Multilayer Film Resin Layer for Flatness and Slippability
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Solution Overview
Problem
Existing laminated films struggle to achieve both high flatness and slippability while maintaining good releasability, as increasing particle content for slippability often reduces flatness and vice versa.
Innovation Solution
A laminated film with a resin layer on a particle-free base film surface, using an acid-modified polyolefin resin and a crosslinking agent, with specific surface roughness and height parameters, and a manufacturing method involving application and drying of a liquid resin layer formation material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If particles are added to the base film to enhance slippability, then the slippability of the base film surface is improved, but the flatness of the resin layer surface deteriorates
Solution Approach 1:
The patent introduces a resin layer as an intermediary between the base film and the adherend. This resin layer contains fine particles that provide slippability, while the base film itself remains substantially free of particles to maintain surface flatness. The resin layer acts as a mediator that delivers the slippability function without compromising the flatness required for high-precision electronic device manufacturing.
Solution Approach 2:
The patent applies local quality by concentrating particles specifically within the resin layer rather than distributing them throughout the base film. The base film maintains a particle-free composition for optimal flatness, while the resin layer contains fine particles (average diameter 1-10 μm) at a controlled content (0.1-5 parts by mass per 100 parts by mass of acid-modified polyolefin resin) to provide localized slippability where it is needed for film formation and processing.
2Manufacturing precision
If particle content in the base film is reduced to enhance flatness, then the flatness of the resin layer surface is improved, but the slippability of the base film surface deteriorates
Solution Approach 1:
The resin layer serves as an intermediary that carries the slippability function. By placing fine particles within the resin layer rather than the base film, the system achieves both flatness (from the particle-free base film) and slippability (from the particle-containing resin layer).
Solution Approach 2:
Particles are locally concentrated in the resin layer where slippability is required, while the base film remains particle-free for flatness. This spatial separation of particle distribution allows simultaneous optimization of both properties.
3Ease of operation
If particle content in the base film is increased to enhance slippability, then the slippability of the base film surface is improved, but the releasability from adherends deteriorates due to particle transfer
Solution Approach 1:
The resin layer acts as an intermediary barrier between the base film and adherend. It contains the fine particles needed for slippability while preventing their transfer to the adherend during peeling, thus maintaining both slippability and releasability.
Solution Approach 2:
Particles are confined to the resin layer with controlled content (0.1-5 parts by mass per 100 parts by mass of acid-modified polyolefin resin), providing slippability without excessive particle transfer. The base film remains particle-free to ensure clean releasability.
4Manufacturing precision
If the base film is made substantially free of particles to enhance flatness, then the flatness of the resin layer surface is improved, but the slippability during film formation and processing deteriorates
Solution Approach 1:
The resin layer serves as a mediator that provides slippability through fine particles while the base film maintains flatness by being substantially free of particles. This separation of functions resolves the contradiction between flatness and slippability.
Solution Approach 2:
The system uses local quality by concentrating particles in the resin layer rather than the base film. The base film has particle-free local quality for flatness, while the resin layer has particle-containing local quality for slippability.
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 film achieves excellent flatness and slippability, suitable for applications like protective films for double-sided tapes and adhesive materials, and process materials in LCD production, with improved releasability and slippability.
Implementation Method 1
a resin layer provided on at least one surface of the base film
Implementation Method 2
the resin layer contains an acid-modified polyolefin resin (A) and a crosslinking agent (C)
Data Source
AI summary
A laminated film including: a base film; and a resin layer provided on at least one surface of the base film, wherein a base film surface on which the resin layer is provided is substantially free of particles, the resin layer contains an acid-modified polyolefin resin (A) and a crosslinking agent (C), and a developed interfacial area ratio (Sdr) and a maximum height (Sz) in a surface of the resin layer measured by a non-contact surface profile measuring apparatus are 0.025 to 0.304% and 0.01 to 0.50 µm, respectively.