Release Film Surface Roughness Control for Blocking and Static
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Solution Overview
Problem
Release films used in laminated ceramic capacitors face issues with surface roughness leading to defects like blocking and static electricity generation when wound up, which affects their unwinding and ceramic slurry coating processes.
Innovation Solution
A release film with a base material having a releasing agent layer on one surface and an antistatic layer on the other, both composed of the same material, with specific surface roughness and thickness ranges to prevent blocking and static electricity, using a polyester resin base material and a laminated structure with fillers to enhance adhesiveness and smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the surface roughness of the releasing agent layer is reduced to prevent defects like repellent of slurry or formation of pinholes, then the smoothness of the releasing agent layer is improved, but blocking occurs when the release film is wound up in a rolled form
Solution Approach 1:
The invention applies different surface roughness characteristics to different surfaces of the release film. The releasing agent layer (first surface) is made smooth (Ra1 ≤ 15 nm) to prevent slurry defects, while the antistatic layer (second surface) is made relatively rough (Ra2 ≥ Ra1) to prevent blocking during winding. This local differentiation of surface properties resolves the contradiction between smoothness and blocking prevention.
Solution Approach 2:
The invention resolves the surface roughness contradiction by introducing a new dimension - the second surface of the base material with an antistatic layer. Instead of trying to make the entire film uniformly smooth or uniformly rough, the solution adds another surface with opposite roughness characteristics, allowing both requirements to be satisfied simultaneously on different surfaces.
2Object-generated harmful factors
If the surface roughness of the base material surface (without releasing agent layer) is set to a relatively high value to prevent blocking, then blocking is prevented, but static electricity is generated when the wound up release film is unwound
Solution Approach 1:
The invention changes the material parameter of the second surface by adding an antistatic layer containing antistatic agents. This material modification allows the surface to have relatively high roughness (Ra2 ≥ Ra1) for blocking prevention while simultaneously possessing antistatic properties (Ra2 in range of 10 to 50 nm) to prevent static electricity generation, thus resolving the contradiction through parameter optimization.
3Object-generated harmful factors
If the surface roughness of the base material surface is set to a relatively high value to prevent blocking, then blocking is prevented, but foreign substances such as dirt or dust adhere to the release film causing defects
Solution Approach 1:
The invention applies different surface properties to different surfaces: the first surface (releasing agent layer) maintains low roughness (Ra1 ≤ 15 nm) to prevent foreign substance adhesion and slurry defects, while the second surface (antistatic layer) has higher roughness (Ra2 ≥ Ra1) to prevent blocking. This localized quality differentiation resolves the contradiction between preventing blocking and preventing foreign substance adhesion.
Data Source
AI summary
A release film that can be used as a carrier film for a green sheet used in a laminated ceramic capacitor is provided. The release film includes a base material having both major surfaces, a releasing agent layer provided on one major surface of the base material, and an antistatic layer provided on the other major surface of the base material, wherein the releasing agent layer and the antistatic layer are mainly composed of the same material, and when the surface roughness of the outer surface of the releasing agent layer is defined as Ra1 [nm] and the surface roughness of the outer surface of the antistatic layer is defined as Ra2 [nm], the relations of Ra1≦15 and Ra1≦Ra2 are satisfied. The release film is capable of preventing occurrence of blocking when being wound in a rolled form for storage and generation of static electricity when being unwound.