TWI611894B - 低微膠之表面保護膜 - Google Patents
低微膠之表面保護膜 Download PDFInfo
- Publication number
- TWI611894B TWI611894B TW105117644A TW105117644A TWI611894B TW I611894 B TWI611894 B TW I611894B TW 105117644 A TW105117644 A TW 105117644A TW 105117644 A TW105117644 A TW 105117644A TW I611894 B TWI611894 B TW I611894B
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- Taiwan
- Prior art keywords
- resin material
- film
- refined
- kpa
- polymer
- Prior art date
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- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 claims description 5
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- VSKJLJHPAFKHBX-UHFFFAOYSA-N 2-methylbuta-1,3-diene;styrene Chemical compound CC(=C)C=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 VSKJLJHPAFKHBX-UHFFFAOYSA-N 0.000 description 2
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 2
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- BEIOEBMXPVYLRY-UHFFFAOYSA-N [4-[4-bis(2,4-ditert-butylphenoxy)phosphanylphenyl]phenyl]-bis(2,4-ditert-butylphenoxy)phosphane Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP(C=1C=CC(=CC=1)C=1C=CC(=CC=1)P(OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC1=CC=C(C(C)(C)C)C=C1C(C)(C)C BEIOEBMXPVYLRY-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
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- FACXGONDLDSNOE-UHFFFAOYSA-N buta-1,3-diene;styrene Chemical compound C=CC=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 FACXGONDLDSNOE-UHFFFAOYSA-N 0.000 description 2
- QYMGIIIPAFAFRX-UHFFFAOYSA-N butyl prop-2-enoate;ethene Chemical compound C=C.CCCCOC(=O)C=C QYMGIIIPAFAFRX-UHFFFAOYSA-N 0.000 description 2
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- GPOGLVDBOFRHDV-UHFFFAOYSA-N (2-nonylphenyl) dihydrogen phosphite Chemical compound CCCCCCCCCC1=CC=CC=C1OP(O)O GPOGLVDBOFRHDV-UHFFFAOYSA-N 0.000 description 1
- PZWQOGNTADJZGH-SNAWJCMRSA-N (2e)-2-methylpenta-2,4-dienoic acid Chemical compound OC(=O)C(/C)=C/C=C PZWQOGNTADJZGH-SNAWJCMRSA-N 0.000 description 1
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- AIBRSVLEQRWAEG-UHFFFAOYSA-N 3,9-bis(2,4-ditert-butylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP1OCC2(COP(OC=3C(=CC(=CC=3)C(C)(C)C)C(C)(C)C)OC2)CO1 AIBRSVLEQRWAEG-UHFFFAOYSA-N 0.000 description 1
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical class C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 description 1
- VSAWBBYYMBQKIK-UHFFFAOYSA-N 4-[[3,5-bis[(3,5-ditert-butyl-4-hydroxyphenyl)methyl]-2,4,6-trimethylphenyl]methyl]-2,6-ditert-butylphenol Chemical compound CC1=C(CC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)C(C)=C(CC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)C(C)=C1CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 VSAWBBYYMBQKIK-UHFFFAOYSA-N 0.000 description 1
- 241000251468 Actinopterygii Species 0.000 description 1
- 229930185605 Bisphenol Natural products 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
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- 239000005977 Ethylene Substances 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 description 1
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- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
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- HGVPOWOAHALJHA-UHFFFAOYSA-N ethene;methyl prop-2-enoate Chemical compound C=C.COC(=O)C=C HGVPOWOAHALJHA-UHFFFAOYSA-N 0.000 description 1
- HEAMQYHBJQWOSS-UHFFFAOYSA-N ethene;oct-1-ene Chemical compound C=C.CCCCCCC=C HEAMQYHBJQWOSS-UHFFFAOYSA-N 0.000 description 1
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- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 description 1
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- WGKLOLBTFWFKOD-UHFFFAOYSA-N tris(2-nonylphenyl) phosphite Chemical compound CCCCCCCCCC1=CC=CC=C1OP(OC=1C(=CC=CC=1)CCCCCCCCC)OC1=CC=CC=C1CCCCCCCCC WGKLOLBTFWFKOD-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B13/00—Conditioning or physical treatment of the material to be shaped
- B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
- B29B13/022—Melting the material to be shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/02—Making granules by dividing preformed material
- B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
- B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/69—Filters or screens for the moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/76—Venting, drying means; Degassing means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本申請案提出一種精製聚合物樹脂材料之方法。該方法包含令該樹脂材料熔化和接受在250kPa至400kPa範圍內之剪應力以形成精製的樹脂材料。精製的樹脂材料可被壓出、固化和切成縮減的微膠樹脂粒，其可於之後被熔化和壓出以形成縮減的微膠膜。
Description
本申請案主張2015年6月5日提出申請之美國專利申請案第62/171,473號之優先權，茲將該案全文以引用方式納入本文中。
本發明係關於聚合物膜材料，及特別地，係關於聚合物表面保護膜和形成尺寸、突起及含括的凝膠和微膠數縮減的此膜之方法。
表面保護膜，亦稱為遮膜、襯墊、或插頁膜，基本上用於提供物理屏障以避免基板的損傷、污染、抓痕、輕刮和擦痕。表面保護膜亦可替換地作為插頁膜以防止軟且易碎的光學膜的層間發黏或阻塞而用於顯示工業的光管理目的。例如，遮膜可以在基板使用之前，在基板的製造、運送或儲存期間內提供此保護。此膜可用於數種用途，如表面的保護性覆蓋、特別是用於保護相對平滑的
表面，如丙烯酸系、環烯烴聚合物(COP)、PMMA、聚碳酸酯，玻璃、經拋光或經塗漆的金屬和上了釉的陶瓷。用於電視、顯示器、電話、平板和其他顯示器的光學介質，例如，須要遮膜，該膜保護表面且可以未損傷、未在表面上留下黏合劑殘渣、或其他污染物或微粒的方式被移除。
許多光學基板亦容易因為遮膜本身的接觸表面的輪廓中的不規則性而受損。在通常為平面的同時，任何遮膜的接觸表面將具有一些下凹區域(坑)和上凸區域(突起)形式的不規則性。特別關心突起，因為它們會引發將要施用遮膜的基板中之對應的轉錄(凹痕)之故。
直到最近，大多數的光學基板才耐得住遮膜接觸表面中的小的不完美性。但是，現在，用於高解析應用之基板材料的展發對於品質的要求更為嚴格。甚至一或二微米的突起也會以無法被接受的方式損及這些材料的表面。此外，這些基板要求高解析度光學檢查，此必須以遮膜到位完成。此意謂遮膜不僅必須透光，還必須展現肉眼觀察的極高透光度和澄清度。雖然在一些情況中，可藉由使用改良的線上照相機系統而經由較高的混濁表面保護膜而偵測缺陷和界定缺陷的特徵，但先前認為“低濁度”材料所具有的澄清度不足用於此檢查。
這些更嚴格的要求導致某些聚合物材料實質上不再被用來作為用於高解析光學基板的遮膜。這是因為自此材料(如聚烯烴(常用者)和聚乙烯(PE))所形成的膜會包括小的聚合物聚集物，基本上將其稱為“凝膠”或“魚
眼”，其無法在壓出程序期間內被移除，且在一些情況中，甚至會因壓出程序而形成。凝膠可包括，例如，未熔化的聚合物纏結物、未熔化/未分散的聚合物，或氧化反應所形成之交聯的鏈。薄聚合物膜中的此凝膠，即使小於100μm者(文中稱為“微膠”且其有時被稱為“微魚眼”)，的存在會導致膜表面處的突起，如圖1和2中所示者。以垂直於表面觀之，這些突起可藉其平面形式面積測定且可藉膜自一般平面表面突起高度hp測定。
過去，僅某些相當昂貴的聚合物(如聚酯)曾可用於製造符合保護目前高解析光學基板之嚴苛要求的膜。極欲提出自成本更有效的聚合物(如PE和其他聚烯烴)形成但其性能等同於經黏合劑塗覆的PET遮膜所提供性能的表面保護膜。
本發明的一個方面提出一種精製聚合物樹脂材料之方法。該方法包含使樹脂材料熔化及接受剪應力在250kPa至400kPa範圍內以形成精製的樹脂材料。該方法另包含壓出和固化該精製的樹脂材料。某些具體實施例中，該聚合物樹脂材料主要包含一或多種聚烯烴。特別的具體實施例中，該聚合物樹脂材料主要包含聚乙烯。
本發明的另一方面提出一種形成聚合物膜之方法。該方法包含提供主要由聚乙烯所構成的聚合物樹脂材料及該聚合物樹脂材料與一或多種抗氧化劑混合以形成
樹脂材料混合物。該方法另包含使該樹脂材料混合物熔化和接受剪應力在250kPa至400kPa範圍內以形成精製的樹脂材料。該精製的樹脂材料經壓出以形成聚合物膜。一些具體實施例中，該方法另包含，在壓出該精製的樹脂材料以形成聚合物膜的動作之前，壓出和固化該精製的樹脂材料，及之後使該壓出和固化之精製的樹脂材料熔化和接受低於70kPa之剪應力。
本發明的另一方面提出一種樹脂材料，其基本上由聚乙烯所構成，該樹脂材料實質上沒有最大尺寸大於100微米的微膠。一個特點中，藉由使先質樹脂材料熔化和接受剪應力在250kPa至400kPa範圍內而使得該樹脂材料經精製。
本發明的另一方面提出一種基本上由聚乙烯所組成之熱塑性聚合物膜，該膜實質上沒有最大尺寸大於100微米的微膠。特別的具體實施例中，該熱塑性聚合物膜具有至少一個公稱平面表面，該表面實質上沒有自該公稱平面表面向外延伸超過1.0微米的突起。
本發明的另一方面提出一種多層熱塑性聚合物膜，其包含界定第一外膜表面的脫模層；和界定與第一外膜表面相反的第二外膜表面的黏著層。該脫模層和該黏著層之至少一者基本上由聚乙烯所組成且質實上沒有最大尺寸大於100微米的微膠。某些具體實施例中，該脫模層和該黏著層二者基本上由聚乙烯所組成且質實上沒有最大尺寸大於100微米的微膠。這些具體實施例中的某些者
中，該膜實質上沒有自該第一或第二外膜表面向外延伸超過1.0微米的突起。
M100‧‧‧方法
10‧‧‧聚合物樹脂混合物
20‧‧‧網
30‧‧‧膜
100‧‧‧壓出膜生產線
110‧‧‧壓出機
120‧‧‧模具
130‧‧‧真空箱
140‧‧‧鑄輥
150‧‧‧壓輥
M200‧‧‧方法
10’‧‧‧精製的聚合物壓出物
200‧‧‧壓出機
210‧‧‧壓出機筒身
211‧‧‧料斗
212‧‧‧雙螺桿
214‧‧‧貨口
216‧‧‧貨口
218‧‧‧模具出口
219‧‧‧切割裝置
300‧‧‧樣本框
310‧‧‧隨機位置
320‧‧‧微膠
圖1係膜截面圖，用以說明微膠尺寸的影響和在表面輪廓上的位置；圖2是照片，出示有含括的微膠埋於其中之聚合物膜表面的表面突起：圖3是可用於根據本發明之方法之壓出膜生產線的示意圖；圖4是根據本發明之具體實施例之方法的方塊流程圖；圖5是可用於實施根據本發明的一些具體實施例之方法的高剪應力壓出設備的圖示；圖6是根據本發明之具體實施例之方法的方塊流程圖；圖7是聚合物膜樣品圖，其附有樣品的一部分的放大照片；和圖8是進行微膠測定的膜材料的照片的螢幕截圖。
藉由提出含括聚合物樹脂材料之精製和自彼製得的聚合物膜材料的數個特定具體實施例和細節，以下
描述用以徹底瞭解本發明之各種具體實施例。但應瞭解，本發明不限於這些特定的具體實施例和細節，其僅為例子。另瞭解，擁有此技藝一般技術之人士，依照已知系統和方法，將理解本發明於其所欲目的之用途及在任何數目的替代具體實施例中之優點。
本發明提出一種用於自聚合物(如聚烯烴，其基本上展現形成和保留所含括的凝膠的趨勢)製造低微膠之表面保護膜之方法。本發明之方法通常含括使聚合物樹脂在熔化期間內(在壓出表面保護膜之程序的期間內或作為預處理步驟的一部分)接受極高的剪應力。如下文將更詳細討論者，高剪應力加工可被用以破壞和熔化在基礎聚合物樹脂材料中之先前未熔化的或纏結的凝膠和微膠，但在無額外設備時，在壓出材料中形成交聯的凝膠和未熔化或纏結的微膠。本發明之方法中，一或多種方式可用於阻礙交聯的凝膠之形成。因此，所得壓出物沒有巨膠(最長尺寸大於100微米的凝膠)且與基礎樹脂和使用標準壓出程序自相同聚合物形成的壓出物比較，前者所具有的微膠較少且較小。
文中所謂“膜”是指厚度低於1000微米的片或薄膜。表面保護膜基本上具有低於100微米的厚度且可具有遠低於50微米的厚度。此膜中，大於10-20微米的任何微膠明顯扭曲膜的實質平坦表面。將理解關於膜表面所謂“實質平坦”是指若多層膜施於平面表面，則公稱規則表面將呈平坦。
因為使用標準技術製得的聚合物膜中形成凝膠和微膠而出現的困難已為習知。在如圖3所示之典型的壓出膜生產線100中，聚合物樹脂材料10(基本上是粒形式或粒和自邊緣修整回收的捲毛之組合)餵入常規的壓出機110以經由模具120(為網20之形式)熔化和壓出該樹脂材料10。用於鑄網，使用傳統的狹縫模具。用於吹製網，使用圓形或橢圓形模具。一些具體實施例(如，無側磨砂(NSM)程序)中，經由使用真空箱130，壓出樹脂材料的網20可被導引至鑄輥140上。其他具體實施例(如，一側磨砂(OSM)程序)中，材料之鑄型不須以真空輔助。將瞭解雖然文中出示和描述真空箱130，但可以使用施以負壓的任何適當裝置。鑄輥基本上光滑以賦予所得鑄膜30光滑、實質上平坦的表面。但是，一些具體實施例中，鑄膜的一或兩面可被賦予有紋理或有圖案的表面。鑄膜30可驅動額外的加工以賦予與光滑表面相反的表面特別的紋理或圖案。此可包括例如，加熱該鑄膜30及之後導引至介於光滑壓輥和橡膠或其他有紋理的壓輥(未示)之間。膜30亦可被修整至預定寬度。所得膜纏在滾筒150上以儲存和/或運送或在使用之前進一步加工。
圖3的例示壓出程序出示單層膜之形成。將瞭解可藉由提供多重壓出機(各者如圖3所示地形成單層或者，或者，將使用共壓出進料塊將單一壓出機的輸出物切成多層)而製得多層膜。各情況中，多層一起在鑄輥上鑄成單一層合膜。各種層可由相同或不同的材料形成。一
些膜，例如，可以三層形成：核心層被與基板和脫模層接觸的黏著層所圍繞。簡言之，壓出的保護層聚合物膜可具有任何數目之不同或類似材料的層。
使用以上程序製得的PE膜將符合許多應用的要求，但微膠存在所引發的表面不規則性會使其無法用於許多表面保護膜應用。在許多類型的凝膠會引發此不規則性(請參考Spalding等人，“Troubleshooting and Mitigating Gels in Polyolefin Film Products,”Plastics Engineering September 2013,pp.50-58.(“Spalding Paper”))的同時，本申請案之方法主要針對控制(1)纏結之未分散的聚合物鏈，其在壓出程序期間內維持未熔化或自壓出模具射出之前固化(“未熔凝膠”或“未熔微膠”)或(2)因為氧化反應或切剪誘發而交聯者(“交聯的凝膠”或“交聯的微膠”)。
兩種類型(和其他者)的凝膠可存在於樹脂製造商提供的基礎樹脂中。上述基礎壓出程序通常移除較大的凝膠，但無法有效地移除較小的未熔凝膠，特別是未熔微膠。曾建議使用相對高(100-200kPa)的剪應力，自PE膜材料移除微膠。請參考Spalding的論文。在Spalding提出使用常規的單螺桿壓出機和Maddock-型混合機，可得到此剪應力程度的同時，本發明者發現此壓出機通常受限於60-70kPa的最高剪應力範圍，此已被證實不足以減少所關注的微膠缺陷。
不僅單螺桿壓出機可用的最高剪應力不足，本發明者發現即使Spalding建議之相對高的剪應力程度也
不足以將微膠降至不會在最終PE膜引發無法接受的表面突起的尺寸。只有在雙螺桿壓出機中使用極高剪應力才可能將未熔的微膠破壞至足夠的程度。但在無其他方式的情況下，發現高溫、高剪應力程序得到大量交聯凝膠。
本發明之方法克服上述問題。例示具體實施例中，本發明提出使聚合物樹脂單獨或與其他膜產品成份一起經精製和/或均質化的方法。此具體實施例的特別變化中，樹脂精製和/或均質化程序作為壓出僅具有低於所欲尺寸或數值標準之聚合物膜的前處理步驟。另一例示具體實施例中，本發明提出連續製膜法，其包括使精製和/或均化基礎樹脂的動作。
本發明之方法可用於製造實質上沒有最大尺寸大於100微米的微膠之聚烯烴膜。特別的具體實施例中，本發明之方法可用於製造任何觀察到的微膠的最大尺寸在10微米至60微米範圍內的聚烯烴膜。一些特別明顯的具體實施例中，本發明之方法可用於製造任何觀察到的微膠的最大尺寸在20微米至50微米範圍內的聚烯烴膜。本發明之方法亦可用於製造每平方毫米的微膠計數(尺寸超過10微米的微膠數)低於0.1的聚烯烴膜。此外，其可用於製造沒有突起自膜的公稱平面延伸超過1.0微米的聚烯烴膜。
對照圖4，用於製造根據本發明之具體實施例之精製樹脂的通用方法M100始於S105。於S110，提供樹脂材料和/或自樹脂製造商接收樹脂材料。方法M100可
以任何熱塑性樹脂材料實施，但如之前討論者，主要針對具有未熔凝膠和微膠的樹脂材料。基本上以粒形式提供的樹脂材料可以與其他成份預混合或複合。於S120，選擇其他構成材料。這些材料包括，特別地，安定化材料，其經特定選擇以阻礙所觀察到之在極高剪應力壓出期間內遇到的交聯效應。
如前示者，已發現極高剪應力(大於250kPa)壓出程序會在壓出樹脂中得到高交聯度。此交聯可歸因於高剪應力本身和壓出機中的所得高溫。認為高剪應力環境製造大量自由基，其可用於交聯熔融物中的聚合物鏈。高熱、長停留時間和氧的存在提高了氧化反應和進一步交聯的趨勢。
為阻礙這些效應，可將一或多種安定化材料加至樹脂。特定的安定劑(如抗氧化劑安定劑)之選擇可取決於，但無限制，主要聚合物、特別的樹脂調合物、所用的剪應力程度、溫控方式、和其他因素。
抗氧化劑安定劑在熱聚合物(如聚乙烯)中的角色是保護聚合物以免氧化性降解。此降解的機構是自動催化的自由基鏈程序。在此程序期間內，形成氫氧化物，其分解成自由基並加速降解反應。抗氧化劑藉(1)清除自由基以中斷過氧化氫分解反應造成的氧化性鏈反應和(2)消耗過氧化氫而防止此降解反應。
本方法之例示具體實施例(如可用於精製的PE和其他聚烯烴樹脂)中，額外構份可包括主要抗氧化劑(其
經配置或經選擇以阻礙與熱相關的交聯)和第二抗氧化劑(其經配置和經選擇以消除剪切誘發的自由基)。抗氧化劑含有一或多個反應性氫原子，其束縛自由基，特別是過氧基自由基，形成聚合型過氧化氫基和相對安定的抗氧化劑物種。目前，用於塑料，酚系抗氧化劑是銷售情況最佳的抗氧化劑。它們包括簡單的酚、雙酚、硫代雙酚和聚酚。阻礙酚(如BASF的Irganox®1076、1010和Ethyl 330)符合自由基清除需求且被視為主要抗氧化劑。其他主要抗氧化劑包括表I中所列者。
可作為第二抗氧化劑的主要抗氧化劑群組包括以磷為基礎的抗氧化劑(通常是亞磷酸酯)。亞磷酸酯藉由將過氧化氫轉化成非鏈傳播的醇，同時亞磷酸酯本身被氧化成磷酸酯而作用。參壬基苯基亞磷酸酯是一種常用的亞磷酸酯。典型的特定第二抗氧化劑是GE的Weston TNPP、BASF的Ultranox 626和Irgafos® 168。其他例示第二抗氧化劑列於表II。
可用於阻礙交聯效應的抗氧化劑中之一些或全數過量使用的話，會具有所不欲的效應。此效應包括，例如，遷徙和模糊。據此，基本上希望選擇阻礙壓出樹脂中之交聯所須的最小量。實驗數據可用以使得用於特別的樹脂或壓出物的終應用之主要和第二抗氧化劑的相對量最適化。
回到圖4，在S130，安定化材料和任何其他成份與基礎樹脂材料混合。此可以分別混合或複合(compounding)操作完成或可藉由在高剪應力複合/壓出設
備的料斗中合併材料而完成。在S140，聚合物混合物或複合物熔化並在超過250kPa的剪應力下剪切。典型的具體實施例中，剪應力將在250kPa至400kPa範圍內。此基本上將使用高剪應力多螺桿壓出機完成，但可使用能夠賦予此剪應力的任何設備。可以基於聚合物和可接受的微膠含量的標準，選擇方法M100中所用之特別的剪應力。例如，用於PE樹脂材料(其中所欲最大微膠尺寸是約50微米且中間微膠尺寸低於20微米)，須要的剪應力超過300kPa。通常，聚烯烴材料所須的剪應力可在300kPa至375kPa範圍內。
為進一步例示本發明，方法M100的動作S140可以使用雙螺桿壓出機(如圖5中所示的壓出機200)進行。壓出機200包括料斗211，聚合物樹脂混合物10可於其中引至壓出機筒身210中。一些具體實施例中，料斗211和壓出機筒身210可包括貨口214，氮可經由彼被引入以替換氧，藉此有助於緩和熔融物中的氧化反應。壓出機內部使用氮有助於降低熔融物中之與熱有關的交聯程度。藉雙螺桿212，樹脂10之後被導引通過筒身210，其之後賦予所須的高剪應力。熔化的聚合物材料之後通至模具出口218，於此處以精製的聚合物壓出物10’壓出。在用於說明的具體實施例中，以長條壓出之精製的聚合物材料10’可使用任何適當的切割裝置219切成粒。這些粒可於之後被包裝和運送以用於進一步加工和/或作為標準壓出生產線中的基礎材料使用。如以下討論者，壓出機200
亦可用於連續加工線以製造最終應用材料。
再度回到圖4，方法M100可包括排放揮發性有機化合物(VOC)(熔融物中的安定劑反應和暴於高應力的結果)的動作。圖5的例示壓出機200中，此可藉由將真空線用於接近壓出機筒身210末端的一或多個貨口216而完成。於S160，精製的聚合物材料經壓出。一些具體實施例中，壓出物可為固化物的聚合物條(其可被切成粒，其尺寸實質上類似於樹脂製造商提供之基礎樹脂粒的尺寸)形式。此方法於S195終結。
自以上方法得到之壓出的聚合物是原始基礎聚合物的精製形式。若施以足夠的剪應力，則該程序將會移除所有未熔的巨膠且顯著降低任何殘留微膠的尺寸，且不會顯著製造交聯凝膠。
方法M100之精製的聚合物輸出物僅為基礎聚合物材料、用於緩和交聯凝膠的任何安定劑、和自彼生成的任何反應物。此精製的材料可於之後在常規的壓出程序中代替基礎樹脂。此情況中，精製的樹脂材料可以與常規的壓出機中的任何最終材料成份混合或複合或者是在引至常規的壓出機中之前的預混合步驟的一部分。或者，任何此最終材料構分可以與基礎樹脂混合或複合，此為以上方法M100中的動作S120的一部分。
使用高剪應力精製程序M100製得的精製樹脂粒曾被用來作為類似於圖3的壓出膜生產線100之膜生產線的輸入材料。對照圖6，以此方式形成聚合物膜之方法
M200始於S205。於S210，聚合物和用於最終膜材料的任何其他成份經選擇。該成份材料可包括，特別地，依前述方式選擇以阻礙交聯效應的安定化材料。在S220，各種聚合物成份摻混在一起。將瞭解一些或所有成份可以在高剪應力複合之前摻混。但是，一些情況中，某些最終材料成份可以在常規的剪應力壓出動作的期間內或之前與高剪應力複合動作之精製的聚合物輸出物摻混。在S230，如前述者，基礎聚合物樹脂和至少任何安定化添加劑使用極高剪應力複合。所得複合/精製的樹脂材料可於之後在S240製成粒或其他可運送形式。
本發明的一些具體實施例中，高剪應力複合動作可為單一連續程序線的一部分。此情況中，因為高剪應力複合動作的輸出物可以直接被供應作為常規的剪應力複合動作的輸入物，所以可以消除動作S240。在S250，複合/精製的聚合物樹脂材料餵至常規的剪應力壓出機。在壓出物進料程序之前或期間內，複合/精製的樹脂材料可以與其他最終產物成份混合。額外的成份可包括經根據本發明之方法精製的其他聚合物樹脂和/或未經精製的聚合物樹脂。壓出機中，最終材料成份經收集熔化並接受常規的剪應力。熔化的聚合物材料可於S260通過一或多個濾器，這些濾器較佳地儘可能緊臨壓出模具以防止濾器下游的微膠的再聚集。在S270聚合物材料經壓出並在鑄輥上鑄造。各種具體實施例中，聚合物材料可被鑄成單層膜或可被鑄成前述多層膜中的一層。此多層膜可以與含有進
行過高剪應力精製程序的樹脂之額外層和/或不包含任何此樹脂的一或多層形成。
方法M200在S295終結。
將瞭解本發明之精製的樹脂和樹脂精製法的用途不限於特別的鑄膜或壓出程序。其可以，例如，與任何鑄造或吹膜程序連結。亦將瞭解本發明之樹脂精製方法(如方法M100)可在壓出/共壓出程序之前使用或者為壓出/共壓出程序以外的其他程序的一部分。
使用本發明之方法製得的膜產品具有顯著減少的微膠含量並澄清度優於自未精製的樹脂製得的膜。本發明之方法可用以，特別地，提供精製的聚烯烴樹脂材料和自彼形成的膜。最特別地，該方法可用以形成精製的PE樹脂材料和具有先前無法得到的微膠尺寸和計數程度的PE膜。根據本發明之具體實施例，可提供PE樹脂材料和實質上沒有最大尺寸超過100微米的凝膠之PE膜。一些變體中，可提供PE樹脂材料和最大微膠尺寸在約10微米至約60微米範圍內的PE膜。特別的具體實施例中，所提供的PE樹脂材料的最大尺寸在約10微米至約40微米範圍內。根據本發明之具體實施例，所提供的PE樹脂材料和PE膜的每平方毫米中之最大尺寸大於10微米的微膠計數在0-0.2範圍內。一些具體實施例中，所提供的PE樹脂材料和PE膜的每平方毫米中之最大尺寸在約10微米至約50微米範圍內的微膠計數在0-0.1範圍內。
藉由限制膜產品中所含括的微膠的尺寸，本
發明之方法亦得以製造具有最少突起的膜。特別地，根據本發明之具體實施例，所提供的PE膜材料中，高於公稱平面表面的突起高度在約0.0至約5.0的範圍內。特別佳的具體實施例中，PE膜實質上沒有高度高於公稱平面表面大於約1.0微米的突起。
根據本發明之具體實施例製得的PE膜基本上所具有的厚度在約15微米至約80微米範圍內。一些所欲的具體實施例中，PE膜的厚度可在約20微米至約60微米範圍內。特別所欲的具體實施例中，PE膜的厚度可在約25微米至約40微米範圍內。PE膜材料可以使用前述安定劑中之任何者形成且亦可包含，無限制地，聚丙烯(PP)、乙烯乙酸乙烯酯(EVA)、乙烯丙烯酸甲酯(EMA)、乙烯甲基丙烯酸(EMMA)、乙烯丙烯酸丁酯(EnBA)、彈性體(如經二茂金屬催化的丁烯、戊烯、己烯或辛烯和乙烯之共聚物)、彈性體或嵌段共聚物(如苯乙烯-丁二烯-苯乙烯(SBS)、苯乙烯-乙烯-丁烯-苯乙烯(SEBS)和苯乙烯-異戊二烯-苯乙烯(SIS))、觸媒中和劑(如硬脂酸鈣和其他者)、使用其他觸媒製造的LLDPE、和賦黏劑。根據本發明製得的PE膜可為單層或與相同或不同的成份材料之多層。一些多層具體實施例中，僅低於整組數目(subset number)的層由經根據本發明之方法精製的PE樹脂形成。
用於表面保護膜之嚴苛的含括微膠及表面起
伏要求的一個效應在於標準的檢查技術可能不足。會引發膜表面之無法被接受的突起的微膠尺寸很小，以一般方法無法偵測。用於評估使用本發明之方法製得之精製的樹脂材料和表面保護膜之目的，須要新的檢查技術。以下段落描述用以提供以下實例中所述數據的檢查方法。
通常，微膠的計數和確定尺寸可藉人工和自動化方法二者進行。所用方法可取決於膜表面的品質和一致性。若膜具有平坦一致的黏著表面(即，將與待保護的基板接觸的表面)，則自動化方法可為較佳者。但是，若膜具有變動或粗糙表面，則人工方法可為減少數據雜訊之較佳者。
人工方法中，微膠計數要求樣本框可以使用具20倍放大效果的立體顯微鏡在共軸反射照明下以肉眼檢查。如圖7所示者，檢視膜材料的樣本框300中之預定數目的隨機位置310。於各位置310處，矩形區域被放大以辨視和計算該位置的微膠數。說明例中，放大區域是4.68×3.52mm(16.4736mm2)。記錄各位置的微膠320數目並用以提供每單位面積的估計計數。
微膠的人工確定尺寸可以使用影像軟體(如Media Cybernetics ImagePro®)完成。ImagePro®，例如，具有“測量”功能，可用以測量在捕捉到的影像中之先前辨視的微膠的最大尺寸，此如圖8中的螢幕截圖所示者。這些測量可於之後用以定出微膠在各種尺寸範圍的頻率。
用於自動化計數和確定尺寸，在共軸反射照
明下，使用20倍放大的立體顯微鏡和數位相機，自樣本框捕捉影像。可在各框上之預定數目的隨機位置捕捉放大的影像。之後使用特殊的影像分析軟體提供計數和尺寸資訊。
表面保護膜的表面起伏和，特別地，突起高度非常明顯。用於以下的例子，高於公稱表面的突起高度係使用Zygo NewView7300 Scanning White Light Interferometer和Metropro®軟體測定。開發特殊應用以測定高於平均表面平面的突起高度。此技術得以測定小如0.1微米的突起高度。
除了微膠和表面起伏測定以外，亦檢查膜樣品的濁度。文中所謂濁度(亦稱為寬角度散射)是指穿透膜試樣的穿透光與入射光的偏差超過2.5°的百分比。以下的實例中，濁度測定係根據ASTM D1003-95完成。採樣、樣品製備、設備、試驗參數、和計算皆在ASTM D1003-95a的範圍內進行。
作為基線，使用類似於圖3所示之常規的剪應力壓出線形成多層PE膜。該多層膜包含核心層、黏著層和脫模層。核心層由99.992%低密度聚乙烯(LDPE)和0.008% Irganox 1010形成。黏合層由75%丁烯共聚物聚乙烯彈性體、15%高密度聚乙烯(HDPE)和10% LDPE形成。
脫模層由85% LDPE和15% HDPE形成。各層的構份經預混合且三種混合物分別餵入三個單螺桿壓出機中。各壓出機中，聚合物材料接受約66kPa之估計的最大剪應力處理並通過包括一個最終5-微米熔融物濾器的多重過濾階段。經過濾的熔融物經膜模具壓出並在平坦的鑄輥上鑄成單一的三層膜。經冷卻的膜之後引至導筒機上。取得膜樣品並使用上述技術檢查以定出微膠尺寸和計數資訊。
使用類似於M200的高剪應力方法，形成精製的多層PE膜。該多層膜包含核心層、黏著層和脫模層。核心層和脫模層二者由59.4% LDPE、40% HDPE、0.48% Irganox® 1076和0.12% Irgafos® 168形成。黏合層由75%丁烯共聚物聚乙烯彈性體、15% HDPE、9.56% LDPE、0.32% Irganox® 1076和0.12% Irgafos® 168形成。
用於黏著層的構份及用於核心和脫模層的構份分別混合並經由高切變壓出機加工。各情況中，材料餵入高剪應力共旋轉雙螺桿壓出機中，於此處接受約350kPa的估計最大剪應力處理。將氮氣注入壓出機的料斗和筒身中以提供氮環境。接近壓出機筒身末端的真空口用以排放VOC。所得聚合物材料經由模具壓出並切成粒。此粒經收集和包裝及密封用於運輸。經包裝的粒於之後拆封，並餵入三個單螺桿壓出機中，黏著層材料餵入一個壓出機中而核心/脫膜層材料餵入兩個壓出機中。各個壓出
機中，聚合物材料接受約50kPa的估計最大剪應力處理並通過包括一個最終5-微米熔融物濾器的多重過濾階段。經過濾的熔融物經膜模具壓出並在平坦的鑄輥上鑄成單一的三層膜。經冷卻的膜之後引至導筒機上。取得膜樣品並使用上述技術檢查以定出微膠尺寸、突起和計數資訊。
使用類似於M200的高剪應力方法，形成另一精製的多層PE膜。該多層膜包含核心層、黏著層和脫模層。核心層和脫模層二者由59.85% LDPE、40% HDPE、0.06% Irganox® 1076和0.09% Sandostab P-EPQ形成。黏著層由54.85%丁烯共聚物聚乙烯彈性體、30% HDPE、15%乙烯辛烯彈性體、0.09% Irganox® 1076和0.09% Sandostab P-EPQ形成。
如實例2中者，用於黏著層的構份及用於核心和脫模層的構份分別混合並經由高切變壓出機加工。各情況中，材料接受約350kPa的估計最大剪應力處理。如同之前者，此粒餵入三個單螺桿壓出機中並經共壓出而形成三層膜。各個壓出機中，聚合物材料接受約50kPa的估計最大剪應力處理。此處，壓出之前，材料通過包括一個最終7.5-微米熔融物濾器的多重過濾階段。取得所得樣品並使用上述技術檢查以定出微膠尺寸和突起資訊。
表III彙整出這三個樣實例各者的微膠含量和突起高度數據。各情況中，自至少10個膜樣品取得數
據，其中的各者以前述方式檢查。可看出使用本發明之高剪應力精製方法形成的兩種PE材料所展現的微膠顯然比常規形成的PE材料所得者來得小。此外，精製的PE樹脂膜材料展現的沒有大於1.0微米突起，實例3的膜沒有超過0.2微米的突起。
*微膠的最大尺寸>10μm
除了微膠的尺寸和數目減少以外，精製的PE膜材料亦展現意外之濁度大幅降低的結果。僅就肉眼看得到的微膠之減少，膜材料的澄清度之改良大於預期。此意謂膜材料的均勻度極高。
嫻於此技術者將容易瞭解本發明傾向於廣泛利用和施用。除了此處描述者以外，由本發明和其先前描述，將顯見或合理地提出本發明的許多具體實施例和因應方式，及許多變體、修飾和對等配置，這些未背離本發明之目的和範圍。
已於先前說明和描述此發明之例示具體實施例，應瞭解本發明不限於文中所揭示的架構。本發明可以
在不背離其精神或基本屬性的情況下，以其他特定形式體現。
300‧‧‧樣本框
310‧‧‧隨機位置
320‧‧‧微膠
Claims (22)
- 一種精製聚合物樹脂材料之方法，該方法包含：令該樹脂材料熔化及接受在250kPa至400kPa範圍內之剪應力以形成實質上沒有最大尺寸大於100微米的微膠之精製的樹脂材料。
- 如申請專利範圍第1項之方法，其中該聚合物樹脂材料主要由一或多種聚烯烴所組成。
- 如申請專利範圍第1項之方法，其中該聚合物樹脂材料主要由聚乙烯所組成。
- 如申請專利範圍第1項之方法，其另包含：使該聚合物樹脂材料與一或多種抗氧化劑混合。
- 如申請專利範圍第1項之方法，其中令該聚合物樹脂材料接受在300kPa至375kPa範圍內之剪應力以形成該精製的樹脂材料。
- 如申請專利範圍第1項之方法，其另包含：壓出和固化該精製的樹脂材料。
- 如申請專利範圍第1項之方法，其中該聚合物樹脂材料至少包含主要重量的聚乙烯，該方法另包含：使該聚合物樹脂材料與一或多種抗氧化劑混合；和壓出和固化該精製的樹脂材料。
- 一種形成聚合物膜之方法，該方法包含：提供主要由聚乙烯所組成之聚合物樹脂材料；使該聚合物樹脂材料與一或多種抗氧化劑混合以形成樹脂材料混合物； 使該樹脂材料混合物熔化和接受在250kPa至400kPa範圍內之剪應力以形成實質上沒有最大尺寸大於100微米的微膠之精製的樹脂材料；和壓出該精製的樹脂材料以形成該聚合物膜。
- 如申請專利範圍第8項之方法，其另包含：在壓出該精製的樹脂材料以形成該聚合物膜的動作之前，壓出和固化該精製的樹脂材料，和使該壓出和固化之精製的樹脂材料熔化和接受低於70kPa之剪應力。
- 一種樹脂材料，其基本上由聚乙烯所構成，該樹脂材料實質上沒有最大尺寸大於100微米的微膠。
- 如申請專利範圍第10項之樹脂材料，其中藉由使先質樹脂材料熔化和接受在250kPa至400kPa範圍內之剪應力而使得該樹脂材料經精製。
- 如申請專利範圍第10項之樹脂材料，其中藉由使先質樹脂材料熔化和接受在300kPa至375kPa範圍內之剪應力而使得該樹脂材料經精製。
- 如申請專利範圍第10項之樹脂材料，其中該樹脂材料為壓出粒形式。
- 一種基本上由聚乙烯所組成之熱塑性聚合物膜，該膜實質上沒有最大尺寸大於100微米的微膠。
- 如申請專利範圍第14項之熱塑性聚合物膜，其中該膜實質上沒有最大尺寸大於50微米的微膠。
- 如申請專利範圍第14項之熱塑性聚合物膜，其中 該膜具有至少一個公稱平面表面，該表面實質上沒有自該公稱平面表面向外延伸超過1.0微米的突起。
- 如申請專利範圍第14項之熱塑性聚合物膜，其中該膜具有至少一個公稱平面表面，該表面實質上沒有自該公稱平面表面向外延伸超過0.5微米的突起。
- 一種多層熱塑性聚合物膜，其包含：界定第一外膜表面的脫模層；和界定與該第一外膜表面相對的第二外膜表面的黏著層，其中該脫模層和該黏著層之至少一者基本上由聚乙烯所組成且質實上沒有最大尺寸大於100微米的微膠。
- 如申請專利範圍第18項之多層熱塑性聚合物膜，其中該脫模層和該黏著層二者基本上由聚乙烯所組成且質實上沒有最大尺寸大於100微米的微膠。
- 如申請專利範圍第18項之多層熱塑性聚合物膜，其中該膜實質上沒有自該第一或第二外膜表面向外延伸超過1.0微米的突起。
- 如申請專利範圍第18項之多層熱塑性聚合物膜，其中該膜實質上沒有自該第一或第二外膜表面向外延伸超過0.5微米的突起。
- 如申請專利範圍第18項之多層熱塑性聚合物膜，其中該黏著層包含55至75重量%的丁烯共聚物聚乙烯和15至30重量%的高密度聚乙烯。
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| WO2006062504A1 (en) * | 2004-12-06 | 2006-06-15 | Avery Dennison Corporation | Multilayer films, adhesive constructions, and articles using the same |
| DE602005005164T2 (de) * | 2005-04-12 | 2008-09-11 | Borealis Technology Oy | Polyethylenfilm mit verbesserter Verarbeitbarkeit und verbesserten mechanischen Eigenschaften |
| US20070045893A1 (en) * | 2005-08-26 | 2007-03-01 | Himanshu Asthana | Multilayer thermoplastic films and methods of making |
| US7393916B2 (en) * | 2005-11-01 | 2008-07-01 | Univation Technologies, Llc | Method of reducing gels in polyolefins |
| WO2009098976A1 (ja) * | 2008-02-05 | 2009-08-13 | Du Pont-Mitsui Polychemicals Co., Ltd. | 粘着性樹脂組成物及び粘着フィルム又はシート |
| JP5883584B2 (ja) * | 2011-06-17 | 2016-03-15 | 日東電工株式会社 | 粘着シート |
-
2016
- 2016-06-03 KR KR1020187000012A patent/KR20180014155A/ko unknown
- 2016-06-03 US US15/172,660 patent/US20160355650A1/en not_active Abandoned
- 2016-06-03 JP JP2017562622A patent/JP6814749B2/ja active Active
- 2016-06-03 TW TW105117644A patent/TWI611894B/zh not_active IP Right Cessation
- 2016-06-03 CN CN201680040884.0A patent/CN107848048B/zh not_active Expired - Fee Related
- 2016-06-03 EP EP16804543.3A patent/EP3302859A4/en not_active Withdrawn
- 2016-06-03 BR BR112017026115A patent/BR112017026115A8/pt not_active IP Right Cessation
- 2016-06-03 WO PCT/US2016/035770 patent/WO2016196965A1/en active Application Filing
-
2017
- 2017-11-30 IL IL256023A patent/IL256023A/en unknown
-
2019
- 2019-08-20 US US16/545,780 patent/US20200002489A1/en not_active Abandoned
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2935502A (en) * | 1958-02-05 | 1960-05-03 | Union Carbide Corp | Process for the high temperature, high pressure shear degradation of solid polyethylene |
| CA2229273A1 (en) * | 1998-02-10 | 1999-08-10 | Balke, Steven T. | Polymer segregation process |
Also Published As
| Publication number | Publication date |
|---|---|
| IL256023A (en) | 2018-01-31 |
| EP3302859A4 (en) | 2019-02-13 |
| KR20180014155A (ko) | 2018-02-07 |
| WO2016196965A1 (en) | 2016-12-08 |
| EP3302859A1 (en) | 2018-04-11 |
| BR112017026115A8 (pt) | 2022-12-27 |
| JP2018519376A (ja) | 2018-07-19 |
| US20200002489A1 (en) | 2020-01-02 |
| US20160355650A1 (en) | 2016-12-08 |
| BR112017026115A2 (pt) | 2018-08-14 |
| TW201716201A (zh) | 2017-05-16 |
| CN107848048B (zh) | 2020-11-13 |
| JP6814749B2 (ja) | 2021-01-20 |
| CN107848048A (zh) | 2018-03-27 |
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| MM4A | Annulment or lapse of patent due to non-payment of fees |