Oriented Polyester Film Surface Layer with Modified Polyolefin Wax
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Solution Overview
Problem
Existing paint replacement films face a trade-off between achieving low coefficient of friction and adhesiveness to functional layers, with the addition of waxes causing processing temperature increases and poor external appearance due to resin degradation.
Innovation Solution
An oriented polyester film with a surface layer containing antioxidant and modified polyolefin wax, where the wax is laminarly dispersed and possesses specific functional groups, acid values, and molecular weights to balance adhesiveness and friction, ensuring excellent adhesion without resin degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wax is added to polyester to reduce coefficient of friction, then moldability is improved, but processing temperature increases and resin degradation occurs causing poor external appearance
Solution Approach 1:
The patent applies parameter changes by carefully controlling the wax content within a specific range (0.01-5 wt%) and selecting waxes with specific melting points (50-150°C) and molecular weights (1000-50000). This optimization allows the wax to provide sufficient lubrication for moldability while preventing excessive processing temperature increases that would cause resin degradation. The antioxidant content is also controlled (0.003-1 wt%) to prevent oxidation during processing.
Solution Approach 2:
The patent uses composite materials by combining polyester with specific types of waxes (polyolefin wax, polyalphaolefin wax, montan wax, or ozokerite) and antioxidants in controlled proportions. This composite approach allows the wax to provide lubrication benefits while the antioxidant protects the resin from degradation, and the controlled composition ensures the processing temperature increase remains within acceptable limits.
2Ease of operation
If wax is added to achieve low coefficient of friction, then moldability is improved, but adhesiveness to functional layers deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the wax content within a narrow range (0.01-5 wt%) and selecting waxes with specific properties (melting point 50-150°C, molecular weight 1000-50000). This precise control ensures sufficient lubrication for moldability while maintaining adequate adhesiveness to functional layers like printing layers and hard coat layers.
Solution Approach 2:
The patent uses composite materials by combining polyester with specific types of waxes and antioxidants in controlled proportions. The antioxidant component (0.003-1 wt%) helps maintain adhesion by preventing oxidation that would compromise the bonding between the film and functional layers, while the wax provides necessary lubrication.
3Stability of the object's composition
If processing temperature is increased to add wax component, then wax dispersion is improved, but external appearance deteriorates due to resin degradation
Solution Approach 1:
The patent applies parameter changes by selecting waxes with specific melting points (50-150°C) that are lower than the polyester processing temperature. This allows the wax to melt and disperse uniformly during processing without requiring excessive temperature increases that would cause resin degradation. The wax content is controlled (0.01-5 wt%) to ensure adequate dispersion while preventing processing temperature from rising too high.
Solution Approach 2:
The patent uses an antioxidant as an intermediary substance (0.003-1 wt%) that protects the polyester resin from oxidation and degradation during the heating and processing required for wax dispersion. The antioxidant acts as a mediator that allows the necessary thermal processing to occur without causing harmful resin degradation that would affect external appearance.
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 high adhesiveness to functional layers while maintaining a low coefficient of friction, preventing resin degradation and ensuring a good external appearance, making it suitable for molding complex shapes like car exterior parts.
Implementation Method 1
Well-known as a method for achieving such a low coefficient of friction is the inclusion therewithin of waxes which are referred to as lubricants
Implementation Method 2
addition of certain wax(es) makes it possible to achieve both adhesiveness and low coefficient of friction without producing poor external appearance due to occurrence of defects and/or degradation of resin during formation into polyester film
Implementation Method 3
there has been a desire to achieve adhesion with respect to any of various functional layers including hard coat layers and printing layers
Data Source
AI summary
An oriented polyester film containing antioxidant and modified polyolefin wax in a surface layer on at least one side thereof, wherein the oriented polyester film is such that the modified polyolefin wax contained in said layer is present in an amount that, as measured based on weight of a composition at said layer, is not less than 0.1 wt % but less than 3.0 wt %, and wherein the modified polyolefin wax is such that acid value thereof is not less than 1 mg KOH/g but less than 50 mg KOH/g, 3 wt % weight loss onset temperature thereof is not less than 300° C., weight-average molecular weight thereof is within a range that is 3,500 to 65,000, and the antioxidant is present in an amount that, as measured based on the weight of the composition, is not less than 0.02 wt % but less than 0.35 wt %.