Film laminate, method for manufacturing a film laminate, protective equipment, method for manufacturing protective equipment

Abstract

The present invention provides a film laminate that can achieve sufficient sterilization effects and eliminates the risk of damage to the film surface structure, a method for manufacturing a film laminate, protective equipment, and a method for manufacturing protective equipment. [Solution] The device comprises a plurality of film-like members 2 that are laminated in a peelable manner, a first engaging member 6 fixed to one of a pair of film-like members 2, and a second engaging member 9 fixed to the other of the pair of film-like members 2. The first engaging member 6 and the second engaging member 9 engage detachably, so that a pair of film-like members 2 are laminated with an air gap between them, and the engaging portions of the first engaging member 6 and the second engaging member 9 are breathable.

Description

Technical Field

[0001] The present technology relates to a film laminate in which a plurality of film-like members are laminated at a predetermined interval, a method for manufacturing the film laminate, a protective device using the film laminate, and a method for manufacturing the protective device. relates to.

Background Art

[0002] Personal protective equipment is widely used as a means of preventing occupational infections among medical workers. In particular, protective equipment such as face shields and protective clothing for preventing exposure to blood and body fluids are used during examinations and surgeries, and are useful for preventing occupational infections caused by blood-borne pathogens (HIV, HBV, HCV) and coronaviruses (such as SARS-CoV-2).

[0003] However, the surface of this type of protective equipment may be soiled with blood, body fluids, etc. splashed from patients during examinations or surgeries. In an environment where such contaminants fly in, it is required to quickly restore visibility while avoiding contact with the contaminants.

[0004] Also, in the shields of helmets used in motorcycle and four-wheel auto racing competitions, and in painting protective glasses used during painting work, etc., there are often the same problems that the surface becomes soiled and the visibility is obstructed.

[0005] In order to solve such problems, conventionally, a plurality of protective films that can be easily laminated are laminated on the surfaces of helmet shields and painting protective glasses. When the visibility is obstructed due to soiling, the uppermost protective film is peeled off together with the dirt to restore visibility. Regarding this type of technology, for example, in Patent Document 1, a protective device for the shield portion of a helmet is disclosed in which a plurality of sheet-like protective covers, that is, disposable visors, are attached so as to cover the shield portion of the helmet.

[0006] ​However, as mentioned above, if the protective device is simply a laminated structure of protective films, reflections will occur at the interfaces between each laminated layer. In addition, there are problems such as a decrease in transparency as the number of laminated layers increases.

[0007] On the other hand, protective equipment with excellent visibility has also been proposed that utilizes the low reflectivity characteristics of optical elements and films of a moth-eye structure with a pitch below the wavelength of visible light (Patent Document 2).

[0008] The laminate described in Patent Document 2, as shown in Figures 35 and 36, comprises a plurality of film-like members, each having a moth-eye structure with irregularities having a pitch of less than or equal to the wavelength of visible light on at least one surface of a substrate, and is laminated in a peelable manner by being fixed via an adhesive layer at at least the ends of the film-like members. In the laminate shown in Figure 35, the adhesive layer is provided only at the ends of the film-like members. In the laminate shown in Figure 36, the adhesive layer is provided over the entire surface of the film-like members.

[0009] By laminating film-like members equipped with a moth-eye structure, it is possible to prevent an increase in reflectivity and a decrease in transmittance, thereby ensuring visibility. Furthermore, if the surface of the laminate becomes contaminated with blood or bodily fluids, or if visibility is obstructed by dirt, the top layer of film-like member can be peeled off along with the dirt to restore visibility. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] Japanese Patent Publication No. 2000-192322 [Patent Document 2] Japanese Patent Publication No. 2015-57317 [Overview of the Initiative] [Problems that the invention aims to solve]

[0011] When protective equipment made by laminating such film-like materials is used for medical purposes, the surface of each film-like material is sterilized by gas sterilization or other methods. Then, by peeling off the contaminated top layer of film-like material, a new sterile surface can be exposed on the outermost surface.

[0012] However, in protective equipment using laminates formed by laminating and fixing film-like members with an adhesive layer, when sterilization is performed using gas, the surface of each film-like member is not exposed in the areas joined by the adhesive layer, so the sterilization gas cannot flow in, and sterilization is not performed.

[0013] In the configuration shown in Figure 35, the central part of the film without an adhesive layer can be sterilized, but the outer edge of the film where the adhesive layer is provided cannot be sterilized. Also, even in the configuration shown in Figure 35, if the adhesive layer completely covers the outer circumference of the film, the front and back surfaces of the film surrounded by the adhesive layer will not be sterilized. In the configuration shown in Figure 36, only the outermost and innermost surfaces of the laminated film are sterilized, and the front and back surfaces of the film where the adhesive layer is present cannot be sterilized.

[0014] Therefore, when the contaminated top layer of film-like material was peeled off, parts of the film-like material that had not been sterilized or parts that had not been sterilized entirely were exposed, and the sterilization process was not sufficiently effective.

[0015] Furthermore, in the case of a transparent laminate having a moth-eye structure on the film surface, if a laminate design using adhesive is used, there is a concern that the moth-eye structure may be damaged when peeling off each film-like component, depending on the adhesive strength.

[0016] Therefore, the objective of this technology is to provide a film laminate, a method for manufacturing a film laminate, a protective device, and a method for manufacturing a protective device that can achieve sufficient sterilization effects and eliminate the risk of damage to the film surface structure. [Means for solving the problem]

[0017] To solve the above-mentioned problems, the film laminate according to this technology has a plurality of film-like members laminated in a peelable manner, a first engaging member fixed to one of the pair of film-like members, and a second engaging member fixed to the other of the pair of film-like members, wherein the pair of film-like members are laminated with a gap between them by the detachable engagement of the first engaging member and the second engaging member, and the engaging portions of the first engaging member and the second engaging member are breathable.

[0018] Furthermore, the method for manufacturing a film laminate according to this technology includes the steps of: forming a film-like member; forming a first engaging member and a second engaging member that engage detachably; fixing the first engaging member to a position on one of the pair of film-like members facing the other film-like member, fixing the second engaging member to a position on the other film-like member facing the first film-like member; and locking the first engaging member and the second engaging member together to laminate the pair of film-like members with an air gap between them.

[0019] Furthermore, the protective equipment relating to this technology is a protective equipment in which a film laminate is attached to the user's face or around the eyes, and the film laminate is as described above.

[0020] Furthermore, the method for manufacturing protective equipment relating to this technology is a method for manufacturing protective equipment in which a film laminate is attached to the user's face or around the eyes, and comprises the steps of forming a film laminate and attaching the film laminate to the protective equipment, wherein the film laminate is as described above. [Effects of the Invention]

[0021] According to the present technology, the film laminate can expose the entire front and back surfaces of each film-like member, including the first and second engaging members, to the sterilizing gas. When the film-like members are peeled off, the newly exposed film-like members and the first engaging member or the second engaging member fixed thereto are also sterilized. Further, since the peeling of the film-like members can be achieved only by disengaging the first and second engaging members, there is no risk of damaging the moss-eye structure formed on the film-like members.

Brief Description of the Drawings

[0022] [Figure 1] FIG. 1 is an exploded perspective view of a film laminate to which the present technology is applied. [Figure 2] FIG. 2 is a cross-sectional view of a film laminate to which the present technology is applied. [Figure 3] FIG. 3 is a cross-sectional view showing a loop member. [Figure 4] FIG. 4 is a cross-sectional view showing a hook member. [Figure 5] FIG. 5 schematically shows a configuration in which a loop member and a hook member are linearly fixed to the left and right side edges of a substantially rectangular film-like member. [Figure 6] FIG. 6 schematically shows a configuration in which a loop member and a hook member are fixed in a broken line shape to the left and right side edges of a substantially rectangular film-like member. [Figure 7] FIG. 7 schematically shows a configuration in which a loop member and a hook member are linearly fixed to the upper and lower side edges of a substantially rectangular film-like member. [Figure 8] FIG. 8 schematically shows a configuration in which a loop member and a hook member are fixed in a broken line shape to the upper and lower side edges of a substantially rectangular film-like member. [Figure 9] FIG. 9 schematically shows a configuration in which a loop member and a hook member are fixed so as to surround the entire periphery of the side edge of a substantially rectangular film-like member. [Figure 10]Figure 10 is a schematic cross-sectional view showing a configuration in which the width of the loop member and hook member that laminates the uppermost film-like member and the intermediate film-like member is narrower than the width of the loop member and hook member that laminates the intermediate film-like member and the lower film-like member, thereby lowering the peeling force relatively. [Figure 11] Figure 11 is a cross-sectional view of a film-like member constituting a film laminate to which this technology is applied. [Figure 12] Figure 12 is a cross-sectional view of other film-like members that make up the film laminate to which this technology is applied. [Figure 13] Figure 13 is a perspective view of other film-like members that make up the film laminate to which this technology is applied. [Figure 14] Figure 14 is a perspective view of a transfer roll master disc on which a pattern of an anti-reflective layer made of a moth-eye structure has been formed. [Figure 15] Figure 15 is a cross-sectional view showing the process of forming an anti-reflective layer consisting of a moth-eye structure, where (A) shows the state in which the side of the substrate coated with transfer material is in close contact with the roll master, (B) shows a film-like member with a moth-eye structure transferred to one side, (C) shows the state in which the transfer material is applied to the other side of the film-like member with a moth-eye structure transferred to one side and it is in close contact with the roll master, and (D) shows a film-like member with a moth-eye structure transferred to both sides. [Figure 16] Figure 12 is an external perspective view showing a medical protective suit as an example of protective equipment. [Figure 17] Figure 17 is a cross-sectional view showing an example of the process of attaching a film laminate to a protective device, where (A) shows the state before attachment and (B) shows the state after attachment. [Figure 18] Figure 18 is a cross-sectional view showing an example of a process in which a film laminate is attached to a protective device using loop members and hook members instead of adhesive layer bonding. [Figure 19] Figure 19 is a cross-sectional view showing another example of the process of attaching the film laminate to a protective device. [Figure 20]Figure 18 is a cross-sectional view showing another example of a process in which a film laminate is attached to a protective device using loop members and hook members instead of adhesive layer bonding. [Figure 21] Figure 21 is a cross-sectional view showing an example of the process of forming a film laminate and attaching it to a protective device, where (A) shows the bottom layer of film material connected to the opening of the protective device, (B) shows the intermediate layer of film material laminated, and (C) shows the top layer of film material laminated. [Figure 22] Figure 22 is a cross-sectional view showing another example of a film laminate to which this technology is applied, where (A) shows the state before lamination of the film-like members and (B) shows the state after lamination of the film-like members. [Figure 23] Figure 23 is a cross-sectional view showing the process of attaching the film laminate shown in Figure 22 to the protective device, where (A) shows the state before attaching the film laminate and (B) shows the state after attaching the film laminate. [Figure 24] Figure 24 is a cross-sectional view showing an example of a snap button, which is an example of the configuration of the first and second engaging members. [Figure 25] Figure 25 shows other configuration examples of the recessed material and the convex member, where (A) is an exploded perspective view of the recessed material and the convex member, (B) is a perspective view showing the process of inserting the projection of the substrate into the hole of the film-like member, (C) is a perspective view showing the process of fitting the cover of the recessed material onto the projection, and (D) is a perspective view showing the process of fitting the cover of the convex member onto the projection. [Figure 26] Figure 26 shows a film laminate obtained by laminating film-like members using the recessed material and convex member shown in Figure 25, where (A) is a side view showing the process of laminating a film-like member to which the recessed material is fixed and a film-like member to which the convex member is fixed, (B) is a side view showing a film laminate consisting of two layers of film-like members, and (C) is a side view showing a film laminate consisting of three layers of film-like members. [Figure 27] Figure 27 is a plan view showing an example of a fastener, which is an example of the configuration of the first and second engaging members. [Figure 28]Figure 28 is a diagram illustrating the configuration of a film laminate sample according to the first embodiment. [Figure 29] Figure 29 is a perspective view showing a method for measuring peel strength. [Figure 30] Figure 30 is a diagram illustrating the configuration of a film laminate sample according to the first embodiment, where (A) shows an example in which loop members and hook members of the same size as the film-like member are used, and (B) shows an example in which loop members and hook members with half the dimensions of the base material are used. [Figure 31] Figure 31 is a diagram illustrating the configuration of a film laminate sample in which loop members and hook members are provided at both ends in the longitudinal direction of a film-like member. [Figure 32] Figure 32 is a diagram illustrating the configuration of a film laminate sample in which loop members and hook members are provided so as to surround all four sides of a film-like member. [Figure 33] Figure 33 is a photograph showing the results of a sterilization test on a film laminate sample in which loop members and hook members are provided to surround all four sides of the film-like member. [Figure 34] Figure 34 is a photograph showing the results of a sterilization test on a film laminate sample in which adhesive was applied to surround all four sides of the film-like material. [Figure 35] Figure 35 is a cross-sectional view showing a laminate in which multiple film-like members are stacked together by adhesive layers provided at the ends of the film-like members. [Figure 36] Figure 36 is a cross-sectional view showing a laminate in which multiple film-like members are stacked by an adhesive layer provided on the entire surface of each film-like member. [Modes for carrying out the invention]

[0023] The following describes in detail, with reference to the drawings, the film laminate to which this technology is applied, the method for manufacturing the film laminate, the protective device, and the method for manufacturing the protective device. It should be noted that this technology is not limited to the embodiments described below, and various modifications are possible within the scope of the essence of this technology. Furthermore, the drawings are schematic, and the proportions of dimensions may differ from those of reality. Specific dimensions should be determined by referring to the following explanation. It should also be noted that there may be differences in the relationships and proportions of dimensions between different drawings.

[0024] [Laminated film] The film laminate 1 to which this technology is applied comprises a plurality of film-like members 2 that are laminated in a peelable manner, a first engaging member fixed to one of a pair of adjacently laminated film-like members 2, and a second engaging member fixed to the other film-like member 2 facing the first film-like member. The film-like members 2 are flexible, transparent sheets. The first and second engaging members engage detachably. As a result, a pair of adjacently laminated film-like members 2 are laminated with a gap between them. The first and second engaging members engage partially without being tightly attached, and there is a gap in the engaging portion, allowing for breathability. In other words, in the film laminate 1, a plurality of film-like members 2 are laminated with a gap between them, and the engaging portions of the first and second engaging members of each film-like member 2 are not sealed.

[0025] Therefore, the film laminate 1 allows the entire front and back surfaces of each film-like member 2, including the first and second engaging members, to be exposed to sterilization gas, and when the film-like member 2 is peeled off, the newly exposed film-like member 2 and the first or second engaging member fixed thereto are also sterilized.

[0026] Furthermore, in medical applications, if the surface becomes contaminated with blood or bodily fluids scattered from the patient during examination or surgery, the top layer of film-like material 2 can be peeled off to quickly restore visibility while avoiding contact with the contaminants. At this time, the film laminate 1 has sterilized the exposed surface of the film-like material 2 and the first and second engaging members, thus reducing the risk of infection to patients, examinees, and other medical personnel. In addition, the back surface of the peeled-off film-like material 2 is also sterilized, so when peeling or disposing of it, patients, examinees, and medical personnel are not exposed to any parts that have not been sterilized.

[0027] [First and second engaging members] The film laminate 1 shown in Figures 1 and 2 uses a loop member 6, on one surface of a base material 4, with numerous loops 5 erected thereon, as a first engaging member, and a hook member 9, on one surface of a base material 7, with numerous hooks 8 erected thereon that detachably engage with the loops 5, as a second engaging member.

[0028] The film-like member 2 has one of the loop member 6 and the hook member 9 on one side, and the intermediate layer film-like member 2 has the other of the loop member 6 and the hook member 9 on the other side. For convenience, the drawings of this application are denoted as "6,9" to indicate that one or the other of the loop member 6 and the hook member 9 is provided on one side and / or the other side.

[0029] As shown in Figure 3, the base material 4 of the loop member 6 is a support for the sheet-shaped loops 5, with countless fine loops 5 erected on one surface, and the other side opposite to the one surface becomes the fixing surface to which it is fixed to the film-like member 2.

[0030] As shown in Figure 4, the base material 7 of the hook member 9 is a support for the hook 5 formed in a sheet shape, with countless minute hooks 8 erected on one surface, and the other surface opposite to the one surface becomes a fixing surface to which it is fixed to the film-like member 2. The hook 5 has a shape that can engage with the loop 5, and is not limited to, for example, a hook shape or a mushroom shape.

[0031] In the film laminate 1, the base material 4 of the loop member 6 is fixed to one of the pair of adjacently laminated film members 2 by a fixing material 10 such as an adhesive or adhesive tape, and the base material 7 of the hook member 9 is fixed to the other film member 2 facing the first film member 2 by the fixing material 10. Furthermore, the loop member 6 and the hook member 9 are provided in opposing positions when the film members 2 are laminated.

[0032] By overlapping the film-like member 2 to which the loop member 6 is fixed and the film-like member 2 to which the hook member 9 is fixed, the hook 8 engages with the loop 5. As a result, one film-like member 2 and the other film-like member 2 are held and laminated with a gap between them, allowing for sterilization with sterilizing gas. Even if a gap is not visible between one film-like member 2 and the other film-like member 2 in a side view, they are only lightly touching and not tightly adhered, allowing sterilizing gas to pass through.

[0033] Furthermore, the loop member 6 and hook member 9 are configured such that the loop 5 and hook 8, which are erected on the base materials 4 and 7, partially engage without the base materials 4 and 7 being in close contact with each other, and there is a gap between the loop member 6 and the hook member 9, allowing for ventilation. Therefore, the film laminate 1 can allow sterilization gas to pass through when the loop member 6 and the hook member 9 are engaged, that is, when the film-like members 2 are laminated. Consequently, even when the loop member 6 and the hook member 9 are fixed so as to surround the outer edge of the film-like members 2, the film laminate 1 can sterilize the inner surface of the film-like members 2.

[0034] The film-like member 2 is peeled off by disengaging the loop member 6 and the hook member 9. At this time, the sterilized surface of the film-like member 2 can be exposed. In addition, since the engagement portions of the breathable loop member 6 and the hook member 9 are also sterilized, the sterilized loop member 6 and the hook member 9 are exposed.

[0035] For such loop members 6 and hook members 9, for example, mechanical fasteners manufactured by 3M or so-called hook-and-loop fasteners can be used.

[0036] [Fixation position] The loop members 6 and hook members 9 are positioned and numbered in such a way that they can stably hold and laminate the film-like member 2 with gaps between them, do not interfere with the user's field of view within the film-like member 2 during use, and allow for easy peeling. From this viewpoint, it is preferable that the loop members 6 and hook members 9 are formed in a tape shape and provided on the side edges of the film-like member 2.

[0037] The fastening pattern can be determined according to the shape and application of the protective device to be attached. For example, as shown in Figure 5, the fastening may be linearly fixed to the left and right side edges of the substantially rectangular film-like member 2; as shown in Figure 6, the fastening may be dashed; as shown in Figure 7, the fastening may be linearly fixed to the upper and lower side edges of the substantially rectangular film-like member 2; and as shown in Figure 8, the fastening may be dashed. Alternatively, as shown in Figure 9, the fastening may surround the entire circumference of the side edges of the film-like member 2. Figures 5 to 9 schematically show the fastening patterns of the loop member 6 and hook member 9 used to stack the film-like members 2. Depending on the stacking position, the loop member 6 or hook member 9 is fixed to one or both of the front and back surfaces of the film-like member 2.

[0038] Furthermore, multiple loop members 6 and hook members 9 may be fixed in parallel to the side edge of the film-like member 2. The formation positions and number of loop members 6 and hook members 9 are not limited to those described above, and can be appropriately set according to the configuration and application of the protective device 21 and the film laminate 1.

[0039] Furthermore, the peeling force required to peel off each tape-like loop member 6 and hook member 9 may be the same or different. For example, when fixing the tape-like loop members 6 and hook members 9 in a dashed line pattern, loop members 6 and hook members 9 fixed near the corners of the film-like member 2 may have a relatively stronger peeling force than those fixed in the middle. Alternatively, when fixing the tape-like loop members 6 and hook members 9 to the upper and lower edges, wider loop members 6 and hook members 9 may be fixed to the upper edge, and narrower loop members 6 and hook members 9 may be fixed to the lower edge, thus varying the peeling force for each part. In addition, within a single tape-like loop member 6 and hook member 9, the peeling force may be varied for each part by changing the hook shape, changing the width, etc.

[0040] Alternatively, tape-shaped loop members 6 and hook members 9 may be mixed on one surface of the film-like member 2. In this case, tape-shaped loop members 6 and hook members 9 are also mixed on the opposing film-like member 2 and arranged so as to face each other.

[0041] [Peeling force] In the film laminate 1, it is preferable that the peeling force of the loop members 6 and hook members 9 that laminate the upper film-like members 2 together is lower than the peeling force of the loop members 6 and hook members 9 that laminate the lower film-like members 2 together. This prevents the loop members 6 and hook members 9 that hold and laminate the lower film-like members 2 from peeling off when the upper film-like members 2 are peeled off, and prevents the lower film-like members 2 from peeling off together with them.

[0042] The peeling force between the film-like members 2 can be adjusted by varying the hook shape of the loop members 6 and hook members 9 provided between each film-like member 2, or by changing the width and number of fastening points of the loop members 6 and hook members 9 to change the fastening area. Figure 10 is a schematic cross-sectional view showing a configuration in which the width of the loop members 6 and hook members 9 that laminate the uppermost film-like member 2 and the intermediate film-like member 2 is narrower than the width of the loop members 6 and hook members 9 that laminate the intermediate film-like member 2 and the lower film-like member 2, thereby lowering the peeling force relatively. The film laminate 1 shown in Figure 10 can prevent the intermediate film-like member 2 from peeling off when the uppermost film-like member 2 is peeled off.

[0043] Furthermore, the adhesive force of the adhesive material 10 that fixes the loop member 6 and the hook member 9 to the film-like member 2 is higher than the peeling force between each film-like member 2 of the film laminate 1. Therefore, when the film-like member 2 is peeled off, the loop member 6 and the hook member 9 will not peel off at the interface with the film-like member 2. In addition, when the film-like member 2 is peeled off, the adhesive material 10 itself will not undergo cohesive failure between the adhesive layers.

[0044] [others] In the above, a loop member 6 and a hook member 9 were used as the first and second engaging members for holding and laminating the film-like member 2. However, the first engaging member may be changed to a hook member 9 if it provides the effects described above. That is, the film-like member 2 may be held and laminated by the engagement of the hook members 9 with each other.

[0045] [Film-like material] The film-like member 2 is a flexible, transparent sheet. The shape of the film-like member 2 is not particularly limited and can be appropriately selected depending on the protective equipment 21 to which it is applied, such as being roughly rectangular as shown in Figure 1.

[0046] As described above, loop members 6 or hook members 9 are provided on the side edges of the film-like member 2. Specifically, the uppermost film-like member 2 has loop members 6 or hook members 9 on its back surface, and the intermediate film-like member 2 has loop members 6 or hook members 9 on both its front and back surfaces. The bottommost film-like member 2 has loop members 6 or hook members 9 on its front surface, and on its back surface, loop members 6 or hook members 9 are provided as appropriate depending on how it is attached to the protective device 21.

[0047] The film-like member 2 may be provided with a peeling tab 20 on its outer edge. The tab 20 is the part that is gripped when peeling off the film-like member 2. Preferably, the tab 20 of the film-like member 2 is provided with a function to identify which film-like member 2 to peel off. This encourages peeling from the uppermost film-like member 2 and prevents accidental peeling of the intermediate film-like member 2 together with the uppermost film-like member 2.

[0048] One identification method for identifying the uppermost film-like member 2 is to progressively decrease the size of the tabs 20 from the top down. That is, as shown in Figure 1, by making the tab 20 formed on the uppermost film-like member 2 larger than the tabs 20 on the lower film-like member 2, and concealing the tabs on the lower film-like member 2, it becomes easier to always grasp only the tab 20 on the uppermost film-like member 2, preventing accidental grasping of the tabs 20 on the lower film-like member 2.

[0049] Furthermore, the position where the tab 20 is formed may be changed for each film-like member 2. For example, the uppermost film-like member 2 may have a tab 20 formed on its right edge when viewed from the front, and the intermediate film-like member 2 may have a tab 20 formed on its left edge when viewed from the front. This makes it possible to peel off the uppermost film-like member 2 by first gripping the tab 20 on the right edge, preventing accidental peeling down to the intermediate film-like member 2.

[0050] In addition, identification may be achieved by changing the color of the tab 20 for each film-like member 2, or by processing physical features such as raised or recessed marks, openings, or notches. Furthermore, a combination of the above-mentioned identification means may be used.

[0051] Furthermore, the film laminate 1 may consist of film-like members 2 that are all the same in each layer, or they may have different functions and optical properties. This is appropriately selected depending on the application of the protective equipment 21 to which the film laminate 1 is applied. In addition, when laminating film-like members 2 with different functions and properties, the lamination order is also appropriately set depending on the application of the protective equipment 21.

[0052] [Moth-eye structure] Here, it is preferable that the film-like member 2 is an optical element having an anti-reflective function, provided with a plurality of structures at a pitch less than or equal to the wavelength of visible light on at least one surface of a flexible transparent substrate. Hereinafter, this fine uneven structure having an anti-reflective function will be referred to as a "moth-eye structure". Furthermore, by using film-like members 2 equipped with moth-eye structures, the film laminate 1 does not impair visibility even when these film-like members 2 are laminated.

[0053] As shown in Figure 11, the film-like member 2 has structures 12 provided on both sides of the substrate 11 via a base layer 13 at a pitch less than or equal to the wavelength of visible light, thereby providing an anti-reflective function on both the opposing front and back surfaces. The multiple structures 12 are regularly arranged in multiple rows on the base layer 13 on the front and back surfaces of the substrate 11. That is, the front and back surfaces of the film-like member 2 have an uneven shape due to a moth-eye structure composed of multiple structures 12. Note that the film-like member 2 may also have structures 12 provided only on the front surface of the substrate 11.

[0054] By providing such uneven shapes on the front and back surfaces of the film-like member 2, an optical adjustment function with low wavelength dependence and excellent visibility can be provided to the protective equipment 21 to which the film laminate 1 is attached. In other words, it can contribute to realizing protective equipment 21 with excellent visibility.

[0055] Here, "optical adjustment function" refers to the optical adjustment function of transmission characteristics and reflection characteristics. The film-like member 2, as an optical element, is, for example, transparent to visible light, and its refractive index n is preferably in the range of 1.30 to 2.00, more preferably 1.34 to 2.00. However, it is not limited to this.

[0056] Furthermore, it is preferable that the refractive index of the structure 12 is the same as or approximately the same as that of the substrate 11. This is because it can suppress internal reflections and improve contrast.

[0057] Figure 11 shows an example in which the structure 12 is formed on the front and back surfaces of the substrate 11 via a base layer 13. This base layer 13 plays a role in improving the adhesion of the structure 12 to the substrate 11. In this case, the base layer 13 is an optical layer integrally molded with the structure 12 on the bottom surface side of the structure 12, and is transparent. It may be formed by curing an energy-ray curable resin composition similar to that of the structure 12.

[0058] Alternatively, as shown in Figure 12, the film laminate 1 may not have a base layer 13, and a film-like member 2 in which a moth-eye structure of multiple structures 12 is directly formed on a base 11 may be used.

[0059] Furthermore, the film laminate 1 may also use a film-like member 2 in which the substrate and the structure are integrally molded, as shown in Figure 13. In the film-like member 2 shown in Figure 13, the structure 12 is integrally molded on both sides of the substrate 11.

[0060] [Base] Here, the substrate 11 will be explained further. The substrate 11 is, for example, a transparent substrate. Examples of materials for the substrate 11 include those mainly composed of transparent plastic materials, but it is not particularly limited to these materials.

[0061] When a plastic material is used as the substrate 11, an undercoat layer (not shown) may be further applied by surface treatment to further improve the surface energy, coatability, slipperiness, and flatness of the plastic material's surface. Examples of this undercoat layer include organoalkoxymetal compounds, polyester, acrylic-modified polyester, and polyurethane. Alternatively, corona discharge treatment or UV irradiation treatment may be performed on the surface of the substrate 11 to obtain an effect equivalent to that of applying an undercoat layer.

[0062] If the substrate 11 is a plastic film, it can be obtained, for example, by stretching the resin described above, or by diluting it in a solvent, forming a film, and drying it. The thickness of the substrate 11 is preferably selected appropriately depending on the application of the film-like member 2, and may be, for example, 10 μm to 500 μm. The shape of the substrate 11 can be, for example, a film or a plate, but is not limited to these shapes. The term "film" includes sheets.

[0063] Examples of materials for the substrate 11 include, but are not limited to, methyl methacrylate (co)polymer, polycarbonate, styrene (co)polymer, methyl methacrylate-styrene copolymer, cellulose diacetate, cellulose triacetate, cellulose acetate butyrate, polyester, polyamide, polyimide, polyethersulfone, polysulfone, polypropylene, polymethylpentene, polyvinyl chloride, polyvinyl acetal, polyetherketone, polyurethane, glass, etc.

[0064] [Structure] Next, the structure 12 will be described. Generally, the wavelength range of visible light is 360 nm to 830 nm, but in this embodiment, the structure 12 is arranged in a regular pattern with a size smaller than or equal to the wavelength range of visible light. From this viewpoint, the arrangement pitch of the structure 12 shall not exceed 350 nm. The structure 12 may have various shapes, such as cone-shaped, columnar, or needle-shaped.

[0065] As described later, the structure 12 is formed by transferring a pattern corresponding to the moth-eye structure onto a transfer material 36, such as an energy-ray curable resin composition, applied to a substrate 11 using a roll master exposure apparatus, and then curing the pattern.

[0066] The cured product of the transfer material 36 may be hydrophilic. Preferably, the transfer material 36 contains one or more hydrophilic functional groups. Examples of such hydrophilic functional groups include hydroxyl groups, carboxyl groups, and carbonyl groups.

[0067] Furthermore, the energy-ray curable resin product forming the structure 12 may have different physical properties on both sides of the substrate 11. For example, by using hydrophobic and hydrophilic properties depending on the application, functions such as anti-fogging can be given to specific surfaces.

[0068] As the energy-ray curable resin composition, it is preferable to use an ultraviolet-curable resin composition. Furthermore, the energy-ray curable resin composition may contain fillers, functional additives, etc., as needed.

[0069] UV-curable resin compositions include, for example, acrylates and initiators.

[0070] The UV-curable resin composition includes, for example, monofunctional monomers, difunctional monomers, polyfunctional monomers, etc. Specifically, it is a mixture of the following materials, either individually or in combination.

[0071] In other words, "monofunctional monomers" include, for example, carboxylic acids (acrylic acid), hydroxy compounds (2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 4-hydroxybutyl acrylate), alkyl or alicyclic monomers (isobutyl acrylate, t-butyl acrylate, isooctyl acrylate, lauryl acrylate, stearyl acrylate, isovonyl acrylate, cyclohexyl acrylate), and other functional monomers (2-methoxyethyl acrylate, methoxyethylene glycol acrylate, 2-ethoxyethyl acrylate, tetrahydrofurfuryl acrylate, benzyl acrylate, ethyl carbitol acrylate, phenoxyethyl acrylate, N,N-dimethylaminoethyl acrylate, Examples include N,N-dimethylaminopropylacrylamide, N,N-dimethylacrylamide, acryloylmorpholine, N-isopropylacrylamide, N,N-diethylacrylamide, N-vinylpyrrolidone, 2-(perfluorooctyl)ethyl acrylate, 3-perfluorohexyl-2-hydroxypropyl acrylate, 3-perfluorooctyl-2-hydroxypropyl acrylate, 2-(perfluorodecyl)ethyl acrylate, 2-(perfluoro-3-methylbutyl)ethyl acrylate, 2,4,6-tribromophenol acrylate, 2,4,6-tribromophenol methacrylate, 2-(2,4,6-tribromophenoxy)ethyl acrylate, and 2-ethylhexyl acrylate.

[0072] Examples of "difunctional monomers" include tri(propylene glycol) diacrylate, trimethylolpropane-diallyl ether, and urethane acrylate.

[0073] Examples of "polyfunctional monomers" include trimethylolpropane triacrylate, dipentaerythritol penta and hexaacrylate, and ditrimethylolpropane tetraacrylate.

[0074] In particular, preferred resin compositions constituting the transfer material 36 include 2-hydroxyethyl acrylate, acrylic morpholine, glycerol acrylate, polyether acrylate, N-vinylformamide, N-vinylpyrrolidone, N-vinylcaprolactone, ethoxydiethylene glycol acrylate, methoxytriethylene glycol acrylate, polyethylene glycol acrylate, EO-modified trimethylolpropane triacrylate, EO-modified bisphenol A diacrylate, aliphatic urethane oligomer, and polyester oligomer.

[0075] Examples of "initiators" include 2,2-dimethoxy-1,2-diphenylethane-1-one, 1-hydroxycyclohexylphenyl ketone, and 2-hydroxy-2-methyl-1-phenylpropane-1-one.

[0076] As "fillers," for example, either inorganic or organic fine particles can be used. Examples of inorganic fine particles include metal oxide fine particles such as SiO2, TiO2, ZrO2, SnO2, and Al2O3.

[0077] Examples of "functional additives" include leveling agents, surface modifiers, and defoaming agents.

[0078] By forming a moth-eye structure consisting of fine irregularities as structure 12, the film laminate 1 has a high level of anti-reflective function. Here, the anti-reflective performance of the film laminate 1 is 5% or less, preferably 1% or less, and more preferably 0.5% or less, including both the front and back surfaces. The shadowless lamps used as light sources during surgery have an illuminance of 100,000 lx or more, and even a few percent of their reflected light can feel dazzling, so it is necessary to suppress reflection as much as possible. The film laminate 1, which has an anti-reflective layer consisting of a moth-eye structure in which multiple structures are composed of a transparent substrate 11 at a pitch of less than the wavelength of visible light as structure 12, has low wavelength dependence and angle dependence and high anti-reflective performance, making it suitable for use as a medical face shield, eye shield, or protective clothing.

[0079] Furthermore, the film laminate 1 can be made anti-fogging by constructing multiple structures with a pitch less than or equal to the wavelength of visible light that constitute the anti-reflective layer made of a moth-eye structure from a hydrophilic resin.

[0080] Furthermore, the film laminate 1 can be given even better anti-reflective performance by forming an anti-reflective layer consisting of a moth-eye structure on both sides of the transparent substrate 11.

[0081] [Manufacturing process for film-like materials] Next, the manufacturing process of the film-like member 2 on which the moth-eye structure is formed will be described. The film-like member 2 is formed when the pattern corresponding to the moth-eye structure is transferred using a roll master exposure apparatus on which a pattern corresponding to the moth-eye structure is formed.

[0082] [Original Roll Record] As shown in Figure 14, the roll master 41 has, for example, a cylindrical or cylindrical shape, and its cylindrical or cylindrical surface serves as a molding surface for forming a plurality of structures 12 on the base surface. A predetermined structure 42 is arranged in two dimensions on this molding surface by, for example, dry etching, wet etching, etc. The structure 42 has, for example, a concave or convex shape with respect to the molding surface. As the material for the roll master 41, for example, glass can be used, but it is not particularly limited to this material.

[0083] The multiple structures 42 arranged on the molding surface of the roll master 41 and the multiple structures 12 arranged on the surface of the base body 11 have an inverted concave-concave relationship. That is, the shape, arrangement, and placement pitch of the structures 42 on the roll master 41 are the same as those of the structures 12 on the base body 11.

[0084] [Transfer process 1] As shown in Figure 15(A), the substrate 11 is coated with a transfer material 36 on one surface, and then the surface coated with the transfer material 36 is brought into close contact with a roll master 41 on which a pattern corresponding to the moth-eye structure is formed. Next, the transfer material 36 is cured by irradiating it with energy rays such as ultraviolet light from an energy ray source 37, and then the substrate 11, which has become integrated with the cured transfer material 36, is peeled off. As a result, a film-like member 2 is obtained on one side of the substrate 11, as shown in Figure 15(B). At this time, if necessary, a base layer 13 may be further formed between the structure 12 and the substrate 11.

[0085] The energy source 37 can be any device capable of emitting energy rays, such as electron beams, ultraviolet rays, infrared rays, laser rays, visible light, ionizing radiation (X-rays, alpha rays, beta rays, gamma rays, etc.), microwaves, or radio waves, and is not particularly limited.

[0086] [Transfer process 2] To obtain a film-like member 2 with multiple structures 12 formed on both sides of a substrate 11, as shown in Figure 15(C), a roll master disc 41 for the moth-eye structure and a transfer material 36 applied to the opposite surface of the substrate 11 with the structure formed on one side are brought into close contact. Then, energy rays such as ultraviolet light are irradiated onto the transfer material 36 from an energy source 37 to harden the transfer material 36. Next, the substrate 11, which has become integrated with the hardened transfer material 36, is peeled off. As a result, a film-like member 2 with multiple structures 12 formed on both sides of the substrate 11 is obtained, as shown in Figure 15(D). In this case, if necessary, a base layer 13 may be further formed between the structures 12 and the substrate 11.

[0087] The resin composition used as the transfer material 36 in this transfer step 2 can be the same as that used in the transfer step 1 described above.

[0088] Furthermore, a protective film may be laminated onto the surface of the film-like member 2 obtained in transfer step 1 or up to transfer step 2. This prevents the film-like member 2 from damaging the structure 12 in subsequent processes or during transportation.

[0089] [Shape forming process] The film-like member 2 obtained above is cut into a predetermined shape according to the protective device 21 to be attached, and processed into tabs 20 as appropriate. Numerically controlled cutting machines, laser processing devices, and punching presses can be used to process the tabs 20. Using a punching press is preferable because it allows for cutting into the predetermined shape and physical processing of the tabs 20 in a single process.

[0090] [Lamination process] Next, loop members 6 and hook members 9 are attached to each film-like member 2 in a predetermined pattern using a fixing material 10 such as adhesive or adhesive tape. Then, the film-like members 2 are laminated by engaging the loop members 6 and hook members 9 of a pair of adjacent film-like members 2 to be laminated. This obtains a film laminate 1. There is no particular limit to the number of layers of film-like members 2, as long as there are multiple layers, and it can be set according to the application of the protective equipment. However, the effect on optical properties increases with the number of layers, so fewer layers are preferable in applications where a clear field of view is required. Also, in medical applications, hygiene is important, and the entire film laminate 1 or protective equipment 21 may be disposable, so 2 to 3 layers are preferable.

[0091] [Sterilization process] Next, the film laminate 1 is sterilized. For sterilization, gas sterilization using ethylene oxide gas or the like, or radiation sterilization using gamma rays or the like, can be used. The film laminate 1 has gaps between each film-like member 2. In addition, the loop member 6 and hook member 9 are not in close contact with the base materials 4 and 7, but rather the loop 5 and hook 8 erected on the base materials 4 and 7 partially engage, and there is a gap between the loop member 6 and the hook member 9, allowing for ventilation. Therefore, the film laminate 1 can be ventilated with sterilization gas while the loop member 6 and the hook member 9 are engaged, that is, while the film-like members 2 are laminated.

[0092] Therefore, all exposed surfaces of the film-like members 2 and the engagement portions of the loop members 6 and hook members 9 can be exposed to the sterilization gas. Furthermore, even when the film-like members 2 are formed using a material that is impermeable to sterilization gases such as ethylene oxide gas, the exposed surfaces of the film laminate 1 can be thoroughly sterilized.

[0093] The sterilization process is performed after the film laminate 1 is formed but before it is attached to the protective device 21, which will be described later. However, it may also be performed together with the protective device 21 after it has been attached, or it may be performed at both of these times.

[0094] When the film laminate 1 is in use, if the top layer of film-like material 2 becomes contaminated and peels off, the lower layer of film-like material 2 is exposed. Since the entire exposed surface of the newly exposed film-like material 2, including the loop material 6 and hook material 9, is sterilized, the risk of infection to patients, examinees, and other healthcare workers can be reduced.

[0095] Furthermore, since the film-like member 2 can be peeled off simply by disengaging the loop member 6 and the hook member 9, there is no risk of damaging the moth-eye structure formed on the film-like member 2. In contrast, in a laminated structure where the film-like members 2 are joined together with adhesive, peeling involves mechanical failure such as interfacial fracture between the adhesive layer and the film-like member 2 or cohesive fracture between the adhesive layers. Depending on the bonding force, this can damage the moth-eye structure and create a risk of adversely affecting visibility. In addition, the scattering of adhesive layer residue and the generation of outgassing from the adhesive layer are particularly undesirable in medical settings.

[0096] Furthermore, in a laminated structure where film-like members 2 are joined together by welding them to each other, delamination involves physical destruction between the film-like members 2, which carries the risk of damage to the moth-eye structure extending into the field of vision. In addition, the scattering of residue due to the destruction of the welded joints is particularly undesirable in medical settings.

[0097] Since the film laminate 1 does not use adhesives and the film-like members 2 are not welded together, it can be used safely without the risks associated with these. Furthermore, in the film laminate 1, multiple film-like members 2 are laminated with gaps between them, and the parts to which the loop members 6 and hook members 9 of each film-like member 2 are fixed are not exposed to the outside, while the sterilized loop members 6 and hook members 9 are exposed. Therefore, the film laminate 1 allows the entire front and back surfaces of each film-like member 2, including the first and second engaging members, to be exposed to sterilization gas, and when the film-like members 2 are peeled off, no unsterilized parts of the newly revealed film-like members 2 are exposed.

[0098] [Protective equipment] The film laminate 1 is attached to the protective equipment 21. The protective equipment 21 is not particularly limited as long as it is used to ensure visibility by peeling off the film-like member 2, and examples include medical protective clothing (coveralls), medical face shields, medical eye shields, medical displays, helmet visors, protective glasses for painting, chemical protective clothing used in disaster situations, etc.

[0099] The protective equipment 21 fitted with the film laminate 1 has the film laminate 1 positioned over the area corresponding to the face or around the eyes of the wearer. If the surface of the film laminate 1 becomes contaminated during use of the protective equipment 21, the top layer of film material 2 can be peeled off to quickly restore visibility while avoiding contact with contaminants. Since the front and back exposed surfaces of each layer of film material 2, including the loop material 6 and hook material 9, are sterilized, the sterilized surface is always visible on the surface, not only during initial use but also after peeling. This reduces the risk of infection to patients, examinees, and other medical personnel in medical applications. Furthermore, since the back side of the peeled film material 2 is also sterilized, patients, examinees, and medical personnel are not exposed to unsterilized parts during peeling or disposal.

[0100] There are no particular restrictions on how the film laminate 1 is attached, and it can be appropriately determined according to the specifications of the protective equipment 21 to be applied. Figure 16 is an external perspective view showing a medical protective suit as an example of protective equipment 21. For example, as shown in Figure 16, the protective equipment 21 has an opening 22 at a position corresponding to the user's face, and the film laminate 1 is attached to this opening 22. The film laminate 1 shown in Figure 17(A) consists of three film-like members 2 laminated together, with the bottom film-like member 2a (i.e., the film-like member 2a positioned closest to the user's face), the middle film-like member 2b, and the top film-like member 2c being laminated via loop members 6 and hook members 9. Note that the number of layers of film-like members 2 constituting the film laminate 1 according to this technology is not limited to three.

[0101] The film-like members 2a, 2b, and 2c are laminated with gaps between them, and the loop member 6 and hook member 9 are also breathable, so that the entire surface of the parts exposed to the outside when the film laminate 1 is first used or when the film-like members 2 are peeled off can be sterilized. Furthermore, even if no gaps appear to be visible between one film-like member 2 and the other film-like member 2 in a side view, they are not tightly attached but only lightly touching, and are laminated in a way that allows sterilization gas to pass through (see Figure 33).

[0102] As shown in Figure 17(A), the bottommost film-like member 2a of the film laminate 1 is formed to be larger than the opening 22. In addition, an adhesive layer 23 made of double-sided tape or the like is provided on the outer edge on the back side of the opening 22. The film laminate 1 is then attached to the protective device 21 by passing the topmost film-like member 2a and the intermediate film-like member 2 through the opening 22 from the back side of the protective device 21, and then adhering the bottommost film-like member 2a to the periphery of the opening 22 via the adhesive layer 23. As a result, the film laminate 1 can be attached to the protective device 21, as shown in Figure 17(B).

[0103] The film-like members 2 are laminated by a loop member 6 or hook member 9 provided on one side engaging with a hook member or loop member provided on the other side of an adjacent, opposing film-like member 2. However, it is not determined which film-like member 2 is provided with the loop member 6 or hook member 9. For convenience, the drawings of this application are denoted as "6·9" to indicate the state in which the loop member 6 provided on one film-like member 2 is engaged with the hook member 9 provided on the other film-like member 2.

[0104] Furthermore, as shown in Figure 18, loop members 6 and hook members 9 may be used instead of bonding with adhesive layer 23. In the configuration shown in Figure 18, either loop member 6 or hook member 9 is provided on the outer edge of the back side of the opening 22 and on the bottommost film-like member 2a. For convenience, the drawings of this application are denoted as "6 / 9" to indicate that either loop member 6 or hook member 9 is provided. The other of either loop member 6 or hook member 9 is provided at an opposing position.

[0105] As shown in Figure 19, the bottommost film-like member 2a may be attached to the surface side of the protective device 21. In this case, an adhesive layer 23 made of double-sided tape or the like is provided on the outer edge of the surface side of the opening 22. The film laminate 1 then adheres the bottommost film-like member 2a to the periphery of the opening 22 via the adhesive layer 23. In the configuration shown in Figure 19, the intermediate film-like member 2b and the topmost film-like member 2c can be made with an area larger than the opening 22. In the configuration in which the bottommost film-like member 2a is attached to the surface side of the protective device 21, as shown in Figure 20, a loop member 6 and a hook member 9 may be used instead of the adhesive layer 23.

[0106] Alternatively, as shown in Figure 21, the film-like member 2a may be connected to the opening 22 of the protective device 21 (Figure 21(A)), then the intermediate layer film-like member 2b may be laminated (Figure 21(B)), and then the uppermost layer film-like member 2c may be laminated (Figure 21(C)) to form a film laminate 1 and a protective device 21 equipped with the film laminate 1.

[0107] [Another example of a film laminate configuration 1] Next, another example of the configuration of the film laminate 1 will be described. Figure 22 is a cross-sectional view showing another example of the configuration of a film laminate to which this technology is applied, where (A) shows the state before lamination of the film-like member 2 and (B) shows the state after lamination of the film-like member 2. Figure 23 is a cross-sectional view showing the process of attaching the film laminate 25 shown in Figure 22 to a protective device, where (A) shows the state before attachment of the film laminate 25 and (B) shows the state after attachment of the film laminate 25.

[0108] The film laminate 25 shown in Figure 22 has a first engaging member which is a recessed member 26 provided on one of the film-like members 2, and a second engaging member which is a convex member 27 provided on the other film-like member 2 that fits detachably into the recessed member 26. The film-like members 2 and the other film-like member 2 are held apart by a gap between them and laminated by the fitting of the recessed member 26 and the convex member 27.

[0109] The recessed material 26 and the convex material 27 are not tightly fitted together but partially interlocked, and there is a gap between the fitted portion of the recessed material 26 and the convex material 27, allowing for ventilation. Therefore, the film laminate 25 can allow sterilization gas to pass between the recessed material 26 and the convex material 27 when the recessed material 26 and the convex material 27 are fitted together, i.e., when the film-like material 2 is laminated. The film-like material 2 is peeled off by disengaging the recessed material 26 and the convex material 27. At this time, since the fitted portion of the breathable recessed material 26 and the convex material 27 has been sterilized, the sterilized recessed material 26 and the convex material 27 are exposed.

[0110] Examples of the detachably fitting recessed member 26 and convex member 27 include, for example, a snap button as shown in Figure 24. There are no particular restrictions on the material of the recessed member 26 and convex member 27; for example, they can be made of resin or metal.

[0111] The recessed member 26 and the convex member 27 are positioned opposite each other when the film-like members 2 are laminated. The recessed member 26 and the convex member 27 are fixed to the film-like members 2 by a fixing material 10 such as an adhesive or adhesive tape. The fixing force of this fixing material 10 is higher than the engagement force of the recessed member 26 and the convex member 27. Therefore, when the film-like members 2 are peeled off, the fitted recessed member 26 and the convex member 27 will not be separated at the interface of one or the other film-like members 2, and a sterilized surface can always be exposed. In addition, when the film-like members 2 are peeled off, the fixing material 10 itself will not undergo cohesive failure between the fixing layers.

[0112] The formation positions of the recessed material 26 and the convex material 27 should be such that they can stably hold and laminate the film-like material 2 with gaps between them, do not obstruct the user's view when attached to the protective device 21, and allow for easy peeling of the film-like material 2. For example, they can be provided on the outer edge of the film-like material 2. Furthermore, there are no particular restrictions on the number of recessed material 26 and convex material 27 installed, as long as they can stably laminate and hold the film-like material 2.

[0113] As shown in Figure 23, the film laminate 25 is attached to the protective device 21 by bonding the bottommost film-like member 2a to an adhesive layer 23 provided on the outer edge of the back side of the opening 22. However, the film laminate 25 may also be attached to the front side of the protective device 21. Furthermore, instead of the adhesive layer 23, a recessed member 26 and a convex member 27 may be used as means for attaching the film laminate 25 to the back or front side of the protective device 21.

[0114] [Another example of a film laminate configuration 2] The recessed member 26 and the convex member 27 may be fixed to the film-like member 2 by sandwiching the film-like member 2 between them. The recessed member 26 shown in Figure 25(A) consists of a base 26b with a projection 51 erected on a circular substrate 50, and a lid 26a with a fitting recess 53 formed around an insertion hole 52 through which the projection 51 is inserted. The lid 26a has an insertion hole 52 on the bottom surface of the fitting recess 53. The projection 51 of the base 26b is inserted through the hole provided in the film-like member 2 (Figure 25(B)), and the tip of the projection 51 is inserted through the insertion hole 52 of the lid 26a from the opposite side (Figure 25(C)). The tip of the projection 51 is slightly thicker than the insertion hole 52 and has a slit in the longitudinal direction, giving it flexibility in the radial direction. Therefore, the tip of the projection 51 inserted through the insertion hole 52 of the lid 26a engages with the area around the insertion hole 52, thereby sandwiching the film-like member 2 between the lid 26a and the base 26b.

[0115] The convex member 27 shown in Figure 25(A) consists of a base 27b with a projection 56 erected on a substrate 55, and a lid 27a with a cylindrical fitting projection 57 formed thereon. The lid 27a has an insertion hole in the bottom surface of the fitting projection 57 through which the projection 56 is inserted. The projection 56 of the base 27b is inserted into a hole provided in the film-like member 2 (Figure 25(B)), and the tip of the projection 56 is inserted into the insertion hole of the lid 27a from the opposite side (Figure 25(D)). The tip of the projection 56 has radial flexibility, similar to the projection 51. Therefore, the tip of the projection 56 that has been inserted into the insertion hole of the lid 27a engages with the area around the insertion hole, thereby sandwiching the film-like member 2 between the lid 27a and the base 27b.

[0116] The open end of the fitting recess 53 of the recessed member 26 is provided with an inwardly protruding portion. On the other hand, the tip of the fitting projection 57 of the convex member 27 is provided with an outwardly protruding portion. As a result, when the fitting projection 57 is inserted into the fitting recess 53, the respective protruding portions engage, allowing the recessed member 26 and the convex member 27 to be fitted together.

[0117] As shown in Figure 26(A), the film-like members 2 can be laminated by fixing the recessed member 26 to one of the adjacent film-like members 2 and the convex member 27 to the other, and then fitting the recessed member 26 and the convex member 27 together. As shown in Figure 26(B), the fitting recess 53 of the recessed member 26 and the fitting convex portion 57 of the convex member 27 fit together only partially without being tightly attached, and there is also a gap between the respective covers 26a and 27a of the recessed member 26 and the convex member 27, allowing for ventilation. Therefore, the film laminate 25 allows sterilization gas to be passed between the recessed member 26 and the convex member 27 when the recessed member 26 and the convex member 27 are fitted together, i.e., when the film-like members 2 are laminated. The film-like members 2 can be peeled off by releasing the fitting recess 53 of the recessed member 26 and the fitting convex portion 57 of the convex member 27. At this time, since the fitting portion of the breathable recessed material 26 and the convex member 27 is sterilized, the sterilized recessed material 26 and convex member 27 are exposed.

[0118] Figure 26(B) shows a film laminate 1 formed by laminating two layers of film-like members 2. Figure 26(C) shows a film laminate 1 formed by laminating three layers of film-like members 2. In this way, when laminating three or more layers of film-like members 2, the recessed member 26 and the protruding member 27 are fixed so that the fitting recesses 53 or fitting protrusions 57 face both sides of the film-like member 2 constituting the intermediate layer.

[0119] [Another example of a film laminate configuration 3] Alternatively, a fastener 30 as shown in Figure 27 may be used as the first and second engaging members that can be engaged and disengaged. In this case, one piece 30a of the fastener 30 is fixed along the side edge of one of the film-like members 2, and the other piece 30b of the fastener 30 is fixed along the side edge of the other film-like member 2. The pair of film-like members 2 are laminated with a gap between them when the fastener is closed. Furthermore, the two pieces 30a and 30b of the fastener 30 engage without being in close contact, and there is a gap between the engaging portions of the two pieces 30a and 30b, allowing for ventilation.

[0120] Therefore, sterilization gas can be passed through the zipper 30 when it is closed, that is, when the film-like members 2 are stacked. The film-like members 2 are peeled off when the zipper 30 is opened. At this time, since the engaging portion of the breathable zipper 30 is sterilized, both sterilized pieces 30a and 30b of the zipper 30 are exposed. [Examples]

[0121] Next, embodiments of this technology will be described. In each of the following embodiments, a film laminate sample was prepared as an example sample, in which film-like members 2 were laminated using loop members 6 and hook members 9 as first and second engaging members, and a film laminate sample was prepared as a comparative example sample, in which film-like members 2 were joined and laminated with an adhesive.

[0122] [First Embodiment] In the first embodiment, the peel force (peel strength [N / 25mm]) was measured and evaluated by changing the structure of the film-like member and the lamination method of the film-like member. In addition, the transmittance [%] and haze [%] of each film laminate sample were measured.

[0123] (Peel strength) Each film laminate sample used in the peel strength test was made by laminating a pair of rectangular film-like members (hereinafter referred to as "first film 31" and "second film 32"). The lamination method involved full film application using loop members 6 and hook members 9 or adhesive film 30, each having base materials 4 and 7 of the same size as the first film 31 and second film 32 (see Figure 28).

[0124] The peel strength [N / 25mm] was determined by a 90° low-speed peel test using an IMADA force gauge (DST-20N) (see Figure 29). The measurement conditions were a tensile speed of 200 mm / sec. The measurement sample size was 25 × 150 mm. Peelability was evaluated by sensory assessment of how easily the material peeled in the TD direction, and was rated as ◎ (excellent), ○ (good), △ (average), and × (poor) in order of ease of peeling.

[0125] (Transmittance / Haze) Transmittance [%] and haze [%] were determined using a haze meter (HM-150N) manufactured by Murakami Color Technology Laboratory Co., Ltd., using the double-beam method (JIS K 7361, JIS K 7136). A φ150 mm integrating sphere was used. The measurement sample was a film laminate in which both side edges of a 50 × 50 mm first film and a second film were laminated with 12.5 mm wide loop members 6 and hook members 9, or adhesive film 30.

[0126] (GAP) The gap (in mm) between the first and second films, i.e., the width of the void, was measured. The void was determined by subtracting the thickness of the first and second films from the thickness of the laminated sample using a Mitutoyo M-type standard caliper N30.

[0127] (Example 1) In Example 1, a first film 31, which had a moth-eye structure on a 188 μm thick PET (Polyethyleneterephthalate) substrate, and a second film 32, which also had a moth-eye structure on a 188 μm thick PET substrate, were laminated using a loop member 6 and a hook member 9 to obtain a film laminate sample. In Example 1, a hook member 9 having a mushroom-shaped hook 5 (hereinafter sometimes referred to as "loop / hook 1") was used.

[0128] (Example 2) In Example 2, a first film 31, which had a moth-eye structure on a PET substrate with a thickness of 188 μm, and a second film 32, which had a moth-eye structure on a PC (polycarbonate) substrate with a thickness of 150 μm, were laminated using a hook member 9 (loop / hook 1) having a loop member 6 and a mushroom-shaped hook 5 to obtain a film laminate sample.

[0129] (Example 3) In Example 3, a first film 31, which had a moth-eye structure on a 150 μm thick PC substrate, and a second film 32, which also had a moth-eye structure on a 150 μm thick PC substrate, were laminated using a hook member 9 (loop / hook 1) having a loop member 6 and a mushroom-shaped hook 5 to obtain a film laminate sample.

[0130] (Example 4) In Example 4, a first film 31 made of PET with a thickness of 188 μm and a second film 32 made of PET with a thickness of 188 μm were laminated using a hook member 9 (loop / hook 1) having a loop member 6 and a mushroom-shaped hook 5 to obtain a film laminate sample.

[0131] (Example 5) In Example 5, a first film 31, which had a moth-eye structure on a PET substrate with a thickness of 188 μm, and a second film 32, which also had a moth-eye structure on a PET substrate with a thickness of 188 μm, were laminated using a loop member 6 and a hook member 9 to obtain a film laminate sample. In Example 5, a hook member 9 having a hook-shaped hook 5 (hereinafter sometimes referred to as "loop / hook 2") was used.

[0132] (Example 6) In Example 6, a first film 31, which had a moth-eye structure on a 150 μm thick PC substrate, and a second film 32, which also had a moth-eye structure on a 150 μm thick PC substrate, were laminated using a loop member 6 and a hook member 9 (loop / hook 2) having a hook-shaped hook 5 to obtain a film laminate sample.

[0133] (Comparative Example 1) In Comparative Example 1, a first film 31, which had a moth-eye structure on a PET substrate with a thickness of 188 μm, and a second film 32, which also had a moth-eye structure on a PET substrate with a thickness of 188 μm, were laminated by attaching both side edges with an adhesive film 30 to obtain a film laminate sample.

[0134] [Table 1]

[0135] As shown in Table 1, the film laminate samples from Examples 1-4 using Loop / Hook 1 had a lower average peel strength compared to the film laminate samples from Examples 5 and 6 using Loop / Hook 2. Furthermore, they were found to have superior peelability. The hook member 9 in Loop / Hook 1 is flexible, and the mushroom shape of the hook 5 is thought to contribute to this flexibility and ease of peeling.

[0136] The average peel strength of the laminated sample in Comparative Example 1, which used an adhesive, was equivalent to that of the film laminated samples in Examples 1-4, which used Loop / Hook 1, but with less variation. In the evaluation of ease of peeling, Comparative Example 1 felt heavier in peel strength compared to Examples 1-4. In other words, it was found that greater variation in peel strength indicates superior ease of peeling.

[0137] Furthermore, comparing Example 1 and Example 4, both using the same film substrate (PET) and laminated with loop / hook 1, Example 1 shows superior transmittance and haze. This indicates that the moth-eye structure has a high visibility effect. It also shows that providing the moth-eye structure on a PC substrate results in higher transmittance than providing the moth-eye structure on a PET substrate.

[0138] [Second Example] In the second embodiment, the peel force (peel strength [N / 25mm]) was measured and evaluated by changing the lamination means and the width dimension of the lamination means. Each film laminate sample was formed by laminating a first film 31, which had a moth-eye structure on a PET substrate with a thickness of 188 μm, and a second film 32, which also had a moth-eye structure on a PET substrate with a thickness of 188 μm. The lamination means used was either a loop member 6 and a hook member 9, or an adhesive film 30. The size of the first and second films 31 and 32 was 25 × 150 mm. The measurement conditions and evaluation conditions for peel strength were the same as in the first embodiment described above.

[0139] (Example 1) In Example 1, as shown in Figure 30(A), a film laminate sample was obtained using a loop / hook 1 with substrate dimensions of 25 × 150 mm.

[0140] (Example 7) In Example 7, as shown in Figure 30(B), a film laminate sample was obtained using a loop / hook 1 with substrate dimensions of 12.5 × 150 mm. The loop member 6 and hook member 9 were attached approximately to the center of the first and second films in the width direction.

[0141] (Example 5) As described above, in Example 5, a film laminate sample was obtained using a loop / hook 2 with substrate dimensions of 25 × 150 mm.

[0142] (Example 8) In Example 8, a film laminate sample was obtained using a loop / hook 2 with base material dimensions of 12.5 × 150 mm. The loop member 6 and hook member 9 were attached approximately to the center of the first and second films in the width direction.

[0143] (Comparative Example 1) As described above, in Comparative Example 1, the first film 31 and the second film 32 were laminated together by bonding their entire surfaces with an adhesive film 30 of the same size to obtain a film laminate sample.

[0144] (Comparative Example 2) Comparative Example 1 involved laminating a first film 31 and a second film 32 with an adhesive film having a width of 12.5 mm, which is half the width of the first and second films, to obtain a laminated film sample. The adhesive film was attached approximately to the center of the first and second films 31 and 32 in the width direction.

[0145] [Table 2]

[0146] As shown in Table 2, regardless of the lamination method, reducing the width by half reduces the peel strength by approximately 40-60%. In other words, it can be seen that the peel strength can be controlled by adjusting the width of the lamination method, and it is possible to set the optimal peel strength according to the application.

[0147] [Third embodiment] In the third embodiment, film laminate samples were prepared by changing the lamination method and the fixing position of the lamination method, and the sterilization effect was verified by exposing them to a sterilization gas. Ethylene oxide gas (EOG) was used as the sterilization gas. A rectangular film measuring 100 x 120 mm was used as the film material. A sticker (sterilization label EO-L manufactured by NOF Corporation) that reveals the words "sterilized" when exposed to EOG was affixed to the center of the film material.

[0148] The sterilization conditions are as follows: Temperature: 50℃ Humidity: 50%RH Exposure time: 8 hours Chamber pressure: 100kPa, Depressurized pressure: -85kPa Flushing: 5 times

[0149] As a result, if the word "Sterilized" appeared, it was evaluated as ○ (Sterilization effect achieved), and if the word "Sterilized" did not appear, it was evaluated as × (Sterilization effect not achieved).

[0150] (Example 9) In Example 9, a first film 31 made of PET with a thickness of 188 μm and a second film 32 made of PET with a thickness of 188 μm were laminated using a hook member 9 (loop / hook 1) having a loop member 6 and a mushroom-shaped hook 5 to obtain a film laminate sample. As shown in Figure 31, in Example 9, the loop / hook 1 was provided at both ends in the longitudinal direction of the first and second films.

[0151] (Example 10) Example 10 was the same as Example 9, except that the loop / hook 1 was provided so as to surround the entire circumference of the side edges of the first and second films, as shown in Figure 32.

[0152] (Example 11) Example 11 was the same as Example 9, except that loop / hook 2 was used as the stacking means.

[0153] (Comparative Example 3) Comparative Example 3 was the same as Example 10, except that an adhesive film 30 was used as the lamination method.

[0154] [Table 3]

[0155] As shown in Table 3, in Example 10, where loops / hooks 1 were provided to surround all four longitudinal sides of the first and second films, the words "Sterilized" appeared on the seal in the center, confirming the sterilization effect (Figure 33). This indicates that the loops / hooks 1 are breathable, allowing for sterilization of the void in the center of the film-like material, and that the loops / hooks 1 themselves are also sterilized. On the other hand, in Comparative Example 3, where adhesive was provided to surround all four longitudinal sides of the first and second films, the words "Sterilized" did not appear on the seal in the center, confirming that sterilization was not possible (Figure 34). Therefore, when the first and second films are separated, the unsterilized areas are exposed.

[0156] In Example 9, where loops / hooks 1 were provided at both ends in the longitudinal direction of the first and second films, and in Example 11, where loops / hooks 2 were provided, the sterilization effect was confirmed. [Explanation of Symbols]

[0157] 1 Film laminate, 2 Film-like member, 4 Base material, 5 Loop, 6 Loop member, 7 Base material, 8 Hook, 9 Hook member, 10 Fixing material, 11 Substrate, 12 Structure, 13 Base layer, 20 Tab, 21 Protective device, 23 Adhesive layer, 25 Film laminate, 26 Recessed material, 27 Convex member, 30 Adhesive, 31 First film, 32 Second film, 34 Hook member, 35 Adhesive, 36 Transfer material, 37 Energy source, 41 Roll master disc, 42 Structure

Claims

1. Multiple film-like members laminated in a peelable manner, It has a first engaging member fixed to one of the pair of film-like members, and a second engaging member fixed to the other of the pair of film-like members, The first engaging member and the second engaging member are detachably engaged, so that a pair of the film-like members are laminated with a gap between them. The engagement portion of the first engagement member and the second engagement member described above is a breathable film laminate.

2. The first engaging member described above is a loop member in which a plurality of loops are erected on one surface of the base material. The second engaging member described above is a hook member having a plurality of hooks erected on one surface of the base material that are detachably engaged with the loop described above. The film laminate according to claim 1, wherein the film-like members are laminated with a gap between them by the engagement of the loop member and the hook member.

3. The film laminate according to claim 2, wherein the peeling force of the loop member and hook member that laminate the upper film-like members together is relatively lower than the peeling force of the loop member and hook member that laminate the lower film-like members together.

4. The film laminate according to any one of claims 1 to 3, wherein the engagement force of the first engagement member and the second engagement member is lower than the fixing force between the first engagement member and the film-like member, and is lower than the fixing force between the second engagement member and the film-like member.

5. The first engaging member described above is a recessed member, The second engaging member described above is a convex member that fits detachably into the concave member, The film laminate according to claim 1, wherein the film-like members are laminated with a gap between them by fitting the recessed member and the convex member.

6. The film laminate according to claim 5, wherein the peeling force of the recessed material and the convex material used to laminate the upper film-like members is relatively lower than the peeling force of the recessed material and the convex material used to laminate the lower film-like members.

7. The film laminate according to any one of claims 1 to 3, 5, or 6, wherein the first engaging member and the second engaging member are each provided on the outer edge of the film-like member.

8. The film laminate according to any one of claims 1 to 3, 5, or 6, wherein the first engaging member and the second engaging member are each provided so as to surround the outer edge of the film-like member.

9. The film laminate according to any one of claims 1 to 3, 5, or 6, wherein each of the above-mentioned film-like members, the first engaging member, and the second engaging member has a surface exposed to the outside that has been sterilized.

10. The above-mentioned film-like member is a film laminate according to any one of claims 1 to 3, 5, or 6, wherein a plurality of structures are provided on at least one surface of a flexible transparent substrate at a pitch less than or equal to the wavelength of visible light.

11. A process for forming a film-like member, A step of forming a first engaging member and a second engaging member that engage detachably, The process involves fixing the first engaging member to a position on one of the pair of film-like members facing the other film-like member, and fixing the second engaging member to a position on the other film-like member facing the first film-like member, A method for manufacturing a film laminate, comprising the step of locking the first engaging member and the second engaging member together and laminating a pair of the film-like members with an air gap between them.

12. A method for manufacturing a film laminate according to claim 11, comprising the step of sterilizing a plurality of the above-mentioned film-like members in a laminated state.

13. In protective equipment in which a film laminate is attached to the user's face or around the eyes, The above-mentioned film laminate is a protective device according to any one of claims 1 to 3, 5, or 6.

14. The protective equipment according to claim 15, wherein the protective equipment is any one of a protective suit, a face shield, an eye shield, or a helmet.

15. In a method for manufacturing protective equipment in which a film laminate is attached to the user's face or around the eyes, The process of forming a film laminate, The process includes attaching the film laminate to a protective device. A method for manufacturing protective equipment, wherein the above-mentioned film laminate is as described in any one of claims 1 to 3, 5, or 6.

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