Release Sheet Substrate with Adhesion Layer and Convex Resin
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Solution Overview
Problem
The existing release sheets often generate peeling traces on the surface of the release agent layer, which can lead to appearance failures and affect the adhesive characteristics when used for applications requiring a smooth contact with adherends, such as pressure sensitive adhesive sheets intended for discrimination, decoration, and surface protection.
Innovation Solution
A substrate for release sheets is developed with a specific structure comprising a support, an adhesion layer, and a resin layer with convex portions having a height difference of 0.5 μm or more, where the adhesion layer contains polyethylene with a density between 930 kg/m3 and 960 kg/m3, and the resin layer is formed using a melt extrusion method to prevent peeling traces from forming on the release agent layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If convex portions are formed on the surface of the resin layer by embossing, then air traps can be discharged to prevent blisters, but peeling traces are generated on the surface
Solution Approach 1:
The invention introduces an adhesion layer between the support and the resin layer to locally enhance bonding strength at the interface. This allows the resin layer to be embossed with convex portions for air discharge while preventing peeling traces from forming, as the adhesion layer provides localized reinforcement without affecting the overall embossing function.
Solution Approach 2:
The invention creates a composite structure consisting of a support, an adhesion layer, and a resin layer. This multi-layer composite material combines the functions of structural support, interfacial bonding, and surface embossing, allowing simultaneous achievement of air trap discharge and peeling trace prevention through the synergistic interaction of layers.
2Shape
If a release sheet with convex portions is used to form grooves on the adhesive surface, then sticking appearance is improved by preventing blisters, but peeling traces are transferred onto the adherend surface
Solution Approach 1:
The adhesion layer provides localized reinforcement at the support-resin interface, enabling the resin layer to maintain its convex portion structure for groove formation while preventing peeling traces from developing and transferring to the adherend surface during the bonding process.
Solution Approach 2:
The adhesion layer acts as an intermediary between the support and the resin layer, absorbing and distributing stresses that would otherwise cause peeling. This mediator layer prevents the formation and transfer of peeling traces while allowing the convex portions to effectively create the desired groove structure on the adhesive surface.
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 substrate effectively inhibits the generation of peeling traces on the release agent layer, ensuring a smooth and aesthetically pleasing surface, which is crucial for applications where the appearance and adhesive properties must be maintained, including pressure sensitive adhesive sheets used for air escape, decoration, and surface protection.
Implementation Method 1
a substrate for release sheet including a support, an adhesion layer (X1), and a resin layer (Y1) containing polyethylene having a density of 930 kg/m3 or more and 960 kg/m3 or less in this order
Implementation Method 2
the resin layer is formed using a melt extrusion method
Data Source
AI summary
The present invention relates to a substrate for release sheet including a support, an adhesion layer (X1), and a resin layer (Y1) containing polyethylene having a density of 930 kg/m3 or more and 960 kg/m3 or less in this order, wherein convex portions are present on the surface of the resin layer (Y1), and a difference in height of the convex portions is 0.5μm or more.