Multilayered Polyester Film with Washable MLCC Release Layer
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Solution Overview
Problem
Existing methods for producing multilayer ceramic capacitors (MLCCs) result in significant environmental pollution due to discarded release films, as the release layers cannot be effectively reused, and current release films suffer from insufficient removability and coatability issues.
Innovation Solution
A multilayered polyester film with specific water contact angles, crystallinity, and surface roughness ratios, incorporating layers made of polyvinyl alcohol and dimethylsiloxane, allows for easy removal and reuse by washing, suitable for MLCC production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a release layer is provided on the polyester film to enable release function, then the releasability is improved, but the removability of the release layer becomes insufficient and the layer cannot be reused
Solution Approach 1:
The release film is divided into multiple functional layers: a polyester film base layer and a release layer with specific crystallinity (0-30%). This segmentation allows each layer to perform its specific function while enabling easy removal of the release layer after use, resolving the contradiction between maintaining releasability during use and enabling removability after use.
Solution Approach 2:
The release layer's degree of crystallinity is controlled within a specific range (0-30%). By optimizing this parameter, the release layer maintains sufficient releasability during the MLCC manufacturing process while also being easily removable afterward through washing, allowing the polyester film to be reused.
2Device complexity
If wax is used as release agent to simplify the structure, then the device complexity is reduced, but the coatability of ceramic slurry and releasability of green sheet become insufficient
Solution Approach 1:
Instead of using simple wax, the invention employs a composite release layer made of specific resin materials with controlled crystallinity. This composite structure provides both the necessary coatability for ceramic slurry application and sufficient releasability for green sheet removal, while maintaining relative structural simplicity.
3Ease of manufacture
If release film is cleaned using metal brush to remove release layer, then the removability is improved, but the release film cannot be uniformly cleaned and damage occurs
Solution Approach 1:
The invention replaces the mechanical cleaning method (metal brush) with a chemical/washing-based removal method. The release layer is designed to be removable through washing processes, providing uniform cleaning without mechanical damage to the polyester film substrate.
4Ease of manufacture
If water-soluble resin layer is provided between release layer and polyester film to improve removability, then the removability is improved, but the removability becomes insufficient
Solution Approach 1:
Instead of adding a water-soluble resin layer, the invention modifies the crystallinity parameter of the release layer itself (controlling it at 0-30%). This parameter optimization enables the release layer to be easily removable through washing without requiring additional water-soluble components, achieving both simplicity and effectiveness.
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 enables efficient removal and reuse of the polyester film, reducing environmental impact by allowing the release layers to be washed off, thus recycling the film for further use.
Implementation Method 1
a layer X which has a water contact angle HX(1) of 0° or higher and 60° or lower
Implementation Method 2
the layer X has a degree of crystallinity C(0) of 0% or more and 30% or less
Data Source
AI summary
A multilayered polyester film which comprises a polyester film and, disposed on at least one surface thereof, a layer X which has a contact angel HX(1) with water of 0-60°, wherein the layer X has a degree of crystallinity C(0) of 0-30%. HX(1): Contact angle at one second after water has come into contact with layer X. A polyester film having excellent recoverability is provided by disposing a layer X on at least one surface of a polyester film, the layer X having a regulated contact angle with water and a regulated degree of crystallinity.