Functional Film Primer Structure for Filler-Rich Layer Adhesion
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Solution Overview
Problem
The challenge is to improve the close contact between a substrate and a functional layer in functional films, particularly when the functional layer contains inorganic filler particles, while maintaining the desired functional properties without compromising the thickness of the film.
Innovation Solution
A functional film structure comprising a substrate made of acetyl cellulose resin, a primer layer with silica particles, and a functional layer also containing silica particles, where a permeation layer is formed by resin permeation into the substrate, ensuring close contact and optimal thickness and particle distribution of the primer and functional layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a primer layer is disposed between the substrate and functional layer to improve close contact, then adhesion is improved, but the thickness of the functional layer must be reduced, causing the number of filler particles to decrease and functional properties to deteriorate
Solution Approach 1:
The primer layer and functional layer are merged into a single integrated layer, eliminating the need for a separate primer layer while maintaining both adhesion and functional properties. This is achieved by formulating the functional layer with specific resin compositions that provide both bonding capability to the substrate and the required functional performance.
Solution Approach 2:
The functional layer is designed to perform multiple functions simultaneously: it provides adhesion to the substrate (replacing the primer layer function) and maintains the required functional properties through optimized filler particle content and distribution. This multi-functional design eliminates the need for a separate primer layer.
2Reliability
If filler particles are added to the functional layer to provide desired function, then functional properties are improved, but close contact between the functional layer and substrate deteriorates
Solution Approach 1:
The resin composition parameters of the functional layer are optimized to balance adhesion and functional properties. Specific resin types and ratios are selected to ensure proper wetting and bonding to the substrate while maintaining the necessary filler particle content for desired functional performance.
Solution Approach 2:
The functional layer uses a composite material system combining specific resins with inorganic filler particles. This composite formulation achieves both good adhesion to the substrate and the required functional properties through the synergistic interaction between the resin matrix and filler particles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the close contact between the substrate and functional layer, allowing the film to effectively exhibit its intended functions, such as anti-reflection or gas barrier properties, while maintaining transparency and structural integrity.
Implementation Method 1
the substrate has a permeation layer adjacent to the primer layer and formed by permeation of a resin contained in the primer layer into part of the substrate
Data Source
AI summary
A functional film 1 according to an embodiment includes: a substrate (10) containing an acetyl cellulose resin; a primer layer (20) containing a filler (40) and disposed on the substrate (10); and a functional layer (30) containing the filler (40) and disposed on the primer layer (20). The substrate (10) has a permeation layer (12) formed by permeation of the resin contained in the primer layer (20) into part of the substrate (10). The permeation layer (12) has a thickness of 0.1 μm or more and 3.5 μm or less. The primer layer (20) has a thickness of 0.1 μm or more and 1.0 μm or less. The filler (40) is silica particles having an average particle size of 20 nm or more and 80 nm or less. The filler (40) in the primer layer (20) has a density of ⅓ or more and ¾ or less of the density of the filler (40) in the functional layer (30). The primer layer (20) and the functional layer (30) each contain a resin. The resin component of the primer layer (20) is the same as the resin component of the functional layer 30.