Pressure Sensitive Adhesive Sheet Coextrusion with Noncrosslinked Resin
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Solution Overview
Problem
The existing methods of manufacturing pressure sensitive adhesive sheets through coextrusion molding face challenges with autohesion of resin pellets, leading to unstable supply and quality issues due to the requirement for small particle diameter autohesion preventing agents, which are difficult to manage and affect transparency.
Innovation Solution
Incorporating a noncrosslinked-type resin as an autohesion preventing agent with compatibility to the main resin, allowing it to dissolve in the molten state and maintain compatibility even with larger particle diameters, thereby stabilizing the adhesive layer formation without strict particle size control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small particle diameter autohesion preventing agents (2.5 μm or less) are used to prevent pellet autohesion in the hopper, then pellet supply stability is improved, but manufacturing complexity and difficulty of material management increase
Solution Approach 1:
The invention changes the particle diameter parameter of the autohesion preventing agent from the conventional 2.5 μm or less to 2.5 μm or more. This parameter change resolves the contradiction by enabling effective autohesion prevention while avoiding the management difficulties associated with ultra-fine particles. The larger particles are easier to handle, store, and incorporate into the resin composition without requiring special precautions against agglomeration.
Solution Approach 2:
The invention uses a readily available, easy-to-manage powder material as the autohesion preventing agent instead of requiring precisely controlled ultra-fine particles. This approach treats the autohesion preventing agent as a simple additive that can be easily incorporated into the resin composition, reducing the complexity of material management while maintaining pellet supply stability.
2Reliability
If small particle diameter autohesion preventing agents (2.5 μm or less) are used, then pellet autohesion is prevented, but transparency of the pressure sensitive adhesive layer deteriorates
Solution Approach 1:
The invention changes the particle diameter parameter from 2.5 μm or less to 2.5 μm or more. This resolves the contradiction between autohesion prevention effectiveness and transparency because larger particles can be effectively incorporated into the resin composition without causing the same level of light scattering that would occur with ultra-fine particles, thereby maintaining or improving transparency while still preventing pellet autohesion.
3Reliability
If powder with average particle diameter of 2.5 μm or less is used as autohesion preventing agent, then pellet autohesion is prevented, but powder agglomeration occurs and supply stability deteriorates
Solution Approach 1:
The invention changes the particle diameter parameter to 2.5 μm or more, which fundamentally resolves the agglomeration problem. Larger particles have lower surface area to volume ratios, reducing interparticle forces that cause agglomeration. This parameter change enables stable powder handling and consistent incorporation into the resin composition while maintaining effective autohesion prevention functionality.
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
This approach enhances the productivity and quality of the pressure sensitive adhesive sheets by reducing the impact of particle diameter on adhesive layer properties, ensuring uniformity and transparency, and preventing autohesion, thus stabilizing the manufacturing process.
Implementation Method 1
the first resin is a noncrosslinked-type resin having compatibility with a main resin contained in a second resin composition... the first resin is supplied as a powder when the second resin composition is prepared
Data Source
Figure 1~2
AI summary
An object is to provide a method of manufacturing a laminate structure comprising a pressure sensitive adhesive sheet that can reduce the upper limit of the average particle diameter of powder capable of functioning as the autohesion preventing agent, and a laminate structure comprising such a pressure sensitive adhesive sheet. [Solving means] A method of manufacturing a laminate structure including a pressure sensitive adhesive sheet (1) is provided. The pressure sensitive adhesive sheet (1) includes a base material (2) and a pressure sensitive adhesive layer (3) laminated on one surface of the base material (2). The method includes a first coextrusion molding step of performing coextrusion molding of a first resin composition for forming the base material (2) and a second resin composition for forming the pressure sensitive adhesive layer (3) thereby to obtain a first laminate as the pressure sensitive adhesive sheet (1). The first laminate is formed such that the base material (2) and the pressure sensitive adhesive layer (3) are laminated on each other. The second resin composition contains a main resin and a first resin that is a noncrosslinked-type resin having compatibility with the main resin. The first resin is supplied as a powder when the second resin composition is prepared.