Transfer Film Protective Layer for IC Card Durability
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Solution Overview
Problem
Current transfer films used for IC cards and similar applications face challenges in achieving high transfer properties and durability, often resulting in transfer failures such as tailing and haze, while also requiring enhanced solvent and abrasion resistance.
Innovation Solution
A transfer film comprising a substrate with a protective layer made of active ray-cured resin and filler, where the resin contains polyfunctional urethane (meth)acrylate and has a volume average particle size of 40 nm or less, along with an optional adhesive layer and release layer, to ensure excellent transfer properties and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coat layer is formed from an ink composition containing inorganic particles and a polyfunctional isocyanate, then durability is improved, but transfer property deteriorates with occurrence of tailing and burr
Solution Approach 1:
The patent changes the chemical parameters of the resin composition by specifying functional group numbers (2-5 for polymerization components, 2-10 for crosslinking components) and molecular weight ranges. This optimization allows the protective layer to achieve both high durability and good transfer property without tailing or burr, resolving the contradiction between strength and manufacturing precision.
Solution Approach 2:
The patent creates a composite protective layer combining active ray-cured resin with specific functional groups, inorganic particles, and crosslinking agents. This composite structure provides enhanced durability while maintaining transferability, solving the contradiction between strength and manufacturing precision through material composition optimization.
2Illumination intensity
If filler particle size is reduced to improve transparency, then haze is reduced, but transfer property and durability are compromised
Solution Approach 1:
The patent optimizes the particle size parameter of inorganic fillers to 10 μm or less, which balances transparency (reducing haze) while maintaining sufficient durability and transfer property. This parameter optimization resolves the contradiction between illumination intensity and reliability.
3Strength
If polyfunctional urethane (meth)acrylate with high functional groups is used to improve durability, then solvent resistance increases, but transfer property may deteriorate
Solution Approach 1:
The patent carefully controls the functional group number parameter within specific ranges (2-5 for polymerization, 2-10 for crosslinking) and molecular weight (500-20,000). This parameter optimization achieves high solvent resistance while preventing transfer failures, resolving the contradiction between strength and manufacturing precision.
Solution Approach 2:
The patent introduces different resin components with specific functional properties at different stages: polymerization components for base structure and crosslinking components for enhanced durability. This local quality differentiation allows the protective layer to exhibit both good transfer property and high solvent resistance.
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 transfer film provides improved durability, solvent resistance, and transparency, preventing haze and transfer failures, while maintaining high transfer efficiency and abrasion resistance.
Implementation Method 1
a protective layer peelably provided on the substrate, wherein the protective layer comprises an active ray-cured resin and a filler
Data Source
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AI summary
An object is to provide a transfer film that can impart sufficient durability such as abrasion resistance and solvent resistance to a transfer object surface and has high transfer property without causing any transfer failures such as tailing and burr. The transfer film according to the present invention comprises a substrate and a protective layer peelably provided on the substrate, wherein the protective layer comprises an active ray-cured resin and a filler; wherein the active ray-cured resin contains polyfunctional urethane (meth)acrylate as a polymerization component; and wherein the filler has a volume average particle size of 40 nm or less.