TW201704417A - 接著性樹脂層以及接著性樹脂薄膜 - Google Patents

接著性樹脂層以及接著性樹脂薄膜 Download PDF

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Publication number
TW201704417A
TW201704417A TW105105823A TW105105823A TW201704417A TW 201704417 A TW201704417 A TW 201704417A TW 105105823 A TW105105823 A TW 105105823A TW 105105823 A TW105105823 A TW 105105823A TW 201704417 A TW201704417 A TW 201704417A
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Taiwan
Prior art keywords
adhesive resin
resin layer
acrylic
adhesive
temperature
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TW105105823A
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English (en)
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TWI709628B (zh
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藤田志朗
鈴木淳史
新見洋人
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藤森工業股份有限公司
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J4/00—Adhesives based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; adhesives, based on monomers of macromolecular compounds of groups C09J183/00 - C09J183/16
    • C09J4/06—Organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond in combination with a macromolecular compound other than an unsaturated polymer of groups C09J159/00 - C09J187/00
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    • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
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    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
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Abstract

本發明係提供一種接著性樹脂層及接著性樹脂薄膜，其中該接著性樹脂層係即便與基材貼合後使其加熱變形，亦能夠防止氣泡的產生，而且對依照以下的順序將基材、接著性樹脂層、及基材積層而成的積層體之基材的變形之追隨性良好。更具體地，本發明係一種含有丙烯酸系接著性樹脂組成物之單層的接著性樹脂層11，該接著性樹脂組成物係至少含有(A)丙烯酸系聚合物、(B)丙烯酸系單體或丙烯酸系寡聚物、及(C)熱聚合起始劑，接著性樹脂層11係於常溫在兩面11a、11b具有黏著性，在升溫速度10℃/分鐘的示差掃描熱量測定(DSC)，在80℃以上能夠確認開始發熱，在120℃~210℃之間能夠確認至少1個波峰。

Description

接著性樹脂層以及接著性樹脂薄膜
本發明，係有關於一種即便貼合在基材後使其加熱變形亦能夠防止氣泡的產生之接著性樹脂層及接著性樹脂薄膜。
本申請案，係基於2015年7月17日提出申請之日本國特願2015-142880號而主張優先權，而且將其內容引用在此。
作為使用後能夠容易地將黏著劑剝離之黏著劑，係使用含有丙烯酸系黏著劑、胺甲酸酯丙烯酸酯等的光硬化型丙烯酸酯化合物、異氰酸酯系硬化劑(交聯劑)、及光聚合起始劑之黏著劑(例如，參照專利文獻1~3)。此種黏著劑係在常溫具有黏著性之同時，因為藉由光照射而使黏著性降低而能夠再剝離，所以被廣泛地使用在半導體加工用或搬運用黏著膠帶。
另一方面，因為丙烯酸系黏著劑，亦能夠與觸控面板、行動電話、顯示器、貼合玻璃等具有透明性或透光性的基材積層而接著，所以被廣泛地使用。但是，在基材與黏著劑之間產生空隙且氣泡殘留時，基材之間的接著強度有低落之可能性。又，在需要透明性之用途時，有因氣泡致使通過基材後的光學特性低落之可能性。
先前技術文獻
專利文獻
[專利文獻1]日本特許第3764133號公報
[專利文獻2]日本特許第3803200號公報
[專利文獻3]日本特開2012-193321號公報
本發明係鑒於上述情形而進行，其課題係提供一種接著性樹脂層及接著性樹脂薄膜，其中該接著性樹脂層係即便與基材貼合後使其加熱變形，亦能夠防止氣泡的產生，而且對依照以下的順序將基材、接著性樹脂層、及基材積層而成的積層體之基材的變形之追隨性良好。
為了解決前述課題，本發明係提供一種接著性樹脂層，其係含有具有丙烯酸系接著性樹脂組成物之單層的接著性樹脂層，其特徵在於：前述接著性樹脂組成物係至少含有(A)丙烯酸系聚合物、(B)丙烯酸系單體或丙烯酸系寡聚物、及(C)熱聚合起始劑，前述接著性樹脂層係於常溫在兩面具有黏著性，在升溫速度10℃/分鐘的示差掃描熱量測定(DSC)，在80℃以上能夠確認開始發熱，在120℃~210℃之間能夠確認至少1個波峰。
前述(C)熱聚合起始劑，係以過氧化物為佳。
前述接著性樹脂組成物，相對於前述相對於(A)丙烯酸系 聚合物100重量份，係以含有5~50重量份的前述(B)丙烯酸系單體或丙烯酸系寡聚物為佳。
前述接著性樹脂組成物，係以含有羥基之丙烯酸系單體作為前述(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分為佳。
前述接著性樹脂組成物，係以含有硬化性胺甲酸酯丙烯酸酯作為前述(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分為佳。
又，本發明係提供一種接著性樹脂薄膜，其特徵在於：在2片隔離膜之間積層前述接著性樹脂層而成。
而且，本發明係提供一種用以形成積層體之接著性樹脂層，該積層體係透過前述接著性樹脂層而積層2片基材而成。
又，本發明係提供一種接著性樹脂層，其特徵在於：透過前述接著性樹脂層而積層2片基材，在將所得到的積層體在夾在2個模具之間的狀態下使前述積層體加熱變形，前述接著性樹脂層係加熱硬化後，黏著力亦為10N/25mm以上。
而且，本發明係提一種積層體，其特徵在於：透過前述接著性樹脂層而積層2片基材而成。
又，本發明係提供一種積層體之製造方法，其特徵在於：透過前述接著性樹脂層而積層2片基材，在將所得到的積層體在夾在2個模具之間的狀態下，使前述接著性樹脂層加熱硬化。
將在前述接著性樹脂層的原材料組成物所含有的溶劑之沸點設為溫度A，將前述熱聚合起始劑具有1分鐘的半衰期之溫度設為溫度B，將在前述接著性樹脂層之製造步驟用 以將前述溶劑除去之加熱時的溫度設為溫度C，將在使前述接著性樹脂層加熱硬化之步驟之模具的加壓溫度設為溫度D時，各溫度係以下述式(1)的順序為佳。
式(1) 溫度A<溫度C<溫度B<溫度D
前述加熱硬化時之模具的溫度係以150~300℃的溫度為佳。
本發明之特徵在於：接著性樹脂組成物係含有丙烯酸系聚合物、丙烯酸系單體或丙烯酸系寡聚物、及熱聚合起始劑，藉由前述成分能夠製造轉移膠帶狀(transfer tape-like)接著性樹脂層。接著性樹脂層係藉由丙烯酸系單體或丙烯酸系寡聚物而對基材具有基材追隨性。能夠提供一種接著性樹脂層以及其製造方法，該接著性樹脂層係藉由熱等的反應開始條件而丙烯酸系單體或丙烯酸系寡聚物硬化，即便貼合在基材後使其加熱變形，氣泡亦不進入。特別是藉由在丙烯酸系單體或丙烯酸系寡聚物的添加量下工夫，能夠保持對基材的追隨性、及轉移膠帶狀接著性樹脂層本身的強度。依照本發明，藉由強迫地、特別是熱壓而能夠使接著性樹脂層半強迫地追隨基材。在積層體製造時不是藉由透過空氣之電子射線照射或能量線照射引起硬化，而是不透過空氣之熱及壓力的雙方對積層體施加熱壓，從抑制產生氣泡及對基材的變形之追隨性的觀點而言，乃是較佳。
依照本發明，能夠提供一種接著性樹脂層及接著性樹脂薄膜，該接著性樹脂層係貼合在基材後，即便加熱變形 亦能夠防止氣泡的產生。
10‧‧‧接著性樹脂薄膜
11‧‧‧接著性樹脂層
11a、11b‧‧‧接著性樹脂層的兩面(黏著面)
12、13‧‧‧隔離膜
12a、13a‧‧‧隔離膜表面(剝離面)
20、30‧‧‧積層體
21、22‧‧‧基材
21a、22a‧‧‧內表面
21b、22b‧‧‧外表面
23‧‧‧熱硬化後的接著層
第1圖係顯示本發明的接著性樹脂薄膜的一個例子之剖面圖。
第2圖係顯示在2片基材之間積層有接著性樹脂層之積層體的一個例子之剖面圖。
第3圖係顯示接著性樹脂層被加熱硬化後之積層體的一個例子之剖面圖。
第4圖係顯示接著性樹脂層被加熱硬化後之曲面狀的積層體的一個例子之剖面圖。
用以實施發明之形態
以下，基於較佳實施形態，參照圖式而說明本發明。
在第1圖，係顯示接著性樹脂薄膜10的一個例子之剖面圖。接著性樹脂薄膜10係具有：2片隔離膜12、13；及被積層在該等之間之接著性樹脂層11。構成接著性樹脂層11之接著性樹脂組成物，係含有(A)丙烯酸系聚合物、(B)丙烯酸系單體或丙烯酸系寡聚物、及(C)熱聚合起始劑。接著性樹脂層11的兩面11a、11b係在常溫具有黏著性(成為黏著面)。
又，在本說明書中，所謂「常溫」係約3℃~約40℃，以約10℃~約30℃為佳，較佳為約15℃~約25℃，最佳為是約23℃。
接著性樹脂層11係在遍及厚度方向的全體含有接著性樹脂組成物。只要含有滿足必要條件之接著性樹脂組成物，接著性樹脂層11亦可由含有同種或異種接著性樹脂組成物之2層以上所構成。接著性樹脂層11係由單層的接著性樹脂層所構成時，因為能夠使層構成單純化而減低成本，乃是較佳。接著性樹脂組成物係含有丙烯酸系接著性樹脂(聚合物)。接著性樹脂組成物的光學特性係不被限定，可為具有透明性，亦可為半透明或不透明。
隔離膜12、13，係在接著性樹脂層11接觸側的表面12a、13a，具有剝離性(成為剝離面)。作為隔離膜12、13之構成，可舉出在樹脂薄膜的一面或兩面設置有剝離劑層之構成、及在樹脂薄膜的樹脂內含有剝離劑之構成。亦能夠使用紙、合成紙、金屬箔、各種薄片等代替樹脂薄膜。隔離膜12、13係具有透明性時，因為能夠在不將隔離膜12、13剝離之接著性樹脂薄膜10的狀態下，進行接著性樹脂層11的光學檢查，乃是較佳。
第1圖所顯示的接著性樹脂薄膜10，係能夠藉由將隔離膜12、13從接著性樹脂層11剝離而露出的黏著面11a、11b，而貼合2片基材。在第2圖，係顯示透過接著性樹脂層11，積層2片基材21、22而成之積層體20的一個例子。2片基材21、22係在單面21a、22a與接著性樹脂層11接觸，其相反側的面21b、22b係以能夠藉由模具熱壓的方式，不與接著性樹脂層11接觸而敞開著。
基材21、22係被接著性樹脂層11貼合之被接著 物。各基材21、22可以是硬質板，亦可以是如薄膜具有可撓性。例如可以是玻璃、聚碳酸酯、丙烯酸樹脂、各種樹脂、陶瓷、金屬等的單板，亦可以是液晶面板、觸控面板、玻璃蓋片、配線基板等由複數種材料所構成之複合體。基材21、22的材質、厚度、形狀等係各自相同、不同皆無妨。基材21、22的內表面21a、22a及外表面21b、22b，係各自可為平坦，任一面或兩面亦可具有段差或凹凸。
將接著性樹脂層11貼合在基材21、22後，使基材21、22熱變形時，作為基材21、22的材質，係以聚烯烴、聚酯、聚碳酸酯、聚醯胺、丙烯酸樹脂、聚氯乙烯、纖維素酯等的熱可塑性樹脂為佳。在熱變形所使用的基材，係不限定為熱可塑性樹脂的基材(薄膜等)單體，亦可在該基材的面上或內部，包含異種材料(金屬、無機物、有機物等)的薄膜、圖案、粒子、細線、微細構造物等。
形成如第2圖的積層體20時，將隔離膜12、13剝離之順序係沒有特別限定。可以在將一方的隔離膜剝離而露出之一方的黏著面，貼合一方的基材之後，將另一方的隔離膜剝離而在露出之另一方的黏著面，貼合另一方的基材。亦可將雙方的隔離膜剝離而露出雙方的黏著面之後，貼合各自基材。
因為接著性樹脂層11係含有具有流動性之(B)丙烯酸系單體或丙烯酸系寡聚物，所以柔軟性較高，而能夠藉由接著性樹脂組成物使基材21、22的接觸面21a、22a全體濕潤化。因此，即便貼合在基材21、22貼合後使積層體20加熱變形亦能夠抑制產生氣泡。因為接著性樹脂層11係含有(C)熱聚 合起始劑，所以藉由貼合後使其熱硬化，而能夠使接合更堅固。相較於照射紫外光，熱硬化的設備係具有較簡便，即便基材21、22係包含透光性較低的部分時或接著性樹脂層11因著色等而不容易透射紫外光時亦能夠確實地硬化之優點。
透過接著性樹脂層11而將2片基材21、22積層而得到的積層體20，係藉由夾在2個模具之間的狀態下進行加熱，能夠使接著性樹脂層11硬化。藉此，(A)丙烯酸系聚合物及(B)丙烯酸系單體或丙烯酸系寡聚物係進行反應(聚合、交聯等)，使得基材21、22之間的接著力上升。又，藉由加熱之同時進行加壓，即便在基材21、22與接著性樹脂層11之間殘留有氣泡，空隙係填埋而能夠將氣泡除去。進行加熱硬化時、係加熱2個模具的至少一方。
將積層體20熱壓時，2個模具與積層體(詳言之，基材21、22的外表面21b、22b)之間，亦可使緩衝片、剝離片、保護片等(插入物)介於中間。在2個模具係在對積層體之按壓面具有凹凸時，因為模具的凸部係直接接觸積層體時，壓力容易集中在凸部，所以設置上述的插入物為佳。
2個模具可覆蓋積層體20的側面亦可不覆蓋。例如亦可以是將一方的模具設作凸型，將另一方的模具設作凹型，將積層體20收容在凹型的凹部之後，使凸型的凸部朝向凹型的凹部接近。
在第3圖，係顯示藉由加熱硬化而得到積層體30的一個例子。在該積層體30，作為接著性樹脂層11熱硬化後之結果，係在2片基材21、22之間，積層含有熱硬化後的接 著性樹脂之接著層23。因為熱硬化後的接著層23係硬度增大，所以即便加熱前的接著性樹脂層11為柔軟亦不容易再剝離。藉此，作為接著性樹脂層11，係能夠使用即便接著力較低但是對基材的變形之追隨性優異的樹脂。接著性樹脂層11在加熱硬化後，接著層23的黏著力(接著力)係以10N/25mm以上為佳。
在製造積層體30時，將2種基材21、22不同時，能夠考慮若干種製造方法。積層體30的製造係能夠採用任一種方法。
作為第1積層方法，可舉出在第1基材21積層接著性樹脂層11，隨後，實施高壓釜處理，在接著性樹脂層11上積層第2基材22且積層積層體20之後，或是邊積層第2基材22邊使用2個模具而使接著性樹脂層11加熱硬化之方法。
作為第2積層方法，可舉出在第2基材22積層接著性樹脂層11，隨後，實施高壓釜處理，在接著性樹脂層11上積層第1基材21之後，或是邊積層第1基材21邊使用2個模具而使接著性樹脂層11加熱硬化之方法。
作為第3積層方法，可舉出將具有凹凸之第1基材21、接著性樹脂層11、第2基材22同時積層之後，或是在積層之同時，使用2個模具使接著性樹脂層11加熱硬化之方法。
第1或第2積層方法，係藉由將基材21、22的一方與接著性樹脂層11先貼合而進行高壓釜處理，基材21、22的一方容易追隨接著性樹脂層。在一方的基材表面存在有段差或凹部等，在與接著性樹脂層之間容易產生空隙之情況，因為 能夠藉由高壓釜處理將該空隙填埋，所以此方法即便熱壓加工的條件為較大的偏差，氣泡亦能夠較少。又，就能夠縮短製程而言，第3積層方法係在成本面最具有優點之方法。
在基材21、22間積層接著性樹脂層11而熱壓時，亦能夠使基材21、22的一方或雙方變形而使積層體產生凹凸。例如在2個模具的按壓面上設置凹凸時，能夠使樹脂薄膜等具有可撓性之基材21、22變形。藉由最初接著性樹脂層11具有流動性，而能夠追隨基材21、22的凹凸。又，藉由熱壓之間進行熱聚合，接著性樹脂層11硬化而能夠抑制產生空隙及氣泡。而且，藉由基材21、22係與接著層23接合，如第4圖所顯示，能夠將基材21、22的變形固定而實現凹凸、曲面、撓曲、彎曲等的成形。在基材的內表面形成有凸部時，亦可在背側的外表面形成有凹部。在第4圖，雖舉出波板狀成形體作為一個例子，但並不特別地被此限定，而能夠形成任意形狀。
接著性樹脂層11在升溫速度10℃/分鐘之示差掃描熱量測定(DSC)，較佳為在80℃以上能夠確認開始發熱，在120℃~210℃之間能夠確認至少1個波峰。若在小於80℃即能夠確認發熱，例如即便在常溫亦有進行熱硬化反應之可能性，則保存性低落。藉由在120℃~210℃之間能夠確認波峰，能夠在與其同程度的溫度使其進行熱硬化。而且，基材21、22亦能夠藉由加熱軟化而容易變形。
為了提升接著性樹脂層11的操作性，接著性樹脂層11係以藉由於100~250℃的溫度及30秒~10分鐘的時間加熱來進行熱硬化為佳。以在該等溫度及時間範圍的至少一部分 的條件下進行熱硬化為佳，以能夠在上述全範圍熱硬化為較佳。實際使用時的熱硬化條件，亦可以是上述範圍外。但是，從保存性的觀點而言，以在常溫係實質上不進行熱硬化為佳，較佳例如為在100℃以下的溫度，加熱10分鐘以內不具有熱硬化的性質。
在接著性樹脂層11未硬化的狀態(加熱前)，在溫度23℃之儲存彈性模數係以1×104~1×106Pa為佳。又，接著性樹脂層11藉由加熱而熱硬化之後，在溫度23℃之儲存彈性模數係以1×104~1×109Pa為佳。相較於加熱前在溫度23℃之儲存彈性模數，藉由加熱而熱硬化之後，在溫度23℃之儲存彈性模數係以變為較高為佳。該等儲存彈性模數，係能夠使各自溫度成為23℃而測定未硬化的狀態(加熱前)之接著性樹脂層、及藉由加熱而熱硬化之後的接著性樹脂層(熱硬化後的接著層)。測定儲存彈性模數時之振動頻率，係例如1Hz。測定熱硬化後的接著層之儲存彈性模數時，係不將接著性樹脂層貼合在基材，而是藉由使接著性樹脂層在隔離膜之間加熱硬化之後，將隔離膜剝離而能夠以得到熱硬化後的接著層的單體。
接著，更詳細地說明亦是轉移膠帶之接著性樹脂層。
在製造本發明的接著性樹脂層所使用之接著劑原材料組成物，由於溶解於有機溶劑者係能夠厚度精確度更良好地塗佈，因此以含有有機溶劑為佳。藉由從接著劑原材料組成物將溶劑乾燥，而能夠得到接著性樹脂層。亦即，接著劑原材料組成物的組成，係可以是在構成接著性樹脂層之接著性樹脂組成 物的組成添加有溶劑者。接著性樹脂層係在常溫(熱硬化前)，能夠作為黏著劑層之功能。
構成(A)丙烯酸系聚合物之單體，可舉出具有酯基(-COO-)之丙烯酸系單體、具有羧基(-COOH)之丙烯酸系單體、具有醯胺基(-CONR2，R係氫原子或烷基等的取代基)之丙烯酸系單體、具有腈基(-CN)之丙烯酸系單體、烯烴類、苯乙烯、乙烯酯類、乙烯醚類、乙烯基矽烷等的非丙烯酸系單體。(A)丙烯酸系聚合物係以由2種以上的單體所構成之共聚物為佳。在光聚合前之(A)丙烯酸系聚合物的數量平均分子量，例如以50,000~1,000,000左右為佳。黏度係例如可舉出1,000~10,000mPa．s左右。
作為具有酯基(-COO-)之丙烯酸系單體，可舉出(甲基)丙烯酸烷酯、具有羥基之(甲基)丙烯酸酯、具有烷氧基或聚醚基之(甲基)丙烯酸酯、具有胺基或取代胺基之(甲基)丙烯酸酯等。又，在本說明書，所謂(甲基)丙烯酸酯，係丙烯酸酯及甲基丙烯酸酯的總稱。
作為具有羧基(-COOH)之丙烯酸系單體，可舉出丙烯酸、甲基丙烯酸、具有羧基(-COOH)之(甲基)丙烯酸酯等。
作為具有醯胺基(-CONR2，R係氫原子或烷基等的取代基)之丙烯酸系單體，可舉出丙烯醯胺、甲基丙烯醯胺等。
作為具有腈基(-CN)之丙烯酸系單體，可舉出丙烯腈、甲基丙烯腈等。
(A)丙烯酸系聚合物係構成單體的50重量%以上，以由丙烯酸系單體所構成為佳。特別是構成單體的50重量% 以上係以由通式CH2=CR1-COOR2(式中，R2為氫或甲基，R2係表示碳數1~14的烷基)表示之(甲基)丙烯酸烷酯的1種或2種以上所構成為佳。作為(甲基)丙烯酸烷酯的具體例，可舉出(甲基)丙烯酸甲酯、(甲基)丙烯酸乙酯、(甲基)丙烯酸正丙酯、(甲基)丙烯酸異丙酯、(甲基)丙烯酸正丁酯、(甲基)丙烯酸異丁酯、(甲基)丙烯酸第三丁酯、(甲基)丙烯酸正戊酯、(甲基)丙烯酸異戊酯、(甲基)丙烯酸正己酯、(甲基)丙烯酸2-乙基己酯、(甲基)丙烯酸正辛酯、(甲基)丙烯酸異辛酯、(甲基)丙烯酸異壬酯、(甲基)丙烯酸癸酯、(甲基)丙烯酸十二酯。特別是以將烷基R2的碳數為4~12的(甲基)丙烯酸烷酯設作必需而(例如50~100莫耳%)使用為佳。
又，作為含有羥基之(甲基)丙烯酸酯，例如可舉出(甲基)丙烯酸2-羥基乙酯、(甲基)丙烯酸2-羥基丙酯、(甲基)丙烯酸3-羥基丙酯、(甲基)丙烯酸4-羥基丁酯、(甲基)丙烯酸6-羥基己酯、(甲基)丙烯酸8-羥基辛酯、聚乙二醇一(甲基)丙烯酸酯、聚丙二醇一(甲基)丙烯酸酯、環己烷二甲醇一(甲基)丙烯酸酯等的1種或2種以上。
(B)丙烯酸系單體或丙烯酸系寡聚物之中，作為丙烯酸系單體，可舉出與構成(A)丙烯酸系聚合物之單體同樣的單體，例如(甲基)丙烯酸烷酯、含有羥基之(甲基)丙烯酸酯、丙烯醯胺等之1種或2種以上。1分子中的(甲基)丙烯醯基等的聚合性官能基的數目可為1亦可為2以上。
特別是含有具有羥基的(甲基)丙烯酸酯單體作為(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分時，具有極 性之羥基係容易分散在接著性樹脂層的全體。藉此，即便在濕度較高的(更或是高溫的)環境，因為水分不容易凝聚且能夠抑制接著性樹脂層產生白濁，乃是較佳。在具有羥基之(甲基)丙烯酸酯，1分子中的羥基的數目可為1亦可為2以上。
又，作為(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部，能夠使用硬化性胺甲酸酯丙烯酸酯。胺甲酸酯丙烯酸酯係在同一分子中具有胺甲酸酯鍵(-NH-COO-)及(甲基)丙烯醯基氧基(設作X=H或CH3，CH2=CX-COO-)之化合物。硬化性胺甲酸酯丙烯酸酯係指胺甲酸酯丙烯酸酯之中，藉由聚合性官能基之(甲基)丙烯醯氧基而具有硬化性之化合物。1分子中的胺甲酸酯鍵之數目可為1亦可為2以上。又，1分子中的(甲基)丙烯醯基氧基的數目可為1亦可為2以上。
作為胺甲酸酯丙烯酸酯，例如可舉出使具有羥基之(甲基)丙烯酸酯化合物與異氰酸酯化合物反應而得到之化合物；及使多元醇化合物與聚異氰酸酯化合物反應而得到之胺甲酸酯預聚合物、具有羥基之(甲基)丙烯酸酯化合物反應而得到之化合物等。作為多元醇化合物，可舉出聚酯多元醇、聚醚多元醇等。
(B)丙烯酸系單體或丙烯酸系寡聚物係藉由使用(C)熱聚合起始劑之熱硬化而成為聚合物的一部分，而且以比聚合物更低黏度低的液體(流動體)為佳。亦能夠併用丙烯酸系單體及丙烯酸系寡聚物。作為丙烯酸系寡聚物，可舉出胺甲酸酯丙烯酸酯寡聚物等的丙烯酸酯寡聚物。(B)丙烯酸系單體或丙烯酸系寡聚物所具有之聚合性官能基的數目，係例如1~10，較 佳為2~5。
相對於(A)丙烯酸系聚合物100重量份，接著性樹脂組成物係以含有5~50重量份的(B)丙烯酸系單體或丙烯酸系寡聚物為佳。若(B)丙烯酸系單體或丙烯酸系寡聚物的添加量太多，使其熱聚合時，會有接著性樹脂層的接著力太低之情形。
作為(C)熱聚合起始劑，可舉出藉由熱而分解來使單體聚合(自由基聚合)及樹脂開始硬化之自由基起始劑。作為自由基起始劑，亦已知在低溫起作用之氧化還原起始劑及有機金屬化合物等，但是就接著性樹脂層的操作性而言，係以在較高溫起作用之(有機)過氧化物系、偶氮系等為佳。熱聚合起始劑係在轉移膠帶的製造過程，特別是為了在溶劑的乾燥步驟不產生反應或(或者)半衰，熱聚合起始劑的半衰期成為1分鐘之溫度(以下稱為「1分鐘半衰期溫度」)，係以比接著劑原材料組成物所含有的有機溶劑之沸點更高為佳。又，為了使熱聚合起始劑在熱壓時的溫度充分地反應一定時間，材料所具有之1分鐘半衰期溫度以比熱壓設定溫度更低50℃以上為佳。
作為(有機)過氧化物系的熱聚合起始劑之具體例，可舉出過氧化苯甲醯基、過氧化乙醯、過氧化癸醯、過氧化月桂醯等的過氧化二醯、過氧化二異丙苯、過氧化二-第三丁基等的過氧化二烷基、過氧化苯甲酸第三丁酯、第三丁基過氧化-己酸2-乙酯等的過氧化烷酯、異丙苯過氧化氫、第三丁基過氧化氫等的過氧化氫等。尤其是以上述1分鐘半衰期溫度為100℃以上之有機過氧化物為佳，以1分鐘半衰期溫度在100℃~200℃的範圍內之有機過氧化物為較佳。作為此種有機過氧化物， 可舉出過氧化新癸酸第三己酯、過氧化新癸酸第三丁酯、過氧化新庚酸第三丁酯、過氧化三甲基乙酸第三己酯、過氧化三甲基乙酸第三丁酯、過氧化二月桂醯、過氧化-2-乙基己酸1,1,3,3-四甲基丁酯、過氧化二琥珀酸、第三己基過氧化-己酸2-乙酯、第三丁基過氧化-己酸2-乙酯、1,1-雙(第三己基過氧化)環己烷、1,1-雙(第三丁基過氧化)環己烷、過氧化異丙基一碳酸第三己酯、第三丁基過氧化順丁烯二酸、第三丁基過氧化己酸3,5,5-三甲酯、第三丁基過氧化一碳酸異丙酯、第三丁基過氧化一碳酸2-乙基己酯、過氧化月桂酸第三丁酯、過氧化苯甲酸第三己酯、過氧化乙酸第三丁酯、過氧化苯甲酸第三丁酯、4,4-雙(第三丁基過氧化)戊酸正丁酯、過氧化二異丙苯、過氧化二-第三己基、過氧化二-第三丁基、對薄荷烷過氧化氫等。
作為偶氮系的熱聚合起始劑，可舉出2,2’-偶氮雙(異丁腈)、2,2’-偶氮雙(2-甲基丁腈)、2,2’-偶氮雙(2,4-二甲基戊腈)、2,2’-偶氮雙(4-氰基戊腈)、2,2’-偶氮雙4-甲氧基-2,4-二甲基戊腈)、2,2’-偶氮雙(甲基異丁酸酯)、1,1’-偶氮雙(1-環己烷腈)等。又，本發明的聚合起始劑係為了控制反應性，能夠使用被封入具有籠狀分子之分子膠囊中之熱聚合起始劑。籠狀分子係以蒽結構為佳。
相對於(A)丙烯酸系聚合物100重量份，(C)熱聚合起始劑的添加量係以0.001~0.5重量份為佳。
在本發明的接著性樹脂層，亦能夠添加聚合延遲劑。藉由使用聚合延遲劑，能夠容易地控制聚合度。又，從使對基材的變形之追隨性提升的觀點而言，乃是較佳。
接著性樹脂組成物能夠進一步含有(A)~(C)以外的任意成分。例如為了使(A)丙烯酸系聚合物、或藉由(B)丙烯酸系單體或丙烯酸系寡聚物的聚合而生成的聚合物交聯，係能夠適合使用異氰酸酯系交聯劑、環氧系交聯劑、金屬鉗合物化合物等的(D)交聯劑(硬化劑)。此時，依照需要，作為(A)丙烯酸系聚合物或(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分，係能夠使用具有與(D)交聯劑反應的官能基之聚合物或單體。與(D)交聯劑反應之官能基，例如異氰酸酯系交聯劑時，係羥基或羧基等。相對於聚合物的官能基，(D)交聯劑的添加量係例如以1.5當量以下為佳。
藉由(D)交聯劑(硬化劑)之(A)丙烯酸系聚合物的硬化，亦可在貼合在被接著物前之製造接著性樹脂層之階段，藉由熟化而使其進行。
作為其它任意成分，例如可舉出抗氧化劑、填充劑、可塑劑等。在製造接著性樹脂層所使用的接著劑原材料組成物，亦可含有水或有機溶劑等的溶劑，亦可為無溶劑的漿狀組成物。在基材上存在ITO等的氧化物導電膜或基金屬(base metal)等有腐蝕的可能性之材料，且其與接著性樹脂層接觸時，作為接著性樹脂組成物的材料，較佳係使用減少酸等的腐蝕性成分，例如使用酸價低的聚合物。
以使在製造本發明的接著性樹脂層之硬化的成分亦即丙烯酸系單體或丙烯酸系寡聚物盡可能硬化為佳。又，使用丙烯酸系寡聚物時，丙烯酸系聚合物及丙烯酸系寡聚物均分子量較大，作為塗料常產生相溶性變差之情形。因此，以添加 相溶劑為佳。無反應性的相溶劑亦無妨，但是因為有在黏著劑層產生分離之可能性，所以能夠使用的材料為受到限定之可能性較高，而且依照種類或添加量而有在耐久試驗產生發泡等的問題之可能性、泛用性較低。因此，若為在熱反應時與丙烯酸系寡聚物一起硬化之相溶劑，因為高分子化而亦能夠抑制發泡等之緣故，以選定具有反應基之材料為佳。而且使用熱反應後會變硬這樣的丙烯酸系單體作為相溶劑時，可期待塗料的安定性，同時亦能夠期待硬化後黏著劑層變硬之效果。丙烯酸系單體係除了相溶性良好以外，相較於丙烯酸系聚合物或丙烯酸系寡聚物，因為黏度較低，所以藉由在塗料的黏度太高時添加，能夠調整成為在製膜時最佳黏度且亦有助於生產性提升。
(接著性樹脂層的製造方法)
在本發明之接著性樹脂層(轉移膠帶)，係能夠藉由將接著劑原材料組成物在含有溶劑的狀態下塗佈在隔離膜且乾燥，而且使用隔離膜保護而製造。接著劑原材料組成物，係以使用塑模或管刮刀而塗佈為佳。在溶劑的乾燥，係以使用乾燥機等使其乾燥為佳。關於溶劑的乾燥時間，考慮生產性時，係以10分鐘以下為佳，以2~5分鐘為更佳。又，因為必須將有機溶劑充分地乾燥，所以在有機溶劑的沸點以上之溫度使其乾燥為佳，以在熱聚合起始劑的1分鐘半衰期溫度以下進行乾燥為佳。
以上，基於較佳實施形態而說明了本發明，但是本發明係不被上述的實施形態限定，在不脫離本發明的要旨之範圍能夠進行各種改變。
積層體亦可為在3片以上的基材之間，各自具有 接著性樹脂層。在積層體所包含之2層以上的接著性樹脂層的1層以上(較佳為全部)係以本實施形態的接著性樹脂層為佳。
將積層體熱壓時，亦可在一對模具之間配置2個以上的積層體。該配置係沒有特別限定，可藉由模具而在壓縮方向堆積2個以上的積層體，亦可在對壓縮方向為垂直的面內(例如任一模具的按壓面上)排列2個以上的積層體。亦可使上述的插入物介於2個以上的積層體之間。
在本發明，係在製造如第1圖的接著性樹脂層11之後，製造如第2圖的積層結構，而且經過熱壓等的熱處理而能夠製造如第3圖的積層體30。在第1圖的接著性樹脂層11之製造時點，較佳為設有藉由加熱從含有溶劑的接著劑原材料組成物將溶劑除去之步驟。又，在隨後之貼合後的製程條件中，必須將接著性樹脂層11加熱而使聚合開始。
在本發明加壓時，為了對積層體加熱而使加熱溫度成為100~250℃，模具的溫度必須在比所需要的加熱溫度更高的溫度加熱。模具的溫度係以100~300℃為佳。有關本發明之加壓時間，從生產性的觀點而言，係以反應在短時間、例如5分鐘以內結束為佳。又，有關加壓溫度．時間，係可設定為可使積層體的強度變得充分之方式。
實施例
以下，基於實施例而具體地說明本發明。
(實施例1)
使用作為含有丙烯酸系聚合物之聚合物溶液之SK-Dyne(註冊商標)2094(綜研化學股份公司)、作為交聯劑之E-AX(綜 研化學股份公司)，相對於丙烯酸系聚合物100重量份，以交聯劑0.2重量份的比例調配。在所得到的混合物，添加作為具有反應性的流動性樹脂成之丙烯酸系單體之丙烯酸4羥基丁酯(大阪有機化學工業股份公司；4HBA)40重量份、作為熱聚合起始劑之第三丁基過氧化己酸2-乙酯(日油股份公司製；製品名：PERBUTYL(註冊商標)O)0.08重量份，而調製接著劑原材料組成物。接著劑原材料組成物係含有作為溶劑之乙酸乙酯(沸點77℃)，作為用以塗佈之塗料而改善黏度等的性狀。
將該接著劑原材料組成物，使用塗佈器且以在乾燥後之接著劑樹脂層(黏著劑層)的厚度成為50μm之方式塗佈在隔離膜(藤森工業股份公司製；製品名：125E-0010DG2.5AS、厚度125μm)的上面後，在乾燥步驟於90℃、2分鐘的條件下使溶劑乾燥而製造積層有接著性樹脂層之積層體。
其次，在得到的積層體之接著性樹脂層的上面，貼合隔離膜(藤森工業股份公司製；製品名：38E-0010BDAS、厚度38μm)而製造實施例1的接著性樹脂薄膜。
隨後，藉由進行1星期的熟化，使丙烯酸系聚合物與交聯劑(環氧系)的反應結束，而形成存在經交聯的丙烯酸系聚合物、具有反應性之流動性樹脂成分、及熱聚合起始劑的3種類之接著性樹脂層。
有關實施例1~19及比較例1~8，係在表1記載之接著劑原材料組成物的組成及表2記載之接著劑樹脂層的厚度，進行製造在隔離膜之間包含接著性樹脂層之積層體。表1或表2所未記載之事項，係與實施例1同樣。但是在實施例2 及實施例6~9，異氰酸酯系的交聯劑(TD-75、CORONATE HX)係不僅是與丙烯酸系聚合物的官能基，亦與含有羥基之丙烯酸系單體(4HBA)的一部分反應而形成經交聯的丙烯酸系聚合物，此時，與實施例1同樣地，接著性樹脂層係存在經交聯的丙烯酸系聚合物、具有反應性之流動性樹脂成分、及熱聚合起始劑之3種類。
又，在表1，商品係以溶液的方式市售時，重量份 的數值係表示構成其中接著性樹脂層之各成分的重量份。
「SK-Dyne 2094」及「SK-Dyne 2147」係各自表示丙烯酸系聚合物的商品名、SK-Dyne(註冊商標)2094(綜研化學股份公司、酸價：33、數量平均分子量7萬、固形分濃度25%)、SK-Dyne(註冊商標)2147(綜研化學股份公司、酸價：33)。「N-7136」係表示丙烯酸系聚合物的商品名、COPONYL(註冊商標)N-7136(日本合成化學工業股份公司、固形分濃度32%)。在表1係將各素材的固體成分量換算重量設作添加量重量份而記載。
「CORONATE HX」係表示聚異氰酸酯系硬化劑的商品名、CORONATE(註冊商標)HX(TOSOH股份公司)。「E-AX」係表示環氧系硬化劑(綜研化學股份公司)。「TD-75」係表示異氰酸酯系硬化劑(綜研化學股份公司)。
「UV-3310B」及「UV-1700」係表示胺甲酸酯丙烯酸酯的商品名(日本合成化學工業股份公司)。UV-3310B的物性係在60℃的黏度：40000~70000mPa．s、重量平均分子量Mw：5000、寡聚物官能基數：2、玻璃轉移溫度Tg：22℃。
PERHEXA(註冊商標)V」係表示以4,4-雙(第三丁基過氧化)戊酸正丁酯作為有效成分之熱聚合起始劑。「PEROCTA(註冊商標)O」係表示以1,1,3,3-四甲基丁基過氧化己酸2-乙酯作為有效成分之熱聚合起始劑。「PERBUTYL(註冊商標)O」係以第三丁基過氧化-己酸2-乙酯作為有效成分之熱聚合起始劑。「PERHEXA(註冊商標)HC」係以1,1-雙(第三己基過氧化)環己烷作為有效成分之熱聚合起始劑。「PERHEXA (註冊商標)Z」係以過氧化苯甲酸第三己酯作為有效成分之熱聚合起始劑。「Irg651」係以2,2-二甲氧基-2-苯基苯乙酮(別名苄基二甲縮酮)作為有效成分之光聚合起始劑。「PERCUMYL(註冊商標)ND」係以1分鐘半衰期溫度較低(約94℃)的過氧化新癸酸異丙苯酯作為有效成分之熱聚合起始劑。「PERCUMYL(註冊商標)P」係以1分鐘半衰期溫度為非常高(約232℃)的二異丙苯過氧化氫作為有效成分之熱聚合起始劑。熱加壓溫度係設定為210℃以下，使用比其高之1分鐘半衰期溫度的熱聚合起始劑時，因為熱反應起始劑的一部分係未反應的狀態下殘留著，且有成為在耐久試驗等產生發泡的原因之可能性，乃是不佳。
<試驗結果>
其次，說明評價方法及其結果。
(DSC測定方法)
藉由升溫速度10℃/分鐘的示差掃描熱量測定(DSC)，來測定接著性樹脂層的發熱起始溫度及波峰溫度。波峰溫度係發熱波峰(發熱量成為最大之波峰)的溫度之測定值。發熱起始溫度係波峰溫度為最低之發熱波峰從基線開始上升時的溫度之測定值。測定範圍係至少20℃~210℃，在該範圍無法確認發熱波峰時，接著性樹脂層不含有熱聚合起始劑時係設作「無」，接著性樹脂層含有熱聚合起始劑時係設作「無法觀察到」。
(藉由多維形狀製造之接著性樹脂層的評價方法)
作為基材，係準備2片裁斷成為15cm×15cm之厚度100μm的平坦聚對酞酸乙二酯(PET)薄膜。該等厚度雖係可相同亦可不同，但是在該評價方法係設為相同厚度。從接著性樹脂薄膜 將一側的隔離膜剝離而貼合至第1片的PET薄膜，而且將相反側的隔離膜剝離而貼合第2片的PET薄膜，透過接著性樹脂層而製成使用2片PET薄膜夾住之積層薄膜。將至此為止作為積層步驟。
使用能夠形成多維形狀之模具，將積層薄膜設置在上下的模具之間，將模具的溫度上升至設定溫度為止。將該設定溫度(實施例9為150℃，實施例1~8、12~19為200℃，實施例10為250℃，實施例11為300℃)作為熱加壓溫度，將到達熱加壓溫度之前的狀態設作預熱。在熱量上升至熱加壓溫度為止之時點，將上下的模具進行加壓而使積層薄膜變形。將上下的模具合閉之時間設作加壓時間，在本評價方法係設定為2分鐘。經過2分鐘後將模具打開，且將積層薄膜取出。
有關多維形狀積層薄膜及其製造過程，係針對積層步驟不良、邊緣浮起、接著強度、微小的追隨性之4項目，採用◎(非常優異)、○(優異)、△(稍微優異)、×(差)之4階段進行評價。
積層步驟不良係依照在熱壓前的積層步驟的接著不良之有無、程度等，如下述進行評價。
◎：在積層薄膜以目視未觀察到氣泡、缺陷且外觀良好。
○：在積層薄膜以目視觀察到一點點氣泡、或缺陷，但外觀沒有實際損害的程度。
△：在積層薄膜以目視觀察到一點點氣泡、或缺陷，但為容許範圍內。
×：在積層薄膜以目視觀察到氣泡、或缺陷且外觀為容許 範圍外。
邊緣浮起，係針對熱壓後的積層薄膜，藉由目視進行外觀確認且如下述進行評價。
◎：在積層薄膜無法確認邊緣浮起。
○：在積層薄膜能夠極稍微地確認邊緣浮起。
△：在積層薄膜能夠確認邊緣浮起但為容許範圍內。
×：在積層薄膜能夠確認邊緣浮起且為容許範圍外。
接著強度係針對由熱壓後的積層薄膜所製成之測定試料，測定2片PET薄膜間的接著強度，如下述進行評價。使用島津製作所的剝離試驗機，將2片PET薄膜之中一方剝下，在其剝離角度180度、拉伸速度300m/min，繼續剝下100mm的長度且將數值穩定的部分之平均值設作接著強度。從該測定值，如下述進行評價。
◎：接著強度為30N/25mm以上
○：接著強度為20N/25mm以上且未滿30N/25mm
△：接著強度為10N/25mm以上且未滿20N/25mm
×：接著強度為未滿10N/25mm
又，微小的追隨性，係針對熱壓後的積層薄膜，藉由目視進行外觀確認，來確認是否有氣泡等的發泡，如下述進行評價。
◎：在積層薄膜無法確認氣泡。
○：在積層薄膜能夠極稍微地確認氣泡。
△：在積層薄膜能夠確認氣泡但為容許範圍內。
×：在積層薄膜能夠確認氣泡且為容許範圍外。
將使用上述評價方法之結果，顯示在下述的表2。
(評價結果)
在實施例中任一者均無法確認在積層體有氣泡等的外觀上的不良。推論這是因為在接著性樹脂組成物中，除了(A)丙烯酸系聚合物以外，在接著性樹脂組成物中，亦含有作為流動性較高的成分之(B)丙烯酸系單體或丙烯酸系寡聚物之緣故。
在比較例1、5，藉由熱壓後的外觀確認，在使基 材變形後的部分，在接著性樹脂層與PET薄膜之間能夠確認到剝離的產生。推論這是因為接著性樹脂組成物中不含有具有反應性之流動性樹脂成分(丙烯酸系單體或丙烯酸系寡聚物)，致使接著性樹脂層未追隨材料變形之緣故。
在比較例2~4及6~8，藉由熱壓後的外觀確認，雖然良好地追隨使基材變形後的部分，但是確認到在全面產生發泡。在比較例2，推論雖然在接著性樹脂組成物中係含有具有反應性之流動性樹脂成分，但是因為起始劑為光聚合起始劑，在熱壓中不進行硬化反應，又，一部分的低分子成分產生氣化，在壓力從模具被釋放時，因溫度引起揮發及密著性低落而剝離掉。該例子的情況係在熱壓中採用若干方法進行照射紫外線，若能夠進行硬化反應時，就能夠解決該課題，但是因為對不透明的模具內照射紫外線係困難的。
在比較例3、7，推論雖然在接著性樹脂組成物中係含有具有反應性之流動性樹脂成分，但是因為不含有起始劑，所在熱壓時硬化反應不進行，基於與比較例2同樣的理由而剝離掉。
在比較例4，推論係由於使用1分鐘半衰期溫度較低的過氧化物作為起始劑，發熱起始溫度太低而在熱壓中不進行硬化反應，基於與比較例2同樣的理由而剝離掉。
在比較例8，推論係由於將1分鐘半衰期較高的氧化物使用作為起始劑，在藉由DSC之測定，無法在210℃以下觀察到波峰且在熱壓時的溫度未開始聚合反應，基於與比較例2同樣的理由而剝離掉。
在比較例6，推論係由於相對於具有反應性之流動性樹脂成分，熱聚合起始劑的量太多，所以在藉由DSC之測定值之發熱起始溫度，波峰溫度較低且從熱壓前開始進行聚合反應，即便反應，聚合物的分子量未變大且密著性未提升之緣故，所以發泡。
從比較例1~3、5、7的結果，得知為了使實施例的功能顯現，必須在接著性樹脂組成物中添加具有反應性之流動性樹脂成分及熱聚合起始劑。又，從比較例4、6、8的結果，得知為了使實施例的功能顯現，在接著性樹脂層之藉由DSC測定之波峰溫度太低或太高均有問題。又，波峰溫度，係能夠藉由調整熱聚合起始劑種類、丙烯酸系聚合物或對流動性樹脂成分之熱聚合起始劑的量等來控制。
在實施例中，因為接著性樹脂層係在流動性較高的狀態下貼合在PET等所貼合之基材，所以能夠堅固地密著。而且，因為藉由熱壓，具有反應性之流動性樹脂成分係產生流動，且在追隨基材的變形後，藉由熱而慢慢地進行熱聚合反應，具有反應性之流動性樹脂成分進行高分子化，而接著性樹脂層的流動性降低且以變形後的狀態進行硬化，所以不僅是在變形部不產生氣泡，在基材之間亦不產生發泡。
如實施例19地添加丙烯酸系寡聚物及相溶性良好的4HBA，具有確保塗料的安定性之效果。因為丙烯酸系聚合物的分子量越大，耐熱性和耐久性有變為越良好之傾向，所以盡可能使用分子量較大的聚合物為佳。藉由添加具有反應性之流動性樹脂成分，能夠觀察到製膜時之接著性樹脂層調平性 (leveling ability)良好且膜厚的均勻性有提升之傾向。
在接著性樹脂層被積層在隔離膜之間的狀態下，將各實施例的接著性樹脂薄膜與「(藉由多維形狀製造之接著性樹脂層的評價方法)」相同條件下進行熱壓後，藉由使用FT-IR(傅立葉(Fourier)變換紅外分光法)將硬化後的接著性樹脂層進行分析時，幾乎無法確認碳-碳雙鍵(丙烯酸系單體的乙烯基等)之波峰。而且在熱壓前後藉由DSC(示差掃描熱量測定)進行分析時，在熱壓前的DSC測定係能夠觀察到發熱波峰，但是在熱壓後的DSC測定係未觀察到發熱波峰。從該等結果認為硬化反應係在熱壓條件下結束。
在比較例1~5及7~8的接著性樹脂層，即便進行熱壓，藉由FT-IR亦能夠確認若干被認為源自碳-碳雙鍵之波峰。比較例1~3及7在熱壓前之DSC，係無法確認發熱波峰。因為無法確認熱引起的反應，所以能夠判斷熱硬化反應係未進展。
比較例5在熱壓前的DSC，係只能夠確認熱聚合起始劑的發熱，但是因為無具有反應性之流動性樹脂成分，所以聚合反應未進行。
比較例4、8在熱壓前的DSC，雖然能夠確認發熱波峰，但是因為發熱起始溫度及波峰溫度較高，所以能夠判斷在上述的熱壓條件下，熱硬化反應未進展。
在比較例6的接著性樹脂層，藉由熱壓後的FT-IR，幾乎無法確認碳-碳雙鍵的波峰。而且在熱壓前的DSC測定，雖然能夠觀察到發熱波峰，但是在熱壓後的DSC測定係未觀察到發熱波峰。從該等結果，認為在比較例6，硬化反 應係在熱壓條件下結束。
(接著性樹脂本身的DSC測定)
在實施例15~18，藉由DSC進行接著性樹脂本身的熱分析。從該結果，雖然亦取決於熱聚合起始劑的種類，但是能夠確認在100℃以上急遽地開始反應。因此，得知在接著劑原材料組成物及接著性樹脂組成物能夠使用之有機溶劑的沸點，係以100℃以下為佳，較佳為80℃以下。
從以上的結果，藉由接著性樹脂層係含有主成分之(A)丙烯酸系聚合物、(B)丙烯酸系單體或丙烯酸系寡聚物、及(C)熱聚合起始劑，能夠製造可抑制因高溫的熱壓加工而產生氣泡和剝離，而製造能夠形成三維形狀之黏著薄膜。
10‧‧‧接著性樹脂薄膜
11‧‧‧接著性樹脂層
11a、11b‧‧‧接著性樹脂層的兩面(黏著面)
12、13‧‧‧隔離膜
12a、13a‧‧‧隔離膜表面(剝離面)

Claims (8)

  1. 一種接著性樹脂層，其係含有具有丙烯酸系接著性樹脂組成物之單層的接著性樹脂層，其特徵在於：前述接著性樹脂組成物係至少含有(A)丙烯酸系聚合物、(B)丙烯酸系單體或丙烯酸系寡聚物、及(C)熱聚合起始劑，前述接著性樹脂層係於常溫在兩面具有黏著性，在升溫速度10℃/分鐘的示差掃描熱量測定(DSC)，在80℃以上能夠確認開始發熱，在120℃~210℃之間能夠確認至少1個波峰。
  2. 如申請專利範圍第1項所述之接著性樹脂層，其中前述(C)熱聚合起始劑為過氧化物。
  3. 如申請專利範圍第1或2項所述之接著性樹脂層，其中前述接著性樹脂組成物，相對於前述(A)丙烯酸系聚合物100重量份，係含有5~50重量份的前述(B)丙烯酸系單體或丙烯酸系寡聚物。
  4. 如申請專利範圍第1至3項中任一項所述之接著性樹脂層，其中前述接著性樹脂組成物，係含有含羥基之丙烯酸系單體作為前述(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分。
  5. 如申請專利範圍第1至4項中任一項所述之接著性樹脂層，其中前述接著性樹脂組成物，係含有硬化性胺甲酸酯丙烯酸酯作為前述(B)丙烯酸系單體或丙烯酸系寡聚物的至少一部分。
  6. 一種接著性樹脂薄膜，其特徵在於：在2片隔離膜之間積層如申請專利範圍第1至5項中任一項所述之接著性樹脂 層而成。
  7. 一種用以形成積層體之接著性樹脂層，該積層體係透過如申請專利範圍第1至5項中任一項所述之接著性樹脂層而積層2片基材而成。
  8. 一種接著性樹脂層，其特徵在於：透過如申請專利範圍第1至5項中任一項所述之接著性樹脂層而積層2片基材，在將所得到的積層體在夾在2個模具之間的狀態下使前述積層體加熱變形，前述接著性樹脂層係加熱硬化後，黏著力亦為10N/25mm以上。
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