KR20130014231A - Method for manufacturing reflective film and reflective film manufactred by the method - Google Patents

Abstract

PURPOSE: A manufacturing method of a reflective film and a reflective film manufactured by the method are provided to maintain high reflectivity and brightness, by printing the adhesive in a pattern print method and thereby maintaining the air gap. CONSTITUTION: An adhesive pattern layer(20) which patterned the adhesive in a constant pattern is formed on a reflecting layer(10). A protective film(30) is equipped on the adhesive pattern layer. The laminator laminates the adhesive pattern layer and the protective film in a protective film equipping step. [Reference numerals] (10) White reflecting layer

Description

Method for manufacturing a reflective film and a reflective film produced by the same {METHOD FOR MANUFACTURING REFLECTIVE FILM AND REFLECTIVE FILM MANUFACTRED BY THE METHOD}

The present invention relates to a method of manufacturing a reflective film for forming an adhesive pattern layer by a pattern printing method and a reflective film produced thereby.

TFT-LCD back light units, which are applied to mobile phones, LCD TVs, LED TVs, and navigation devices, which are frequently used in everyday life, are becoming cheaper and higher in brightness as their usage increases and develops.

In order to improve the performance of the backlight unit, a film having high reflection performance is required. In addition, a thin film is possible for notebooks, mobile phones, LED TVs, LCD TVs, and a metal thin film having excellent optical properties is required.

In general, a conventional reflective film is manufactured by silver deposition or sputtering. In Japanese Patent Laid-Open No. 2008-009006, a metal thin film was formed using a deposition method.

In Japanese Patent Laid-Open No. 2002-129259 and the like, it is known to form a reflective film having a high reflectance by vacuum deposition with silver as a main component. The surface of the flexible substrate such as PET was subjected to vacuum deposition using metals such as silver (Ag), aluminium (Al), nickel (Ni), and rhodium (Rh) having high reflectivity, and then the lamination of the reflective film through lamination to the support. In the case of vacuum deposition, a high vacuum chamber (chamber) is required, and the shape and size of the substrate are limited, coating thickness is uneven, and there is a problem due to a large equipment cost.

In addition, there is a limit that can be estimated at a high price when judging from the low yield and the low speed and high equipment cost coming from the deposition process.

Accordingly, the present inventors have successfully reached the present invention as a result of diligent efforts to solve these problems. That is, the present invention formed a metal thin film prepared by the coating method and secured weather resistance through the surface treatment, and has a laminating process with a pressure-sensitive adhesive printing to develop a weather resistant strong reflective film that can maintain high reflectance and brightness It became.

In addition, when manufacturing the reflective film by the conventional casting method, there is a problem that the luminance, reflectance decreases, and the yellow index rises due to the organic material on the silver reflective surface, and the oxidation of silver cannot be prevented without the protective layer. In Japanese Patent Laid-Open No. 2005-280131, a weatherproof improved reflective film was prepared with a weatherproof resin layer. However, improving weather resistance with the resin layer can reduce the decrease in reflectance and the occurrence of yellowing, but there is a shortage when evaluating weather resistance for a long time.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a reflective film capable of maintaining high air reflectance and brightness by printing an adhesive in a pattern printing method, and a reflective film produced thereby.

The present invention provides a method for manufacturing a reflective film, comprising the step of forming an adhesive pattern layer on which a pattern of an adhesive is patterned on a reflective layer.

The present invention provides a reflective film produced by the above production method.

The present invention provides a backlight unit including a reflective film.

According to the present invention, as the adhesive pattern layer is formed on the reflective layer by a pattern printing method, there is provided a method of manufacturing a reflective film having excellent optical characteristics and brightness, and a reflective film produced thereby.

1 is a cross-sectional view of a reflective film according to the present invention.
2 is a photograph of a reflective film according to the present invention (indicating the line width and the distance between the open area).
3 is a view showing an example of an adhesive pattern layer of a reflective film according to the present invention.

The manufacturing method of the reflective film which concerns on this invention includes forming the adhesive pattern layer which patterned the adhesive in a predetermined pattern on the reflective layer.

The method may further include providing a protective film on the adhesive pattern layer.

In the providing of the protective film, the adhesive pattern layer and the protective film may be laminated using a laminator.

The protective film is polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyether sulfone (PES), nylon (Nylon), polytetrafluoroethylene (PTFE), polycarbonate (PC), cellophane (Cellophane) , Polyarylate (PAR), and polyimide (PI) may be a film selected from.

The thickness of the protective film may be 10 ~ 200㎛. For example, the thickness of the protective film may vary from 12 μm, 19 μm, 25 μm, 38 μm, 50 μm, 75 μm, 100 μm, 125 μm, 188 μm.

The reflective layer may be a white reflective layer including a white pigment.

As the adhesive, at least one adhesive selected from acrylic, polysiloxane, and polyester adhesives may be used.

The adhesive may include 5 to 50 parts by weight of an adhesive solid, 0.01 to 1 part by weight of an inorganic filler, and 49 to 96 parts by weight of a solvent, based on 100 parts by weight of the total adhesive. When added in the above range can provide excellent optical properties and adhesion, if too small or too large than the addition amount may be reduced optical properties and adhesion.

As said adhesive solid content, 1 or more types chosen from an acrylic resin, a polysiloxane resin, and a polyester resin can be used.

The inorganic filler may include at least one selected from Al ₂ O ₃ , SiO ₂ , and TiO ₂ .

The adhesive pattern layer may be formed as a straight pattern, a polygonal pattern, or a mixed pattern thereof.

The polygonal pattern may be a hexagonal mesh, a square mesh, a dot, a triangular mesh, or a mesh pattern in which these are mixed.

As such, the adhesive pattern layer may have a straight or polygonal shape. One straight pattern may be arranged sporadically or regularly, or may be a discontinuous form where the straight patterns are connected or unconnected, and may be a mesh form as an example of polygonal shape. Specifically, a hexagon mesh, a square mesh, a circular pattern Dot, triangular mesh, or a mesh pattern of a mixture thereof. Each vertex region of the triangular mesh and the square mesh may be partially cut to have a deformed mesh pattern. As such, the pattern of the adhesive pattern layer may be formed continuously or discontinuously. Here, the shape of the adhesive pattern layer is not limited thereto, and may be variously changed.

 The pattern may have a line width of 0.1 μm to 5000 μm. When provided in the line width range can provide excellent optical properties, if the line width is too thin, the adhesion may be reduced.

An air gap of the pattern may be 100 μm to 10000 μm. Here, the air layer is a space formed by the height of the actual pattern on the basis of the cross-section is formed between the adhesive pattern layer and the protective film, it is possible to improve the brightness by the air layer.

The adhesive pattern layer may include direct gravure printing, flexography printing, gravure offset, imprint, lithography printing, screen printing, and The adhesive may be formed by printing the adhesive by a method selected from rotary screen printing.

The method may further include forming a surface treatment layer between the reflective layer and the adhesive pattern layer using a surface treatment agent including at least one selected from a silane coupling agent and an acid compound.

The surface treating agent may be prepared by adding a solvent to at least one selected from a silane coupling agent and an acid.

For example, based on 100 parts by weight of the surface treating agent, at least one selected from a silane compound and an acid compound as the silane coupling agent is added in an amount of 0.005 to 50 parts by weight, and the solvent is 50 to 99.995 parts by weight. It can be prepared by addition. When added in the above range can provide an excellent antioxidant effect, if too less than the addition amount may be lowered the antioxidant effect in too many cases.

Here, the silane compound and the acid compound may be used or mixed, respectively, and when the silane compound is added alone, 0.005 to 50 parts by weight may be added, and when the acid compound is added alone, 0.01 to 50 parts by weight is added. can do. When the silane compound and / or the acid compound are added in the above range, excellent optical properties may be provided, and when the amount of the silane compound and / or the acid compound is added too small or too much, the optical properties may be degraded.

The silane coupling agent may be selected from 3-mercaptopropyltrimethoxysilane, Methyltrimethoxysilane, TetraEthoxysilane, Trimethylorthosilicate, Methyltriethoxysilane, Dimethyldimethoxysilane, Propyltrimethoxysilane, Propyltriethoxysilane, Trimethoxy (octadecyl) silane, Isobutyltrimethoxysilane, Isobutyltriethoxysilane, Phenyltrimethoxyyltrione, and ethoxysilane. .

As the acid compound, at least one acid compound selected from Oleic acid, Neodecanoic acid, Valeric acid, Lauric acid, Malvalic acid, Decanoic acid, Butyric acid, and Heptanoic acid may be used.

The solvent may be one or more selected from acetone, MEK, MIBK, MAK, toluene, xylene, methanol, ethanol, isopropanol, and n-butanol.

The surface treatment agent may further include an inorganic filler to improve optical properties.

The inorganic filler may use one or more selected from MgO, ZnO, SiO ₂ , and TiO ₂ .

For example, the surface treating agent may be prepared by adding a solvent to at least one selected from the silane coupling agent and the acid and the inorganic filler.

On the basis of 100 parts by weight of the surface treatment agent, at least one selected from the silane coupling agent (acid) and acid (acid) is added to 0.005 to 50 parts by weight, the inorganic filler is added to 0.01 to 0.1 parts by weight, The solvent may be prepared by adding 49.9 to 99.998 parts by weight.

The surface treatment layer may include a microgravure coating, a gravure coating, a flexo coating, a spin coating, a slot die coating, a lip coating. ), And spray coating may be formed using the surface treatment agent.

In addition, the present invention can provide a reflective film produced by the manufacturing method.

Such a reflective film may be composed of, for example, FIG. 1 and a white reflective layer, an adhesive pattern layer, and a protective film, and may further include a surface treatment layer.

The present invention may provide a backlight unit including the reflective film.

The reflective film may be applied to various display apparatuses, and may be used as, for example, a reflective film of a backlight unit of the display apparatus.

Hereinafter, the manufacturing method of the reflective film will be described in detail.

Forming a pattern adhesive layer on the white reflective film, which is a white reflective layer; The pattern adhesive on the reflective film has an adhesive layer including acrylic co-polymer, polysiloxane resin, or polyester resin. ), Providing an adhesive layer in a pattern form by a method such as imprint, lithography printing, screen printing, rotary screen printing, etc .; Lamination to comprise the protective PET.

The manufacturing method of the white reflective film is a film made by mixing a white pigment into a synthetic resin, which is formed by forming a plurality of fine pores inside the synthetic resin or film-forming a white synthetic resin film based on silica, zirconia, calcium carbonate, magnesium carbonate It is prepared by coating. The method of forming the hollow hole includes a method of impregnating an inert gas with a polyester film or the like or mixing a resin which is not compatible with polyester, a method containing inorganic particles such as silica and barium sulfate.

Synthetic resins include polyester resins, polyethylene resins, polystyrene resins, polypropylene resins, polyether resins, polyurethane resins, polyvinyl chloride resins, polyvinyl acetate resins, acrylic resins, epoxy resins, cellulose General synthetic resins such as counting paper can be used, and polyester resins such as polyethylene terephthalate can be used. A UV blocker may also be included to prevent yellowing to the light source.

The adhesive pattern layer may include direct gravure printing, flexography printing, gravure offset, imprint, lithography printing, screen printing, rotary, and the like. It may be provided in a pattern form by a method such as rotary screen printing.

The pattern may be printed by processing a mesh of a hexagon mesh (Honeycomb), a square mesh, a circle (Dot), a triangular mesh, irregular lines, a combination of points and the shape of the aforementioned shapes.

The pattern of the adhesive pattern layer, the line width can be processed to 0.1㎛ ~ 5000㎛ and the distance between the lines can be manufactured to 100㎛ ~ 100000㎛. The height can be produced from 0.02㎛ ~ 5㎛, preferably from 0.05㎛ ~ 3㎛.

The composition of the adhesive layer may be prepared by including 10 to 30 parts by weight of an adhesive solid, 0.01 to 1 part by weight of an inorganic filler, and 89.99 to 69 parts by weight of a solvent based on 100 parts by weight of the total adhesive layer composition.

The adhesive may be prepared by acrylic co-polymer, polydimethyl siloxane gum, methyl vinyl siloxane gum, polyester, adhesives and the like.

The inorganic filler included in the adhesive layer may be used by mixing Al 2 O 3, SiO 2, TiO 2, and the like.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited thereto.

Example 1

As the white reflective layer, the white reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

Adhesive was prepared by mixing 17.5 parts by weight of acrylic co-polymer type adhesive, 40 parts by weight of butyl glycol acetate, 42.5 parts by weight of butyl acetate. This adhesive was printed on the white reflective film by direct gravure printing in nine types according to line width, open area and pattern shape.

Subsequently, the protective film was laminated with polyethylene terephthalate (PET) 12 μm in a continuous process.

Example 2

White reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

The adhesive was prepared by mixing 25 parts by weight of a polyester type adhesive, 20 parts by weight of MEK, 20 parts by weight of butyl acetate, and 35 parts by weight of butyl glycol acetate. This adhesive was printed on the surface treatment layer by direct gravure printing in nine types according to line width, open area and pattern shape.

Subsequently, the protective film was laminated with polyethylene terephthalate (PET) 12 μm in a continuous process.

Example 3

White reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

The adhesive was prepared by mixing 15 parts by weight of polysiloxane type adhesive, 50 parts by weight of xylene, and 35 parts by weight of toluene. This adhesive was printed on the surface treatment layer by direct gravure printing in nine types according to line width, open area and pattern shape.

Subsequently, the protective film was laminated with polyethylene terephthalate (PET) 12 μm in a continuous process.

Comparative Example 1

White reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

Adhesive was prepared by mixing 11 parts by weight of acrylic co-polymer type adhesive, 50 parts by weight of butyl glycol acetate, 39 parts by weight of butyl acetate. The adhesive was microgravure coated, and the protective film was laminated to 12 µm polyethylene terephthalate (PET).

Comparative Example 2

White reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

Subsequently, the adhesive was prepared by mixing 20 parts by weight of a polyester type adhesive, 20 parts by weight of MEK, 20 parts by weight of butyl acetate, and 40 parts by weight of butyl glycol acetate. The adhesive was microgravure coated, and the protective film was laminated to 12 µm polyethylene terephthalate (PET).

Comparative Example 3

White reflective film is E6SR which is commercialized in Toray Advanced Materials (TAK).

Subsequently, the adhesive was prepared by mixing 11 parts by weight of polysiloxane type adhesive, 50 parts by weight of xylene, and 39 parts by weight of toluene. This adhesive was microgravure-coated on the surface treatment layer, and the protective film was laminated to 25 micrometers of polyethylene terephthalate (PET).

Hereinafter, the composition of each layer in each Example and Comparative Example is summarized as shown in [Table 1], and [Table 2] summarizes the optical property result data in each Example and Comparative Example.

Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 glue Acrylic co-polymer 17.5 - - 11 - - Polyester - 25 - - 20 - Poly siloxane - - 15 - - 11 Solvent 82.5 75 85 89 80 89 Upper PET Hood 12 12 12 12 12 25

Unit: cd Optical characteristics by line width and open area width Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 ore
Special
castle Line: 300 Open: 500 9 point
Average
Luminance 4895 4902 5031 - - - Line: 300 Open: 1000 5061 4976 5059 - - - Line: 300 Open: 2000 5045 5031 5109 - - - Line: 300 Open: 5000 5098 5084 5301 - - - Line: 300 Open: 1130 5064 5014 5268 - - - Line: 400 Open: 5000 5231 5184 5338 - - - Line: 300 Open: 2000▩ 5132 5111 5298 - - - Line: 300 Open: 5000▩ 5219 5161 5368 - - - Line: 300 Open: 4000▩ 5217 5129 5302 - - - Front lamination - - - 4215 4135 4381

10: White reflective layer
20: adhesive layer (pattern)
30: protective film (PET)

Claims (25)

A method of manufacturing a reflective film, comprising the step of forming an adhesive pattern layer on which the adhesive is patterned in a predetermined pattern on the reflective layer. The method according to claim 1,
Method for manufacturing a reflective film, characterized in that it further comprises the step of providing a protective film on the adhesive pattern layer. The method according to claim 2,
In the step of providing the protective film, a method of manufacturing a reflective film, characterized in that for laminating the adhesive pattern layer and the protective film using a laminator (Laminator). The method according to claim 2,
The protective film is polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyether sulfone (PES), nylon (Nylon), polytetrafluoroethylene (PTFE), polycarbonate (PC), cellophane (Cellophane) , Polyarylate (PAR), and polyimide (PI) is a method for producing a reflective film, characterized in that the film. The method according to claim 2,
The thickness of the protective film is a manufacturing method of the reflective film, characterized in that 10 ~ 200㎛. The method according to claim 1,
The reflective layer is a method of manufacturing a reflective film, characterized in that the white reflective layer containing a white pigment. The method according to claim 1,
The adhesive is a method of manufacturing a reflective film, characterized in that at least one adhesive selected from acrylic, polysiloxane, and polyester adhesives. The method according to claim 1,
The adhesive, based on 100 parts by weight of the total, 5 to 50 parts by weight of the adhesive solids, 0.01 to 1 parts by weight of the inorganic filler, and 49 to 96 parts by weight of the solvent. The method according to claim 8,
As the adhesive solid, at least one selected from acrylic resin, polysiloxane resin, and polyester resin is used. The method according to claim 8,
The inorganic filler is a method for producing a reflective film, characterized in that it comprises at least one selected from Al ₂ O ₃ , SiO ₂ , and TiO ₂ . The method according to claim 1,
The adhesive pattern layer is a method of manufacturing a reflective film, characterized in that formed in a straight pattern or a polygonal pattern or a pattern of a mixture thereof. The method of claim 11,
The polygonal pattern is a hexagonal mesh (Honeycomb), square mesh, circle (Dot), triangular mesh, or a method of manufacturing a reflective film, characterized in that the mesh pattern of a mixture thereof. The method according to claim 1,
The pattern is a method of manufacturing a reflective film, characterized in that the line width is 0.1 ㎛ ~ 5000㎛. The method according to claim 1,
Air gap of the pattern (Air gap) is a manufacturing method of the reflective film, characterized in that 100㎛ ~ 10000㎛. The method according to claim 1,
The adhesive pattern layer may include direct gravure printing, flexography printing, gravure offset, imprint, lithography printing, screen printing, and Method for manufacturing a reflective film, characterized in that formed by printing the adhesive by a method selected from Rotary screen printing (Rotary screen printing). The method according to claim 1,
And forming a surface treatment layer between the reflective layer and the adhesive pattern layer with a surface treatment agent including at least one selected from a silane coupling agent and an acid compound. Method of manufacturing a reflective film. 18. The method of claim 16,
The surface treatment agent is prepared by adding a solvent to at least one selected from the silane coupling agent and the acid compound,
Based on 100 parts by weight of the surface treating agent, at least one selected from the silane coupling agent and the acid compound is added in an amount of 0.005 to 50 parts by weight, and the solvent is prepared by adding 50 to 99.995 parts by weight. Method for producing a reflective film, characterized in that. 18. The method of claim 16,
The silane coupling agent is selected from 3-Mercaptopropyltrimethoxysilane, Methyltrimethoxysilane, TetraEthoxysilane, Trimethylorthosilicate, Methyltriethoxysilane, Dimethyldimethoxysilane, Propyltrimethoxysilane, Propyltriethoxysilane, Trimethoxy (octadecyl) silane, Isobutyltrimethoxysilane, Isobutyltriethoxysilane, and Phenethoxysilane. Method for producing a reflective film comprising a silane compound. 18. The method of claim 16,
The acid (acid) compound, Oleic acid, Neodecanoic acid, Valeric acid, Lauric acid, Malvalic acid, Decanoic acid, Butyric acid, Heptanoic acid manufacturing method of a reflective film, characterized in that it comprises at least one selected from. 18. The method of claim 16,
The surface treatment agent, a method for producing a reflective film, characterized in that it further comprises an inorganic filler. The method of claim 20,
The surface treating agent is prepared by adding a solvent to at least one selected from the silane coupling agent and the acid compound and the inorganic filler.
Based on 100 parts by weight of the surface treating agent, at least one selected from the silane coupling agent and the acid compound is added in an amount of 0.005 to 50 parts by weight, and the inorganic filler is added in an amount of 0.01 to 0.1 parts by weight, 49.9 to 99.998 parts by weight of the solvent was prepared by adding a reflective film. The method of claim 20,
The inorganic filler is a method of manufacturing a reflective film, characterized in that it comprises at least one selected from MgO, ZnO, SiO ₂ , and TiO ₂ . 18. The method of claim 16,
The surface treatment layer may include a microgravure coating, a gravure coating, a flexo coating, a spin coating, a slot die coating, a lip coating. ), And a method of manufacturing a reflective film, characterized in that formed by the surface treatment agent using a method selected from spray coating (spray coating). Reflective film produced by the manufacturing method according to any one of claims 1 to 23. A backlight unit comprising the reflective film according to claim 24.

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