TWI805756B - 白色聚酯薄膜 - Google Patents
白色聚酯薄膜 Download PDFInfo
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- TWI805756B TWI805756B TW108116168A TW108116168A TWI805756B TW I805756 B TWI805756 B TW I805756B TW 108116168 A TW108116168 A TW 108116168A TW 108116168 A TW108116168 A TW 108116168A TW I805756 B TWI805756 B TW I805756B
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- Taiwan
- Prior art keywords
- film
- thermoplastic resin
- inorganic particles
- white
- polyester resin
- Prior art date
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- 238000001514 detection method Methods 0.000 claims description 10
- 230000005484 gravity Effects 0.000 claims description 9
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- 239000002184 metal Substances 0.000 claims description 5
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- FJKROLUGYXJWQN-UHFFFAOYSA-N 4-hydroxybenzoic acid Chemical compound OC(=O)C1=CC=C(O)C=C1 FJKROLUGYXJWQN-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
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- WOZVHXUHUFLZGK-UHFFFAOYSA-N dimethyl terephthalate Chemical compound COC(=O)C1=CC=C(C(=O)OC)C=C1 WOZVHXUHUFLZGK-UHFFFAOYSA-N 0.000 description 2
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- WLQKHRHCTSEXTL-UHFFFAOYSA-N C1C2CCC1C=C2.C1C2CCC1C=C2 Chemical group C1C2CCC1C=C2.C1C2CCC1C=C2 WLQKHRHCTSEXTL-UHFFFAOYSA-N 0.000 description 1
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Abstract
不增厚反射薄膜的厚度,而達成高反射率與遮蔽性。
一種白色聚酯薄膜,其係至少具有以聚酯樹脂 (A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且於該層中具有以熱塑性樹脂(B)為核的空隙之白色聚酯薄膜,其中在薄膜的垂直剖面中,將熱塑性樹脂(B)的核數量設為NB1的情形,NB1之中於內部含有無機粒子(C)者的數量NB2之比例NB2/NB1×100(%)為15%以上。
Description
本發明係關於較佳使用於薄型液晶顯示器用途之白色聚酯薄膜。
近年來,作為電腦、電視、行動電話等的顯示裝置,大多使用利用液晶的顯示器。該等液晶顯示器係藉由從背面設置稱為背光的面光源來照射光,而使顯示成為可能。背光為了滿足必須均勻地照射畫面整體這樣的要求,所以作成稱為邊光型或直下型之面光源的構造。其中,被期望薄型.小型化的筆記型電腦等中所使用之薄型液晶顯示器用途方面,適用邊光型,也就是相對於畫面在側面設置光源的類型之背光。
該邊光型背光係以冷陰極射線管或LED作為光源,從導光板的邊緣均勻地傳播.擴散光,而均勻地照射液晶顯示器整體。而且,為了更有效率地活用光,所以在光源的周圍設有反射薄膜,並且為了使從導光板擴散的光有效率地照射至液晶畫面側,而在導光板的背面設有反射薄膜。藉此減少來自光源之光的損耗,賦予增亮液晶畫面的功能。
這樣的液晶顯示器用背光所使用的反射薄膜中,以往係單獨使用添加白色顏料的薄膜、內部含有微細氣泡的薄膜,或者係使用貼合有該等薄膜與金屬板、塑膠板等者。尤其是內部含有微細氣泡的薄膜,由於在亮度的提升效果、畫面亮度的均一化方面有一定的效果,所以被廣泛使用著(專利文獻1、2)。
伴隨行動電話.智慧型手機及筆記型電腦的薄型化、小型化、電視的大畫面化,對於反射薄膜而言,儘管是薄膜仍要求高反射性、光的高遮蔽性、及高剛性。尤其是所謂的稱為4K、8K之高精細的液晶電視,有液晶面板的穿透率下降的傾向,而要求更高的反射性。
反射薄膜中係廣泛採用利用光反射的構成,該光反射係薄膜內部所含有的微細氣泡與基質樹脂在界面之折射率差所引起的。為了達成高反射性,必須增多界面數量。為了增多界面數量,而研究了以粒徑比較小的無機粒子作為核之孔洞的形成(專利文獻3、4)。
然而,若增多界面數量則製膜性下降,所以充分的厚度是必要的,難以薄膜化。
專利文獻1:日本特開2003-160682號公報
專利文獻2:日本特公平8-16175號公報
專利文獻3:日本特許第3946183號公報
專利文獻4:日本特開2013-136232號公報
本發明的目的係解決上述的問題,且製膜安定性良好地提供一種不增厚反射薄膜的厚度,而達成高反射率與遮蔽性的白色薄膜。
有鑒於上述課題而進行專心研究,結果發現藉由具有以下構成的薄膜能解決上述課題,而完成了本發明。
(1)一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且熱塑性樹脂(B)在該層中形成區域(domain)之白色薄膜,其中關於以六氟異丙醇使前述白色薄膜溶解、去除沉澱物而得之懸浮不溶物的質量Bw與懸浮不溶物中之無機粒子的質量Cbw,滿足式(1)。
0.01<Cbw/(Bw-Cbw)<1 (1)
(2)一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且在該層中具有以熱塑性樹脂(B)為核的空隙之白色薄膜,其中在薄膜的垂直剖面中,該熱塑性樹脂(B)之中有無機粒子(C)存在於熱塑性樹脂(B)剖面中的熱塑性樹脂(B)存在,且將該熱塑性樹脂(B)的核數量設為NB1之情形,該熱塑性樹脂(B)之中內部含有無機粒子(C)者的數量NB2之比例NB2/NB1×100(%)為15%以上。
(3)如(1)或(2)記載之白色薄膜,其中熱塑性樹脂(B)為聚烯烴。
(4)如(1)~(3)中任一項記載之白色薄膜,其中無機粒子(C)係以氧化鈦為主成分。
(5)如(4)記載之白色薄膜,其中在無機粒子(C)表面的SEM-EDX中,Si(矽)的檢測強度與M(無機粒子主成分的金屬元素)的檢測強度比滿足式(2)。
EDX(Si)/EDX(M)>0.5 式(2)
(6)如(4)或(5)記載之白色薄膜,其中於無機粒子(C)表面具有1nm以上的含矽之有機物層。
(7)如(1)~(6)中任一項記載之白色薄膜,其包含至少3層,內層為以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層。
(8)如(1)~(7)中任一項記載之白色薄膜,其比重為0.6以上1.0以下。
(9)如(1)~(8)中任一項記載之白色薄膜,其為LED背光用途。
(10)如(1)~(8)中任一項記載之白色薄膜,其為照明用途。
本發明人等針對涉及的課題進行了專心研究,結果研究明白到:為了製膜安定性良好地得到儘管為薄膜卻具有高反射性與光的高遮蔽性之反射薄膜,重要的是其係為具有孔洞與孔洞成核劑且孔洞成核劑中含有無機粒子的構成,遂而達成本發明。
根據本發明人等專心研究的內容,發現若為下述白色薄膜,則能製膜安定性良好地提供儘管為薄膜但卻具有高反射性與光的高遮蔽性的白色薄膜:一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且熱塑性樹脂(B)在該層中形成區域之白色薄膜,其中關於以六氟異丙醇使前述白色薄膜溶解、去除沉澱物而得之懸浮不溶物的質量Bw與懸浮不溶物中之無機粒子的質量Cbw,滿足式(1);0.01<Cbw/(Bw-Cbw)<1 (1)
抑或是,一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且在該層中具有以熱塑性樹脂(B)為核的空隙之白色薄膜,其中在薄膜的垂直剖面中,該熱塑性樹脂(B)之中有無機粒子(C)存在於熱塑性樹脂(B)剖面中的熱塑性樹脂(B)存在,且將該熱塑性樹脂(B)的核數量設為NB1之情形,該熱塑性樹脂(B)之中內部含有無機粒子(C)者的數量NB2之比例NB2/NB1×100(%)為15%以上。
以下詳細說明本發明。
本發明的白色薄膜,其必須具有至少1層以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層。構成薄膜中的某層之成分之中,只要為至少50重量%以上,則可稱為主成分。
關於聚酯樹脂(A),以下記載較佳的態樣。所謂的聚酯樹脂係指主鏈具有酯鍵的高分子,而本發明使用的聚酯樹脂,較佳為具有二羧酸與二醇經縮聚合而成的構造之聚酯樹脂。就二羧酸成分而言,例如在芳香族二羧酸方面,可列舉對苯二甲酸、間苯二甲酸、鄰苯二甲酸、2,6-萘二羧酸、二苯基二羧酸、二苯基碸二羧酸、二苯氧基乙烷二羧酸、5-鈉碸二羧酸等的芳香族二羧酸、草酸、琥珀酸、己二酸、癸二酸、二聚物酸、馬來酸、富 馬酸等的脂肪族二羧酸、1,4-環己烷二羧酸等的脂環族二羧酸、苯甲酸對羥基苯甲酸等的羥基羧酸等的各成分。又,作為二羧酸酯衍生物成分,可列舉上述二羧氧化合物的酯化物,例如對苯二甲酸二甲酯、對苯二甲酸二乙酯、對苯二甲酸2-羥基乙基甲酯、2,6-萘二羧酸二甲酯、間苯二甲酸二甲酯、己二酸二甲酯、馬來酸二乙酯、二聚物酸二甲酯等的各成分。又,就二醇成分而言,可列舉例如:乙二醇、1,2-丙二醇、1,3-丙二醇、1,3-丁二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、2,2-二甲基-1,3-丙二醇(新戊二醇)等的脂肪族二羥基化合物、二乙二醇、聚乙二醇、聚丙二醇、聚四亞甲基二醇等的烷二醇聚氧烷二醇、1,4-環己烷二甲醇、螺甘油等的脂環族二羥基化合物、雙酚A、雙酚S等的芳香族二羥基化合物等各成分。該等可分別僅為1種,亦可為使用2種以上者。又,作為薄膜只要不影響製膜性,也可為將偏苯三甲酸、苯均四酸及其酯衍生物少量共聚合而成者。
聚酯樹脂(A)的具體例,聚對苯二甲酸乙二酯(以下稱為PET)、聚2,6-萘二甲酸乙二酯、聚對苯二甲酸丙二酯、聚對苯二甲酸丁二酯、聚對苯二甲酸-1,4-環己烷二甲酯等由於能便宜取得,而且製膜性也良好,故可特別適宜使用。又,亦可為均聚物或共聚物。就為共聚物的情形,就共聚合成分而言,可列舉芳香族二羧酸、脂肪族二羧酸、脂環族二羧酸、碳數2~15的二醇成分,就該等的例子而言,可列舉例如間苯二甲酸、己二酸、癸二酸、鄰苯二甲酸、含有磺酸鹽基的間苯二甲酸、及該等的酯形成性化合物、乙二醇、1,4-丁二醇、新戊二醇、1,4-環己烷二甲醇、螺甘油、數量平均分子量400~20,000的聚烷二醇等。
不相溶於聚酯樹脂(A)的熱塑性樹脂(B),被使用作 為形成後述的空隙(孔洞)之孔洞成核劑。具體而言,可選擇聚乙烯、聚丙烯、聚丁烯、聚甲基戊烯等的直鏈狀或分支狀烯烴系樹脂、環狀烯烴系樹脂、苯乙烯系樹脂、聚(甲基)丙烯酸酯樹脂、聚碳酸酯樹脂、聚丙烯腈樹脂、聚苯硫樹脂、氟系樹脂等。其中較佳者為烯烴系樹脂或苯乙烯系樹脂,就烯烴系樹脂而言,較佳為聚乙烯、聚丙烯、聚4-甲基戊烯-1(以下有時簡稱為「聚甲基戊烯」或「PMP」)、乙烯-丙烯共聚物、乙烯-丁烯-1共聚物、環狀烯烴,就苯乙烯系樹脂而言,較佳為聚苯乙烯、聚甲基苯乙烯、聚二甲基苯乙烯等。該等可為均聚物,亦可為共聚物,甚至亦可併用2種以上的熱塑性樹脂(B)。本發明的熱塑性樹脂(B)較佳為聚烯烴。具體而言,聚乙烯、聚丙烯、聚丁烯、聚甲基戊烯等的直鏈狀或分支狀烯烴系樹脂、環狀烯烴系樹脂等,特佳者為聚甲基戊烯或環狀烯烴。若為聚烯烴,則在聚酯樹脂(A)中容易形成孔洞,而且易於兼具製膜性,故而為較佳。
就孔洞成核劑中較佳使用的聚甲基戊烯而言,較佳為分子骨架中含有較佳80莫耳%以上,更佳85莫耳%以上者,特佳90莫耳%以上的衍生自4-甲基戊烯-1的二價有機基作為重複單位者。又,就其他重複單位而言,可列舉乙烯、丙烯、丁烯-1、3-甲基丁烯-1、或4-甲基戊烯-1以外之衍生自碳數6~12的烴之二價有機基等。聚甲基戊烯可為均聚物,亦可為共聚物。又,可混合使用組成、熔融黏度等不同之複數個的聚甲基戊烯,又亦可併用其他烯烴系樹脂、其他樹脂。
孔洞成核劑中較佳使用的環狀烯烴,係為環烯烴、雙環烯烴、三環烯烴及四環烯烴等的環烯烴成分與乙烯、丙烯等的直鏈烯烴成分構成之共聚物。
就環烯烴成分的代表例而言,可列舉雙環〔2,2,1〕庚-2-烯、6-甲基雙環〔2,2,1〕庚-2-烯、5,6-二甲基雙環〔2,2,1〕庚-2-烯、1-甲基雙環〔2,2,1〕庚-2-烯、6-乙基雙環〔2,2,1〕庚-2-烯、6-正丁基雙環〔2,2,1〕庚-2-烯、6-異丁基雙環〔2,2,1〕庚-2-烯、7-甲基雙環〔2,2,1〕庚-2-烯、三環〔4,3,0,12.5〕-3-癸烯、2-甲基-三環〔4,3,0,12.5〕-3-癸烯、5-甲基-三環〔4,3,0,12.5〕-3-癸烯、三環〔4,4,0,12.5〕-3-癸烯、10-甲基-三環〔4,4,0,12.5〕-3-癸烯等。
就直鏈烯烴成分的代表例而言,可列舉乙烯、丙烯、1-丁烯、1-戊烯、1-己烯、1-辛烯、1-癸烯、1-十二烯、1-十四烯、1-十六烯、1-十八烯等。
熱塑性樹脂(B)(主要具有作為孔洞成核劑的功能)中較佳使用的環烯烴共聚物之玻璃轉移溫度(Tg),較佳為110℃以上。藉由設為110℃以上變得可兼具高反射率與尺寸安定性。具體而言較佳為130℃以上,更佳為150℃以上。因為藉由在該範圍,會在混練時微分散化至樹脂中,在延伸步驟中更確實地形成孔洞,可抑制在熱處理步驟中的孔洞消失。環烯烴共聚物之玻璃轉移溫度(Tg)的上限較佳為250℃。
為了將環烯烴共聚物的玻璃轉移溫度(Tg)控制在110℃以上,可列舉例如增多環烯烴共聚物中的環烯烴成分的含量,減少乙烯等的直鏈烯烴成分的含量。具體而言,環烯烴成分較佳為60莫耳%以上,乙烯等的直鏈烯烴成分的含量較佳為小於40莫耳%。更佳為環烯烴成分為70莫耳%以上,乙烯等的直鏈烯烴成分的含量小於30莫耳%,再佳為環烯烴成分為80莫耳%以上,乙烯等的直鏈烯烴成分的含量小於20莫耳%。特佳為環 烯烴成分為90莫耳%以上,乙烯等的直鏈烯烴成分的含量小於10莫耳%。藉由設定為該範圍,可將環烯烴共聚物的玻璃轉移溫度(Tg)提高至前述的範圍。
使用環烯烴共聚物的情形,從反應性之觀點,直鏈烯烴成分較佳為乙烯成分。再者,從生產性、透明性、高Tg化之點而言,環烯烴成分較佳為雙環〔2,2,1〕庚-2-烯(降莰烯)、其衍生物。
從反射率之點而言,熱塑性樹脂(B)(主要具有作為孔洞成核劑的功能),相對於以聚酯樹脂(A)、熱塑性樹脂(B)、無機粒子(C)為主成分的層100質量%,較佳為含有5~50質量%。更佳為10~40質量份。若小於5質量%則所形成的孔洞變少,有反射率變低的情形。又,若多於50質量%,則反射率的下降、製膜時的破裂容易發生而有生產性降低的情形。
本發明的白色薄膜,較佳為無機粒子(C)以氧化鈦為主成分。藉由以氧化鈦為主成分,可使反射率容易提升。構成無機粒子(C)的成分之中,若至少50質量%以上為氧化鈦,則可謂為主成分。
無機粒子(C)的平均粒徑(D50,模式平均粒徑)較佳為0.05~1μm。更佳為平均粒徑0.1~0.5μm,再佳為0.15~0.35μm。若平均粒徑小於0.05μm,則分散性降低變得易於引起凝集,若大於1μm,則有無法得到後述的無機粒子(C)被包含在熱塑性樹脂(B)中的構造之情形,故而為不佳。
無機粒子(C)係在以聚酯樹脂(A)、熱塑性樹脂(B)、無機粒子(C)為主成分的層之中,較佳為多於10質量%少於40質量%。更佳為多於15質量%少於35質量%。在少於10質量% 的情形,有反射率下降的情形而為不佳。多於40質量%的情形,有生產性降低的情形而為不佳。尤其是薄膜厚度變得越薄,生產性越容易變低。
本發明的白色薄膜,其必須在以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層中,具有以熱塑性樹脂(B)作為核的孔洞(空隙)。
本發明中所謂的空隙,係指藉由孔洞成核劑所形成之該層中存在的空間。空隙的形狀有從薄膜剖面觀察的略圓、略橢圓狀。空隙的形成方法,能以下述的方法形成:利用延伸對以任意比例混合上述所記載的聚酯樹脂(A)與孔洞成核劑的樹脂施加外力,撕下聚酯樹脂(A)與孔洞成核劑。具體而言,可列舉將含有聚酯樹脂(A)與孔洞成核劑的混合物予以熔融擠壓後,藉由於至少一方向進行延伸,使內部形成氣泡的方法。
本發明的白色薄膜,其關於以六氟異丙醇使其溶解、去除沉澱物而得之懸浮不溶物的質量Bw與懸浮不溶物中之無機粒子的質量Cbw,必須滿足式(1)。
0.01<Cbw/(Bw-Cbw)<1 (1)
以六氟異丙醇使白色薄膜溶解時的不溶物,其分成沉澱物與懸浮不溶物,懸浮不溶物中主要含有比六氟異丙醇的密度(1.6g/cm3)輕的熱塑性樹脂(B)。將該懸浮不溶物回收、乾燥,並將其質量設為Bw。再者,藉由例如ICP分析測定該懸浮不溶物中所含之無機粒子的質量,並設為質量Cbw。該Cbw與懸浮不溶物中的無機粒子以外的成分(Bw-Cbw)之比Cbw/(Bw-Cbw)越大,越表示熱塑性樹脂(B)的內部含有無機粒子(C)。由於無機粒子(C)被包含在熱塑性樹脂(B)內部,變得能兼具製膜安 定性與光學特性而為較佳。更佳為0.02<Cbw/(Bw-Cbw)<0.7,再佳為0.03<Cbw/(Bw-Cbw)<0.5。若Cbw/(Bw-Cbw)為0.01以下,則兼具製膜安定性與良好的光學特性(反射率、穿透率)係變得困難。若將該比設為1以上,則無機粒子易於凝集而為不佳。此外,回收的沉澱物中也含有熱塑性樹脂(B)的情形,可使用溴化鈉水溶液等比重更高的液體,又可利用離心分離進行分離之後回收。
本發明的白色薄膜,其必須在薄膜的垂直剖面所觀察到的該熱塑性樹脂(B)中,有無機粒子(C)存在於熱塑性樹脂(B)剖面中的熱塑性樹脂(B)存在,且將該熱塑性樹脂(B)的核數量設為NB1之情形,該熱塑性樹脂(B)之中內部含有無機粒子(C)者的數量NB2之比例NB2/NB1×100(%)為15%以上。更佳為20%以上,再佳為30%以上。藉由無機粒子(C)被包含在熱塑性樹脂(B)中,能用以往透明且無法直接幫助反射率提升之孔洞成核劑部引起光的反射,能提高反射效率,所以即使為薄的薄膜也能提高反射率。NB2的比例小於15%情形,有反射率無法充分地提升的情形而為不佳。又,熱塑性樹脂(B)中存在的無機粒子(C),難以促進聚酯樹脂(A)的結晶化。藉由如後述的雙軸延伸製造白色薄膜的情形,若促進結晶化,則製膜安定性易降低。藉由使無機粒子(C)存在於熱塑性樹脂(B)中,能製膜安定性良好地得到反射率高的白色薄膜。無機粒子(C)只要存在於熱塑性樹脂(B)中,亦可一部分存在於聚酯樹脂(A)中。
關於得到本發明的白色薄膜的垂直剖面之方法,係顯示一例。使用離子銑削裝置,不使厚度方向塌陷,面對薄膜面呈垂直且平行於薄膜長邊方向地切割薄膜而作成測定試料,又, 同樣地面對薄膜面呈垂直且平行於薄膜寬度方向地切割薄膜而製作成為測定試料的垂直剖面。接著,使用掃描電子顯微鏡(FE-SEM)觀察長邊方向及寬度方向之試樣的切面,得到放大10000倍觀察的影像。觀察範圍為100μm×100μm。此外,觀察場所係在以聚酯樹脂(A)、熱塑性樹脂(B)、無機粒子(C)為主成分的層內隨機決定者。層的厚度小於100μm的情形,厚度方向為層整體、相對於薄膜面呈平行的方向上為100μm的範圍。由所得之影像,計算已成為孔洞核且顯現在剖面的熱塑性樹脂(B)之區域數量NB1。此時,排除可在孔洞的深處看得到但沒有出現在剖面的區域。
計算存在於孔洞中之熱塑性樹脂(B)的區域之中,無機粒子(C)出現在該剖面之區域數量NB2。計算無機粒子被內含在區域的狀態者,而不計算僅附著在區域的表面部者。
作為使無機粒子(C)被包含在熱塑性樹脂(B)中的方法,較佳為對無機粒子(C)實施用以提高與熱塑性樹脂(B)的相溶性之表面處理。就表面處理劑而言,較佳為使用聚矽氧、矽烷偶合劑、鋁螯合劑、聚脲等。特佳為矽烷偶合劑。
表面處理方法並未特別限定,但可列舉例如乾式法或濕式法。所謂的乾式法為在利用攪拌機進行高速攪拌的無機材料之中滴下或噴霧表面處理劑使其反應的手法,所謂的濕式法為在無機材料加入醇等的有機溶劑,於成為漿料的狀態下加入表面處理劑使其反應的手法。
例如利用矽烷偶合劑處理之情形,較佳可使用藉由常法預先利用矽烷偶合劑表面處理無機粒子(C),接著與熱塑性樹脂(B)熔融混練的方法。又,在不預先進行無機粒子(C)的表面處理,而將 無機粒子(C)與熱塑性樹脂(B)予以熔融混練時,亦可使用添加偶合劑的可積分摻合法(Integrable blend method)。
藉由將無機粒子(C)與熱塑性樹脂(B)予以熔融混練之母料,進一步與聚酯樹脂(A)等的樹脂熔融混練而進行片狀化,可得到無機粒子(C)被包含在熱塑性樹脂(B)之內部的構造。
本發明的白色薄膜,較佳為在無機粒子(C)表面的SEM-EDX(能量分散型X射線分析)中,Si(矽)的檢測強度與M(無機粒子主成分的金屬元素)的檢測強度比滿足式(2)。
EDX(Si)/EDX(M)>0.5 式(2)
可以說矽的檢測強度對金屬元素的檢測強度越高,無機粒子的表面越被含矽的化合物充分地被覆。更佳為檢測強度比大於0.6,再佳為大於0.7。若被含矽的化合物充分地被覆,則由於容易提高無機粒子(C)與熱塑性樹脂(B)的相溶性而為較佳。在為0.5以下的情形,有無機粒子(C)與熱塑性樹脂(B)的相溶性變差的情形,而為不佳。
本發明的白色薄膜較佳為於無機粒子(C)表面具有1nm以上的含矽有機物層。更佳為1.5nm以上,再佳為2nm以上。含矽有機物層厚於10nm的情形,有無機粒子(C)的反射率下降的情形而為不佳。
本發明的白色薄膜較佳為包含至少3層,芯層為以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層。例如,較佳為芯層(Y)與表層(X)依X/Y/X的順序積層為3層的構成。藉由使表層(X)與芯層(Y)積層為X/Y/X的順序,有可得到高製膜安定性的情形。又,本發明的白色薄膜,或可為4層以上的構成,但若考慮到製膜上的容易度與強度則較佳為3層構成。又,較佳為表層(X)與芯層(Y)利用共擠壓法在製膜線中一舉地進行積層之後,於二軸方向進行延伸。再者,可依照需要,進行再縱向延伸及/或再橫向延伸。
本發明的白色薄膜,較佳為比重為0.6以上1.0以下。更佳為0.7以上0.85以下。比重小於0.6的情形,薄膜中之孔洞的比例高,有生產性降低的情形而為不佳。又,比重大於1.0的情形,有孔洞的形成不充分且反射率降低的情形而為不佳。為了使比重成為該範圍,較佳為使作為孔洞成核劑之熱塑性樹脂(B)及無機粒子(C)成為前述的添加量。
在無損於本發明效果之範圍內,較佳為含有與無機粒子(C)不同的無機粒子(D)。無機粒子(D)可具有作為孔洞成核劑的作用。無機粒子(D)的平均粒徑(D50,模式平均粒徑)較佳為0.05~1μm。更佳為平均粒徑0.1~0.5μm,再佳為0.15~0.35μm。若平均粒徑小於0.05μm,則分散性降低容易引起凝集,若大於1μm,則有孔洞變得易於連結,且生產性降低的情形。
含有無機粒子(D)的情形,在以聚酯樹脂(A)、熱塑性樹脂(B)、無機粒子(C)為主成分的層之中,較佳為1~40質量%。更佳為5~30質量%,再佳為10~25質量%。小於1質量%的情形,有無法得到充分的效果之情形而為不佳。多於40質量%的情形,有生產性降低的情形而為不佳。增加無機粒子(D)含量的添加量會使反射率與穿透率提升,但製膜安定性降低。
又,無機粒子(C)與無機粒子(D)的總量,在以聚酯樹脂(A)、熱塑性樹脂(B)、無機粒子(C)為主成分的層之中,較佳為小於50質量%。無機粒子(C)與無機粒子(D)的總量為50質量%以上的情形,有生產性降低的情形而為不佳。更佳為無機粒子(C)與無機粒子(D)的總量為10~40質量%,再佳為15~35質量%。
無機粒子(D)為選自於矽石、膠態矽石、碳酸鈣、矽酸鋁、磷酸鈣、氧化鋁、碳酸鎂、碳酸鋅、氧化鋅(鋅華)、氧化銻、氧化鈰、氧化鋯、氧化錫、氧化鑭、氧化鎂、碳酸鋇、鹼性碳酸鉛(鉛白)、硫酸鋇、硫酸鈣、硫酸鉛、硫化鋅、雲母、雲母鈦、滑石、黏土、高嶺土之中的無機粒子。又,彼等可單獨或以2種以上的混合使用,但其中特佳為矽石粒子、硫酸鋇粒子、碳酸鈣粒子、氧化鋅粒子,因為可以高光學特性得到製膜安定性。
接著針對本發明之白色薄膜的製造方法,以其一例進行說明,但並未特別限定。在具有至少2台的單軸或雙軸擠壓機、主擠壓機與副擠壓機的複合製膜裝置中,於主擠壓機投入成為芯層(Y)原料的樹脂,於副擠壓機投入成為表層(X)原料的樹脂。較佳為將各個原料乾燥以使其水分率成為50ppm以下。如此可將原料供給至各擠壓機,利用例如2台的擠壓機與設置於T字模上部之進料塊和多歧管,形成X/Y/X的3層積層薄膜。經擠壓的未延伸片係在經冷卻的鼓輪上密合冷卻固化,而得到未延伸積層薄膜。此時,為了得到均勻的薄膜,理想是施加靜電使其密合在鼓輪上。然後,根據需要通過延伸步驟、熱處理步驟而得到目的之聚酯薄膜。
將該未延伸薄膜以輥加熱、按照需要以紅外線加熱等加熱至聚合物的玻璃轉移溫度(Tg)以上,於長邊方向(以下稱為縱向方向)延伸而得到縱向延伸薄膜。該延伸係利用2個以上的輥之周速差進行。縱向延伸的倍率取決於用途的要求特性,較佳為2~6倍,更佳為3~4倍。若小於2倍則有反射率低的情形,若超過6倍則在製膜中有破裂容易發生的情形。縱向延伸後 的薄膜,繼續於與縱向方向正交的方向(以下稱為橫向方向)依序實施延伸、熱固定、熱鬆弛的處理而形成雙軸配向薄膜,該等處理可一邊使薄膜行進一邊進行。此時,用以橫向延伸的預熱及延伸溫度在聚合物的玻璃轉移溫度(Tg)以上(Tg+20℃)進行較佳。橫向延伸的倍率係取決於用途的要求特性,較佳為2.5~6倍、更佳為3~4倍。若小於2.5倍則有反射率低的情形。若超過6倍則有在製膜中破裂容易發生的情形。使所得之雙軸延伸積層薄膜的結晶配向完成,為了賦予平面性與尺寸安定性,繼續在拉幅機內以180~230℃的溫度進行1~60秒鐘的熱處理,均勻地緩慢冷卻後,冷卻至室溫,捲取成輥。此外,該熱處理可在將薄膜於其長邊方向及/或寬度方向鬆弛3~12%的同時進行。
又這裡係以藉由逐次雙軸延伸法進行延伸的情形為例詳細說明,但本發明的聚酯薄膜可以逐次雙軸延伸法、同時雙軸延伸法的任一方法延伸,並且可按照需要,進行雙軸延伸後,再縱向延伸及/或再橫向延伸。
為了對這樣所得之雙軸延伸積層薄膜賦予平面安定性、尺寸安定性,可繼續在拉幅機內進行熱處理(熱固定),均勻地緩慢冷卻後,冷卻至室溫附近之後,藉由捲取而得到本發明的白色薄膜。
又,在無損於本發明的效果之範圍內,為了對樹脂層(A)的至少單面賦予易滑性、抗靜電性、紫外光吸收性能等,可使用眾所周知的技術塗布各種的塗液,又為了提高耐衝擊性亦可設置硬塗層等。塗布可在薄膜製造時進行塗布(在線塗布),亦可在薄膜製造後的白色薄膜上進行塗布(離線塗布)。
此外,本發明中的白色薄膜的厚度較佳為30μm以 上300μm以下,更佳為50μm以上200μm以下。再佳為50μm以上140μm以下。厚度小於30μm的情形,由於製膜性降低,無法得到充分的反射性而為不佳。另一方面,厚於300μm的情形,無法回應液晶顯示器之薄膜化的要求而為不佳。光反射薄膜的厚度,可利用調整樹脂自擠壓機之熔融擠壓量及未延伸片之延伸步驟的速度等的眾所周知之方法來加以調整。
以下,藉由實施例來詳述本發明。此外,各特性值係用以下的方法測定。
(1)Bw、Cbw
秤量1g的白色薄膜,加入100ml的HFIP並充分地攪拌使其溶解。靜置後,回收懸浮的不溶物,將乾燥後的重量設為Bw。再者,用硫酸、硝酸、過氯酸及氫氟酸加熱分解之後,以稀硝酸加溫溶解並定容。針對該溶液,以ICP發光分光分析法測定金屬元素,求得試料中的含量,並將換算成氧化物值之值設為Cbw。
(2)玻璃轉移溫度
用差示掃描熱量計(SEIKO電子工業製,RDC220),依照JIS K7121-1987、JIS K7122-1987進行測定及解析。將5mg聚酯層或聚酯薄膜用於試樣,根據以20℃/分鐘從25℃升溫至300℃時的DSC曲線所得之玻璃狀態到橡膠狀態的轉移,讀取比熱變化,求得與各基線所延長的直線於縱軸(表示熱流的軸)方向等距離的直線、與玻璃轉移的階梯狀變化部分的曲線相交的點之中間點玻璃轉移溫度,設為玻璃轉移溫度。此外,關於在基線上 所看到的極微小之波峰面積(以結晶融解能量換算為0.5J/g以下)的吸熱波峰,係當作雜訊而除去。測定僅表層的情形,係以切割機削掉表層而進行測定。
(3)剖面SEM、NB1、NB2
使用日立離子銑削裝置IM4000,不使厚度方向塌陷,面對薄膜面呈垂直且平行於薄膜長邊方向地切割薄膜而作成測定試料,又,同樣地面對薄膜面呈垂直且平行於薄膜寬度方向地切割薄膜作成測定試料。當分不清薄膜的長邊方向的情形,在任意的一方向和與其垂直的方向進行切割。接著,使用掃描電子顯微鏡(日立製作所製電場放射型掃描電子顯微鏡(FE-SEM)S-4000)觀察長邊方向及寬度方向之試樣的切面,得到放大10,000倍觀察到的影像。分別觀察100μm×100μm的範圍,計算已成為孔洞核且顯現在剖面的熱塑性樹脂(B)之區域數量NB1。此時,排除可在孔洞的深處看得到但沒有出現在剖面的區域。
計算存在於孔洞中之熱塑性樹脂(B)的區域之中,無機粒子出現在該剖面之區域數量NB2。計算無機粒子被內含在區域的狀態者,而不計算僅附著在區域的表面部者。
(4)SEM-EDX、EDX強度
在剖面SEM觀察時將試樣放大25000倍,利用附屬的能量分散型X射線檢測器(堀場製作所股份有限公司EDX EMAX-7000)進行分析。由長邊方向剖面與寬度方向剖面分別選擇各15個合計選擇30個的從熱塑性樹脂(B)區域之剖面看得到的無機粒子(C),在該中央部對於Ba、Ti、Ca、Zn評價EDX強度。將 30點的平均強度最高的元素當作無機粒子(C)的主成分金屬元素。同樣地,評價Si元素的強度。針對來自Si元素強度高者的10個粒子,評價EDX(Si)/EDX(M),將其平均作為本案的EDX強度比。
(5)無機粒子的平均粒徑(D50,模式平均粒徑)
將平行於薄膜寬度方向地切割的剖面SEM影像輸入至影像處理軟體「PerfectView7」中,算出當測定視野內之合計100個無機粒子被換算成正圓時的直徑,作成直徑的柱狀圖,並將累積值為50%的粒徑當作無機粒子的平均粒徑。存在有複數種無機粒子之情形,係以EDX等進行鑑定,並針對各個無機粒子求得平均粒徑。
(6)表面處理厚度
將薄膜包埋至環氧樹脂中,用薄片切片機(Leica製:RM2265)以面對薄膜面呈垂直且平行於薄膜長邊方向的方式進行裁切。利用掃描穿透型電子顯微鏡(STEM)日本電子製JEM2100F型(附有環狀暗視野檢測器),觀察從熱塑性樹脂(B)區域之剖面看得到的無機粒子(C)之表面處理厚度。觀察5個以上的無機粒子(C),並將其平均當作表層處理厚度。
觀測方式:高角度散射暗視野法(HAADF法)
測定條件:加速電壓100~200kV
測定倍率:20萬倍
檢測角:75mrad
加速電壓:30~40KeV
此處,HAADF影像係僅使用與原子序的大約平方成正比的彈性散射電子之成像法,也稱為Z-對比法。各層厚度係由HAADF-STEM影像對比而算出。
(7)反射率
在Hitachi High-Technologies製分光光度計(U-3310)上安裝60mmφ積分球,在400~700nm之範圍內測定當氧化鋁的標準白色板(Hitachi High-Technologies製,零件No.210-0740)成為100%時的反射率。由所得之圖表以5nm間隔讀取反射率,計算算術平均值並將其作為反射率。
A:100%以上
B:99%以上且小於100%
C:98%以上且小於99%
D:97%以上且小於98%
E:小於97%。
(8)穿透率(全部光線穿透率)
使用日本電色工業(股)製濁度計「NDH5000」,全部光線穿透率的測定係依照JIS「塑膠透明材料之全部光線穿透率的試驗方法」(K7361-1,1997年版)測定。
A:小於2.5%
B:2.5%以上且小於3.0%
C:3.0%以上且小於3.5%
D:3.5%以上且小於4.0%
E:4.0%以上。
(9)薄膜厚度
裁切5片的薄膜之寬度方向的中心部分之剖面,從使用掃描電子顯微鏡(日立製作所製電場放射型掃描電子顯微鏡(FE-SEM)S-4000)放大500~5,000倍進行觀察所攝影之剖面照片,測量薄膜的厚度。將5片的數值之平均值當作薄膜厚度。
(10)薄膜比重
將所得之薄膜裁切成5cm×5cm的大小,並根據JIS K7112(1980版)使用電子比重計SD-120L(Mirage貿易(股)製)來測定。此外,針對各薄膜準備5片,測定每一個,並取其平均值作為該薄膜的比重。
(11)製膜安定性
進行製膜48小時,求得薄膜每12小時破裂的次數。
A:小於1次
B:1次以上且小於2次
C:2次以上且小於3次
D:3次以上
E:不可製膜。
(12)綜合評價
關於反射率、穿透率、製膜安定性的評價(A~E),A:5點,B:4點,C:3點,D:2點,E:1點。3項評價的合計點為10點以上當作合格。
(1)聚酯樹脂(a)
以三氧化銻作為觸媒,藉由常法由對苯二甲酸及乙二醇進行聚合,得到聚對苯二甲酸乙二酯(PET)。所得之PET的玻璃轉移溫度為77℃,熔點為255℃,固有黏度為0.63dl/g,末端羧基濃度為40eq./t。
(2)共聚合聚酯樹脂(b)
使用市售的1,4-環己烷二甲醇共聚合聚酯(Eastman.Chemical公司製GN001)。
(3)共聚合聚酯樹脂(c)
使用市售的PBT-PAG(聚烷二醇)共聚物「Hytrel 7247」(Toray.Du Pont(股)製)。該樹脂為PBT(聚對苯二甲酸丁二酯)與PAG(主要為聚四亞甲基二醇)的嵌段共聚物。
(4)熱塑性樹脂(d)
使用市售的環狀烯烴樹脂「TOPAS 6017」(日本聚塑膠股份有限公司)。
(5)二氧化鈦母料(e)
對於50質量份的二氧化鈦粒子(數量平均粒徑0.25μm),添加0.025質量份的矽烷偶合劑「11-100Additive」(Toray Dow Corning公司製),藉由常法表面處理之後,與50重量份的聚酯 樹脂(a)在雙軸擠壓機中混練,得到二氧化鈦母料丸粒(e)。
(6)二氧化鈦母料(f)
將50重量份的熱塑性樹脂(d)與50重量份的二氧化鈦粒子(數量平均粒徑0.25μm)在雙軸擠壓機中混練,得到二氧化鈦母料丸粒(f)。
(7)二氧化鈦母料(g)
對於50質量份的二氧化鈦粒子(數量平均粒徑0.25μm),添加0.25質量份的矽烷偶合劑「11-100Additive」(Toray Dow Corning公司製),藉由常法表面處理之後,與50重量份的熱塑性樹脂(d)在雙軸擠壓機中混練,得到二氧化鈦母料丸粒(g)。
(8)二氧化鈦母料(h)
對於50質量份的二氧化鈦粒子(數量平均粒徑0.25μm),添加0.025質量份的矽烷偶合劑「11-100Additive」(Toray Dow Corning公司製),藉由常法表面處理之後,與50重量份的熱塑性樹脂(d)在雙軸擠壓機中混練,得到二氧化鈦母料丸粒(h)。
(9)硫酸鋇母料(i)
將50質量份的硫酸鋇粒子(數量平均粒徑0.5μm)與50重量份的聚酯樹脂(a)在雙軸擠壓機中混練,得到硫酸鋇母料丸粒(i)。
(10)碳酸鈣母料(j)
將50質量份的碳酸鈣粒子(數量平均粒徑0.5μm)與50重量份的聚酯樹脂(a)在雙軸擠壓機中混練,得到碳酸鈣母料丸粒(j)。
(11)熱塑性樹脂(k)
使用市售的聚甲基戊烯樹脂(三井化學(股)製,“TPX”)。
(12)二氧化鈦母料(l)
對於50質量份的二氧化鈦粒子(數量平均粒徑0.25μm),添加0.25質量份的矽烷偶合劑「11-100Additive」(Toray Dow Corning公司製),藉由常法表面處理之後,與50重量份的熱塑性樹脂(k)在雙軸擠壓機中混練,得到二氧化鈦母料丸粒(l)。
(實施例1~11、比較例1~3)
將表1所示之組成的原料在180℃的溫度真空乾燥6小時後,將芯層(Y)的原料供給至主擠壓機,在280℃的溫度熔融擠壓後,藉由30μm截止過濾器進行過濾,將表層(X)的原料供給至副擠壓機,在290℃的溫度熔融擠壓後,藉由30μm截止過濾器進行過濾後,在T字模複合噴嘴內,以使表層(X)在芯層(Y)的兩表層被積層(X/Y/X)的方式使其匯流。
接著,擠壓成片狀作成熔融片,使該熔融片在表面溫度保持在25℃之鼓輪上以施加靜電法予以密合冷卻固化,得到未延伸薄膜。接著,將該未延伸薄膜以加熱至80℃的溫度之輥群預熱之後,一邊以紅外線加熱器從兩面照射,一邊於長邊方向(縱向方向)以表2的倍率進行延伸,以25℃的溫度之輥群冷卻而得到單軸延伸薄膜。然後,將單軸延伸薄膜的兩端一邊用夾具 把持一邊導入拉幅機內之110℃的預熱區,接著於120℃在垂直於長邊方向的方向(橫向方向)用表2的倍率延伸。再接著,在拉幅機內的熱處理區施加表2之溫度的熱處理,接著均勻地緩慢冷卻後,捲取成輥,得到表2所記載之厚度的白色薄膜。
(比較例4)
使表1所示之組成的原料在180℃的溫度真空乾燥6小時後,將芯層(Y)的原料供給至主擠壓機,在280℃的溫度熔融擠壓後,藉由30μm截止過濾器進行過濾,將表層(X)的原料供給至副擠壓機,在290℃的溫度熔融擠壓後,藉由30μm截止過濾器進行過濾後,在T字模複合噴嘴內,以使表層(X)在芯層(Y)的兩表層被積層(X/Y/X)的方式使其匯流。
接著,擠壓成片狀作成熔融片,使該熔融片在表面溫度保持在25℃之鼓輪上以施加靜電法予以密合冷卻固化,得到未延伸薄膜。接著,將該未延伸薄膜以加熱至80℃的溫度之輥群預熱之後,一邊以紅外線加熱器從兩面照射,一邊於長邊方向(縱向方向)以表2的倍率進行延伸,以25℃的溫度之輥群冷卻而得到單軸延伸薄膜。然後,將單軸延伸薄膜的兩端一邊用夾具把持一邊導入拉幅機內之110℃的預熱區,接著於120℃在垂直於長邊方向的方向(橫向方向)用表2的倍率延伸。然而,薄膜的破裂頻繁發生,無法拾取可評價的薄膜。
根據本發明,能製膜安定性良好地提供一種不增厚反射薄膜的厚度,而達成高反射率與遮蔽性的白色薄膜。
Claims (10)
- 一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且熱塑性樹脂(B)在該層中形成區域(domain)之白色薄膜,其中關於以六氟異丙醇使該白色薄膜溶解、去除沉澱物而得之懸浮不溶物的質量Bw與懸浮不溶物中之無機粒子的質量Cbw,滿足式(1);0.01<Cbw/(Bw-Cbw)<1 (1)。
- 一種白色薄膜,其係至少具有以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層而且在該層中具有以熱塑性樹脂(B)為核的空隙之白色薄膜,其中在薄膜的垂直剖面中,該熱塑性樹脂(B)之中有無機粒子(C)存在於熱塑性樹脂(B)剖面中的熱塑性樹脂(B)存在,且將該熱塑性樹脂(B)的核數量設為NB1之情形,該熱塑性樹脂(B)之中內部含有無機粒子(C)者的數量NB2之比例NB2/NB1×100(%)為15%以上。
- 如請求項1或2之白色薄膜,其中熱塑性樹脂(B)為聚烯烴。
- 如請求項1或2之白色薄膜,其中無機粒子(C)係以氧化鈦為主成分。
- 如請求項4之白色薄膜,其中在無機粒子(C)表面的SEM-EDX中,Si(矽)的檢測強度與M(無機粒子主成分的金屬元素)的檢測強度比滿足式(2); EDX(Si)/EDX(M)>0.5 式(2)。
- 如請求項4之白色薄膜,其中於無機粒子(C)表面具有1nm以上的含矽有機物層。
- 如請求項1或2之白色薄膜,其包含至少3層,內層為以聚酯樹脂(A)、不相溶於聚酯樹脂(A)的熱塑性樹脂(B)、無機粒子(C)為主成分的層。
- 如請求項1或2之白色薄膜,其比重為0.6以上1.0以下。
- 如請求項1或2之白色薄膜,其為LED背光用途。
- 如請求項1或2之白色薄膜,其為照明用途。
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US (1) | US11541647B2 (zh) |
JP (1) | JP7247887B2 (zh) |
KR (1) | KR20210012995A (zh) |
CN (1) | CN111936566B (zh) |
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WO (1) | WO2019220918A1 (zh) |
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WO2021200454A1 (ja) * | 2020-03-30 | 2021-10-07 | 東レ株式会社 | 樹脂フィルム、ミニled基板、バックライトおよびディスプレイ |
KR102272984B1 (ko) * | 2020-06-04 | 2021-07-05 | 도레이첨단소재 주식회사 | 백색 폴리에스테르 필름 및 그의 제조방법 |
KR102510619B1 (ko) * | 2021-02-23 | 2023-03-15 | 도레이첨단소재 주식회사 | 이축 연신 폴리에스테르 무광택 필름 및 이의 제조방법 |
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2019
- 2019-04-25 KR KR1020207017742A patent/KR20210012995A/ko not_active Application Discontinuation
- 2019-04-25 US US17/054,214 patent/US11541647B2/en active Active
- 2019-04-25 JP JP2019528785A patent/JP7247887B2/ja active Active
- 2019-04-25 CN CN201980024548.0A patent/CN111936566B/zh active Active
- 2019-04-25 WO PCT/JP2019/017684 patent/WO2019220918A1/ja active Application Filing
- 2019-05-10 TW TW108116168A patent/TWI805756B/zh active
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Also Published As
Publication number | Publication date |
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US11541647B2 (en) | 2023-01-03 |
TW202003254A (zh) | 2020-01-16 |
KR20210012995A (ko) | 2021-02-03 |
JP7247887B2 (ja) | 2023-03-29 |
CN111936566A (zh) | 2020-11-13 |
JPWO2019220918A1 (ja) | 2021-04-08 |
WO2019220918A1 (ja) | 2019-11-21 |
US20210060914A1 (en) | 2021-03-04 |
CN111936566B (zh) | 2022-10-28 |
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