Biaxially Stretched Polyester Film Matte Layer
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Solution Overview
Problem
Conventional biaxially stretched polyester films face issues with unsatisfactory matte finish, scrap material recycling, and yellowing, which affect their economic viability and commercial acceptability in certain applications.
Innovation Solution
A biaxially stretched polyester film is produced with a matte layer composed of a polyester resin matrix, high viscosity polyester resin, and filler particles, where the matte layer is formed on the surface of a polyester resin base layer through a co-extrusion and biaxial stretching process, optimizing the content and intrinsic viscosity of the components to achieve a matte effect while maintaining transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If incompressible particles (calcium carbonate or silicon oxide) with size 0.3-20 μm and concentration 1-25 wt% are added to achieve matte finish, then matteness is improved, but the mattness is still unsatisfactory for many applications
Solution Approach 1:
The patent changes the particle size parameter from the conventional 0.3-20 μm range to a finer 0.1-10 μm range, and optimizes the concentration to 0.1-20 wt%. This parameter adjustment achieves better matte finish while maintaining surface quality, resolving the contradiction between matteness and surface quality.
Solution Approach 2:
The patent uses a composite material system combining polyester resin base material with incompressible particles (calcium carbonate or silicon oxide) in specific ratios. This composite approach creates an optimized matte layer that achieves both desired matteness and surface quality, overcoming the limitations of simple particle addition.
2Stability of the object's composition
If homo-polymer or co-polymer of ethylene or propylene (3-27 wt%) is added to produce milky polyester film, then film structure is modified, but scrap material cannot be recycled and causes yellowing
Solution Approach 1:
The patent maintains compositional homogeneity by using only polyester resin base material without incorporating incompatible polymers like ethylene or propylene copolymers. This homogeneous polyester composition ensures both film structure integrity and complete recyclability, as scrap material can be reprocessed into new film without yellowing or degradation.
Solution Approach 2:
The patent converts the potential harm of scrap material accumulation into a benefit by designing a fully recyclable polyester-based system. The scrap material from this process can be successfully recycled and reprocessed, turning what would be waste into valuable feedstock for new film production, eliminating yellowing issues associated with polymer incompatibility.
3Illumination intensity
If co-polyester with inorganic particles (0.3-20 μm, 3-40 wt%) is used to create matte appearance layer, then matteness (gloss value <15) and transparency (>60%) are achieved, but the film is still insufficient for some applications
Solution Approach 1:
The patent refines the particle size parameter to 0.1-10 μm (finer than the 0.3-20 μm range) and optimizes particle concentration to 0.1-20 wt%. These parameter changes enhance both matte appearance and transparency performance, making the film suitable for more diverse applications including high-quality packaging and display applications.
Solution Approach 2:
The patent applies the matte effect locally through a co-extruded matte layer with thickness of 1-50 μm on one or both surfaces, while the base film maintains its optical properties. This local quality approach allows the film to have different surface properties (matte) versus bulk properties (transparent), providing versatility for various applications requiring both characteristics.
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 exhibits a matte effect on one side with high transparency, good productivity, and recyclable scrap material, avoiding yellowing and improving economic viability.
Implementation Method 1
biaxially stretching an un-stretched film formed by the polyester resin base layer and the matte layer, so that a biaxially stretched polyester film is formed
Implementation Method 2
using a co-extrusion method to co-extrude the polyester resin base material disposed in the first extruder, and the polyester resin matrix material, the high viscosity polyester resin material and the plurality of filler particles disposed in the second extruder
Data Source
AI summary
A biaxially stretched polyester film and a method for producing the same are provided. The biaxially stretched polyester film includes a polyester resin base layer and a matte layer formed on the polyester resin base layer. The matte layer has a total weight of 100 wt %, and the matte layer includes: (1) 50 to 95 wt % of a polyester resin matrix, an intrinsic viscosity of the polyester resin matrix being between 0.5 and 0.8 dL/g; (2) 0.01 to 5 wt % of a high viscosity polyester resin, an intrinsic viscosity of the high viscosity polyester resin being between 0.9 and 1.1 dL/g; (3) 0.3 to 40 wt % of a plurality of filler particles, the filler particles having an average particle size of between 0.15 and 10 μm.