements of the second photoacid generator to be used in the present invention.

Comparative Example 4

An ink jet recording head was produced and evaluated in the same manner as Example 1 except that the resin composition 4 was used in place of the resin composition 1 and the resin composition 1 was used in place of the resin composition 2. Table 4 shows the evaluation results. The cationic polymerization resin (compound represented by the formula 2-a) in the resin composition 1 does not comply with requirements of the second cationic polymerization resin to be used in the present invention. Further, the photoacid generator (compound represented by the formula 4-a) in the resin composition 1 does not comply with requirements of the second photoacid generator to be used in the present invention either.

Comparative Example 5

An ink jet recording head was produced and evaluated in the same manner as Example 1 except that the resin composition 5 was used in place of the resin composition 1 and the second coating resin layer8awas not formed. Table 4 shows the evaluation results.

As shown in Table 3, an ink jet recording head having an ink flow path member15whose ink ejection orifice surface was subjected to hydrophilic treatment was able to be produced by Example 1 and Example 2.

According to the present invention, it is possible to provide the process for easily forming a hydrophilic coating by photolithography without requiring any apparatus exclusively used for hydrophilic treatment, and the hydrophilic coating formed by the process. It is also possible to provide the process for forming an ink jet recording head including the hydrophilic coating and the ink jet recording head formed by the process.

This application claims the benefit of Japanese Patent Application No. 2010-250778, filed Nov. 9, 2010, which is hereby incorporated by reference herein in its entirety.