Biaxially Stretched Polyester Film Matte Layer Design
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Solution Overview
Problem
Conventional biaxially stretched polyester films face issues with unsatisfactory mattness, economical inefficiencies due to scrap material recycling challenges, and commercial unacceptability of yellowed films, as well as suboptimal performance in certain applications.
Innovation Solution
A biaxially stretched polyester film with a polyester resin base layer and a matte layer formed through co-extrusion, where the base layer contains a high viscosity polyester resin material and the matte layer includes filler particles, achieving a matte effect on one side while maintaining transparency, and allowing for recyclable production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If incompressible particles (calcium carbonate or silicon oxide) are added to polyethylene terephthalate to create matte finish, then the film achieves a matte appearance, but the degree of mattness is unsatisfactory for many applications
Solution Approach 1:
The patent changes the particle size parameter of the inorganic particles from the conventional 0.3-20 μm range to a finer 0.1-10 μm range, with particular emphasis on particles smaller than 1 μm. This parameter change results in significantly improved matte appearance while maintaining film quality, directly resolving the contradiction between achieving matte appearance and obtaining satisfactory degree of mattness
Solution Approach 2:
The patent creates a composite material system combining polyethylene terephthalate base resin with specifically sized inorganic particles (silicon oxide, calcium carbonate, or titanium oxide) at optimized concentrations of 0.1-10 wt%. This composite approach, with precise control of particle size and concentration, achieves superior matte appearance compared to conventional formulations, resolving the insufficiency of prior matte finishes
2Reliability
If homo-polymer or co-polymer of ethylene or propylene is added to polyester particles to produce milky polyester film, then the film achieves desired properties, but scrap material cannot be recycled and causes yellowing on the finally produced film
Solution Approach 1:
The patent extracts and eliminates the problematic homo-polymer or co-polymer of ethylene or propylene from the film formulation, replacing it with inorganic particles dispersed in polyethylene terephthalate. This removal of the problematic component enables scrap material to be recycled without causing yellowing, while the inorganic particle system maintains or improves film properties
Solution Approach 2:
The patent adopts inorganic particles (silicon oxide, calcium carbonate, titanium oxide) as replaceable additives that can be easily incorporated into the polyester matrix. These particles do not cause recycling issues or yellowing, making the film production process more economical and environmentally friendly compared to using organic copolymers
3Illumination intensity
If a transparent base layer with matte appearance layer is created using co-polyester and inert inorganic particles, then the film achieves high degree of matteness and transparency, but performance is still insufficient for some applications or markets
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: reduces inorganic particle size to 0.1-10 μm (particularly <1 μm), controls particle concentration at 0.1-10 wt%, and adjusts film thickness to 3-50 μm for the matte layer. These coordinated parameter changes achieve superior matte appearance with enhanced transparency and performance for demanding applications
Solution Approach 2:
The patent creates a localized matte layer with specific thickness (3-50 μm) and composition on one side of the film, while the base layer maintains high transparency. This local quality approach allows the matte effect to be concentrated where needed while preserving overall film performance for specific applications
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. The polyester resin base layer includes: (1) 50 to 95 wt % of a polyester resin base material, and an intrinsic viscosity of the polyester resin base material being between 0.5 and 0.8 dL/g; and (2) 0.01 to 5 wt % of a high viscosity polyester resin material, and an intrinsic viscosity of the high viscosity polyester resin material being between 0.9 and 1.1 dL/g. The matte layer includes: (1) 50 to 95 wt % of a polyester resin matrix material, and an intrinsic viscosity of the polyester resin matrix material being between 0.5 and 0.8 dL/g; and (2) 0.3 to 40 wt % of a plurality of filler particles, and the filler particles having an average particle size of between 0.15 μm and 10 μm.