Non-Silicone Release Sheet for Blocking-Resistant Adhesive Rolls
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Solution Overview
Problem
Conventional pressure-sensitive adhesive sheets using silicone-based release sheets face issues with silicone compound transfer, leading to poor conductivity and adverse effects on electric components like hard disk drives due to silicone deposition, and non-silicone-based alternatives suffer from poor releasability and blocking when wound up in a rolled form.
Innovation Solution
A release sheet with a polyolefin-based thermoplastic elastomer release agent layer, free from silicone compounds, having specific density and Young's modulus ranges, and a base material with controlled surface roughness to prevent silicone transfer and ensure superior releasability and blocking resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silicone resin is used as a release agent layer, then releasability is improved, but silicone compound transfer to the pressure-sensitive adhesive layer occurs causing contamination of electric components
Solution Approach 1:
The invention extracts and removes the silicone resin from the release agent layer composition, replacing it with a fluororesin-based material. This eliminates the source of silicone compound transfer to the pressure-sensitive adhesive layer while maintaining the release function through alternative chemistry (fluororesin instead of silicone resin).
Solution Approach 2:
The invention introduces a fluororesin as an intermediary substance between the base material and the pressure-sensitive adhesive layer. This fluororesin-based release agent layer serves as a mediator that provides the necessary release properties without transferring harmful silicone compounds to adjacent components.
2Object-generated harmful factors
If a non-silicone-based release agent is used to prevent silicone transfer, then contamination is reduced, but releasability becomes poor
Solution Approach 1:
The invention changes the chemical composition parameter of the release agent layer from silicone resin to fluororesin. This parameter change maintains the release function through different chemical mechanisms (fluororesin properties) while eliminating silicone compound transfer, thus resolving the contradiction between preventing contamination and maintaining releasability.
3Productivity
If the release sheet is wound up in a rolled form for storage, then storage efficiency is improved, but blocking and wrinkle occur on the release sheet
Solution Approach 1:
The invention utilizes the inherent flexibility of the thin film structure (release sheet with release agent layer) to enable rolled-form storage. The thin film nature allows the release sheet to be wound without excessive rigidity, improving storage efficiency while the controlled composition prevents blocking during the rolling process.
4Reliability
If the release agent layer contains silicone compound, then releasability is improved, but the silicone compound vaporizes and deposits on electric contact portions causing poor conductivity
Solution Approach 1:
The invention extracts and removes silicone resin from the release agent layer, replacing it with fluororesin. This eliminates the source of silicone compound vaporization and subsequent deposition on electric contact portions, while maintaining releasability through the fluororesin-based release mechanism.
Solution Approach 2:
The invention converts the potential harm of silicone compound transfer and deposition into a benefit by using fluororesin, which provides equivalent or superior release properties without the contamination issue. The fluororesin-based system transforms the problem of silicone transfer into an opportunity to use a more environmentally stable material.
Data Source
AI summary
A release sheet is provided. The release sheet comprises: a base material having one surface and the other surface; and a release agent layer provided on the one surface of the base material. The release agent layer contains substantially no silicone compound and is constituted of a polymer material containing a polyolefine-based thermoplastic elastomer of which density is in the range of 0.80 to 0.90 g/cm3. A Young's modulus of the release agent layer is in the range of 0.1 to 0.3 GPa. An arithmetic mean deviation of a profile Ra of the other surface of the base material is in the range of 100 to 1800 nm. This makes it possible to sufficiently suppress adverse effects on electric components and the like, prevent blocking from occurring when the release film is wound up in a rolled form and stored in this state, and exhibit superior releasability. A pressure-sensitive adhesive article is also provided.