US20120141732A1 - Protective film with release surface - Google Patents

Protective film with release surface Download PDF

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Publication number
US20120141732A1
US20120141732A1 US12/992,123 US99212309A US2012141732A1 US 20120141732 A1 US20120141732 A1 US 20120141732A1 US 99212309 A US99212309 A US 99212309A US 2012141732 A1 US2012141732 A1 US 2012141732A1
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United States
Prior art keywords
film
protrusions
release
layer
films
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Abandoned
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US12/992,123
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English (en)
Inventor
Shailesh C. Patel
Bankim B. Desai
Gary M. Balakoff
Paul E. Thomas
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Tredegar Film Products LLC
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Tredegar Film Products LLC
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Priority to US12/992,123 priority Critical patent/US20120141732A1/en
Assigned to TREDEGAR FILM PRODUCTS CORP. reassignment TREDEGAR FILM PRODUCTS CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BALAKOFF, GARY M., DESAI, BANKIM B., PATEL, SHAILESH C., THOMAS, PAUL E.
Publication of US20120141732A1 publication Critical patent/US20120141732A1/en
Assigned to TREDEGAR FILM PRODUCTS CORPORATION reassignment TREDEGAR FILM PRODUCTS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THOMAS, PAUL E, BALAKOFF, GARY M, DESAI, BANKIM B, PATEL, SHAILESH C
Abandoned legal-status Critical Current

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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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/024—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material the sheet or web-like material being supported by a moving carriage
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G49/00—Conveying systems characterised by their application for specified purposes not otherwise provided for
    • B65G49/05—Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles
    • B65G49/06—Conveying systems characterised by their application for specified purposes not otherwise provided for for fragile or damageable materials or articles for fragile sheets, e.g. glass
    • B65G49/068—Stacking or destacking devices; Means for preventing damage to stacked sheets, e.g. spaces
    • B65G49/069—Means for avoiding damage to stacked plate glass, e.g. by interposing paper or powder spacers in the stack
    • 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
    • C09J7/20—Adhesives in the form of films or foils characterised by their carriers
    • C09J7/203—Adhesives in the form of films or foils characterised by their carriers characterised by the structure of the release feature on the carrier layer
    • 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
    • C09J7/20—Adhesives in the form of films or foils characterised by their carriers
    • C09J7/22—Plastics; Metallised plastics
    • 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
    • C09J7/40—Adhesives in the form of films or foils characterised by release liners
    • C09J7/403—Adhesives in the form of films or foils characterised by release liners characterised by the structure of the release feature
    • 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
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/0056—Provisional sheathings
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • 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
    • C09J2301/00—Additional features of adhesives in the form of films or foils
    • C09J2301/10—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet
    • C09J2301/16—Additional features of adhesives in the form of films or foils characterized by the structural features of the adhesive tape or sheet by the structure of the carrier layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612—Composite web or sheet

Definitions

  • the disclosure relates to films for use in protecting substrate surfaces during manufacturing, storage, transport or use.
  • the disclosure also relates to a method for making the films.
  • Surface protection films also known as masking films, are typically used to provide a physical barrier to prevent damage, contamination, scratching, scuffing, or other marring of a substrate.
  • Masking films may be used to provide such protection during manufacture, shipping, or storing prior to use of the substrate, for example.
  • Such films may be used in numerous applications as protective coverings for surfaces, particularly for protecting relatively smooth surfaces, such as acrylics, polycarbonates, glass, polished or painted metals and glazed ceramics.
  • Optical substrates for televisions, monitors, and other displays require masking films that both protect the surface and may be removed without damaging, leaving residues of an adhesive, or other contaminants or particulates on the surface.
  • corona-treated films are films that have been exposed to an electrostatic discharge to oxidize the surface of the film. This oxidation increases the film's surface tension and attraction to polar surfaces.
  • Such corona-treated films typically are smooth films and rely on very precise corona treatment to facilitate adhesion. Unless embossed, corona-treated films are typically subject to wrinkling, which makes it difficult to use and handle the films.
  • a further disadvantage is that the adhesion promoting effects of corona treatment dissipate with time.
  • masking films are relatively difficult to use and handle. Because masking films are designed to adhere to a surface, they may also adhere to themselves when the masking film is wound on a roll or the adhesion surface otherwise contacts a portion of the masking film. Blocking, as it is called, may result in processing difficulties including delays and wasted material. To reduce the tendency for self adherence, masking films may be coated with a weak adhesive. The weak adhesive on the masking film may prevent the film from adhering tightly to itself on the roll, however, the weak adhesive may also not provide sufficient adherence to the surface to be protected.
  • Other films may be provided with one matte surface opposite the adhesion surface; often called one side matte (“OSM”) masking films.
  • OSM side matte
  • the irregularity of a matte surface does not provide a good surface for adhesion and provides antiblocking properties to the masking film.
  • a masking film comprises a polymeric film web having at least one three-dimensional release surface.
  • the three-dimensional release surface comprises a plurality of raised protrusions formed integral with the film.
  • the raised protrusions comprise a plurality of spaced-apart ribs
  • the three-dimensional release surface comprises polymer nubs.
  • the masking film comprises an adhesion layer opposite the three-dimensional release surface.
  • FIG. 1 is a cross sectional view of a masking film shown adhered to a substrate and comprising a release layer and an adhesion layer, wherein the release layer comprises a three-dimensional release surface having a plurality of apertured protrusions.
  • FIG. 1A is a cross sectional view of a masking film shown adhered to a substrate and comprising a release layer and an adhesion layer wherein the release layer comprises a three-dimensional release surface having a rhomboid embossed pattern.
  • FIG. 1B is a cross sectional view of a masking film shown adhered to a substrate and comprising a release layer and an adhesion layer wherein the release layer comprises a multiplanar film.
  • FIG. 2 is a cross sectional view of a masking film having a first release layer, a core layer, and a second release layer, wherein each release layer comprises a three-dimensional release surface having a plurality of unapertured protrusions.
  • FIG. 3 is a cross sectional view of a masking film comprising a single layer film having two release surfaces.
  • FIG. 4 is a perspective view of a masking film having an adhesion layer and a release layer with a three-dimensional release surface comprising spaced apart longitudinal ribs.
  • FIG. 4A is a cross sectional view of a masking film similar to the embodiment of FIG. 4 , except without any adhesion layer.
  • FIG. 5 is a perspective view of a masking film having an adhesion layer and a release layer having a three-dimensional surface comprising polymer beads.
  • FIG. 5A is a cross sectional view of the masking film of FIG. 5 , as seen along line and arrows A-A of FIG. 5 .
  • FIG. 6 is a cross sectional view of another embodiment of a film with two three-dimensional release surfaces.
  • FIG. 7 is a schematic illustration of a vacuum lamination process.
  • FIG. 8 is a schematic illustration of an embossing and/or vacuum forming process useful in making certain of the embodiments.
  • a “laminate” or “composite,” as used herein to describe webs or films are synonymous. Both refer to a web structure comprising at least two webs or films joined to form a multiple-layer unitary web.
  • the webs may be coextruded or joined by a lamination process, including adhesive lamination, thermal lamination, pressure lamination, and combinations thereof, as well as other lamination techniques known to those in the art.
  • Adhesives used to form the laminate may be any of a large number of commercially available pressure sensitive adhesives, including water based adhesives such as, but not limited to, acrylate adhesives, for example, vinyl acetate/ethylhexyl acrylate copolymer which may be combined with tackifiers.
  • Other adhesives include pressure sensitive hot melt adhesives or double sided tape.
  • polymer includes homopolymers, copolymers, such as, for example, block, graft, impact, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” is meant to include all possible stereochemical configurations of the material, such as isotactic, syndiotactic and random configurations.
  • embodiments of the masking film comprise a release layer having a three-dimensional release surface.
  • the masking film comprises an adhesion layer and a release layer with a three-dimensional release surface.
  • the masking film comprises two three-dimensional release surfaces located on opposite sides of the film.
  • the masking films may comprise a single layer or multiple layers. Intermediate layers may be interposed between the adhesion layer and the release layer or between the two release layers.
  • FIG. 1 is a diagrammatic representation of an exemplary embodiment of the present disclosure.
  • Substrates with a masking film according to the embodiments placed between them are prevented from adhering to each other by creating a gap between stacked sheets allowing for an air space between the substrate sheets.
  • a “film” refers to a thin sheet or web comprising a polymer.
  • a film may be produced, for example, by extruding a molten thermoplastic polymer in an extrusion cast or blown process. The polymer may be further processed between rollers and cooled to form the web.
  • Films can be monolayer films, coextruded films, and composite films, for example.
  • Composite films may be produced by a coextrusion process or by bonding one or more films together.
  • a film may be dimensionally described as having a machine direction, a cross direction, and a z-direction.
  • the machine direction is defined by the direction in which the film passes through the manufacturing process.
  • films are produced as long sheets or webs which have a much longer length than width, in such a case the machine direction is usually the length (also referred to as the x-direction) of the sheet.
  • Perpendicular to the machine direction is the cross direction or traverse direction (also referred to as the y-direction or width) of the sheet.
  • the thickness of the film is measured in the z-direction.
  • the z-direction of a three-dimensional formed film includes the height of any three-dimensional features of the formed film and the thickness of the film.
  • a three-dimensional formed film is a film that has been processed to form three-dimensional features on at least one surface of the film. Therefore, three-dimensional formed films have a z-direction measurement, loft, that is significantly greater than the nominal thickness of the film. Typically, the loft is at least one and a half times the nominal thickness of the film.
  • Examples of three-dimensional formed films are films that have a plurality of protrusions extending from a continuous land area which protrusions may be apertured or unapertured.
  • the three-dimensional formed film may comprise a multiplanar film.
  • Multiplanar films are films that have a continuous surface and a discontinuous surface spaced from one another in the z-direction. Multiplanar films are distinguished from three-dimensional films in that the protrusions may originate from either the continuous surface or the discontinuous surface, or both. Protuberances may be formed on any or all of the available planes. Examples of multiplanar films are disclosed in U.S. Pat. No. 7,518,032, the disclosure of which is incorporated herein by reference.
  • the three-dimensional features of the three-dimensional formed films may be produced using any suitable process. Most commonly, an embossing process, a hydroforming process, or a vacuum forming process, may be used to advantage.
  • the three-dimensional features may have a cross-section that is circular, oval, triangular, square, pentagonal, hexagonal, or any other desired shape.
  • the pattern of the protrusions of the three-dimensional film may exist in either a regular geometric array or a random array.
  • regular geometric patterns can include, but are not limited to, continuous lines (raised ribs) that are straight or wavy, protrusions on straight or wavy lines, on a 60 degree equilateral triangle array, a square pattern array, or an array that has mixed spacing and angles but is repeating in clusters or groups of protrusions.
  • Random arrays are random without any regular repeating pattern of individual protrusion or of clusters or groups of protrusions.
  • Formed films can be created, for example, by drawing a polymeric web against a forming structure using a vacuum or forcing the web against the forming structure using high pressure jets or air or water.
  • Such processes are known from the teachings of US 2004/0119208 and US 2004/0119207, and the prior art references cited therein. The disclosure of these published applications, and those of the prior art cited therein, are incorporated herein by reference.
  • a direct cast vacuum formation process a molten polymer is extruded from a die directly onto a forming structure and then subjected to vacuum to draw the polymer into apertures in the forming structure. The film is cooled, the shape of the film is set and the film is removed from the forming structure.
  • the portions of the polymer that were drawn into the apertures in the forming structure result in the protrusions.
  • the level of vacuum and other process parameters can be adjusted to draw the polymer into the apertures and form the protrusions without rupturing the film, or the process can be practiced to rupture the film to form apertures at the apex of the protrusion.
  • the release layer may be a formed film created by a hydroforming process in which the three-dimensional protrusions are formed by directing high pressure streams of water against the surface of a polymer film while the film is supported on a forming structure. The high pressure water will force the film into apertures in a forming screen in the same manner as the vacuum to create the protrusions.
  • the release layer may be a formed film made in a reheat process in which a precursor polymeric film is heated to close to the melting point and then subjected to vacuum while supported on a forming structure as in the direct cast vacuum process described above.
  • apertured formed film refers to a three-dimensional formed film with apertures or holes at the apex of the protrusions of the film.
  • the apertured formed film may be produced by the vacuum forming and hydroforming processes mentioned above in a manner to create the apertures in the apex of the protrusions.
  • the protrusions may be created by deforming the film using a pin plate as taught in U.S. Pat. No. 7,083,843, the disclosure of which is incorporated herein by reference.
  • the protrusions may be formed by deep embossing a precursor film, such as by passing a film through a nip formed between a first roll having a plurality of spaced protrusions and a second anvil roll having a smooth, hard surface. As the film is passed through the nip, the film is deformed in the areas corresponding to the protrusions from the first roll. Deep embossing is disclosed, for example, in U.S. Pat. No. 5,229,186, the disclosure of which is incorporated herein by reference.
  • the z-direction dimension of the three-dimensional feature is a function of the diameter of the hole in the forming screen. Other factors also contribute to the z-direction height of the three-dimensional features such as film composition, basis weight of the film, and temperature of the film while being apertured. Typically, smaller diameter protrusions are shorter in z-direction than larger diameter apertures.
  • Three-dimensional formed films may comprise at least one thermoplastic polymer.
  • three-dimensional formed films may comprise at least one polymer selected from polyethylene, copolymers of polyethylene, low density polyethylene, linear low density polyethylene, high density polyethylene, medium density polyethylene, polypropylene, copolymers of polypropylene, blends of polyethylene and polypropylene, random copolymer polypropylene, polypropylene impact copolymers, polybutene, metallocene polyolefins, metallocene linear low density polyethylene, polyesters, copolymers of polyesters, plastomers, polyvinylacetates, poly (ethylene-co-vinyl acetate), poly (ethylene-co-acrylic acid), poly (ethylene-co-methyl acrylate), poly (ethylene-co-ethyl acrylate), cyclic olefin polymers, polybutadiene, polyamides, copolymers of polyamides, polystyrenes, polyurethanes, poly (ethylene-co
  • the olefin monomer is either ethylene or propylene, but thermoplastic polyolefins may include higher molecular weight olefins.
  • polyolefins may also include polymers and copolymers of olefin monomers such as, but not limited to, ethylene, propylene, butene, isobutenes, pentene, methyl pentene, hexene, heptene, octene, and decene.
  • Functionalized olefin monomers such as linear low density polyethylene-g-maleic anhydride (LLDPE-g-MA) available from E.I. du Pont de Nemours & Co., Inc., Wilmington, Del., under the trade designation BYNEL, may also be used.
  • LLDPE-g-MA linear low density polyethylene-g-maleic anhydride
  • the layers of the masking films can also contain elastic or semi-elastic polymers.
  • elastic, or semi-elastic polymers include low crystallinity polyethylene, metallocene catalyzed low crystallinity polyethylene, ethylene vinyl acetate copolymers (EVA), polyurethane, polyisoprene, butadiene-styrene copolymers, styrene block copolymers such as styrene/isoprene/styrene (SIS), styrene/butadiene/styrene (SBS), or styrene/ethylene-butadiene/styrene (SEBS) block copolymers, and blends of such polymers.
  • the elastic material may comprise other modifying elastic or non-elastomeric materials. Examples of elastomeric block copolymer are sold under the brand name KRATON, by Kraton Polymers, LLC.
  • any of a variety of fillers may be added to the thermoplastic polymers and may provide certain desired characteristics, including, but not limited to, roughness, anti-static, abrasion resistance, printability, writeability, opacity and color.
  • Such fillers are well known in the industry and include, for example, calcium carbonate (abrasion resistance), mica (printability), titanium dioxide (color and opacity) and silicon dioxide (roughness).
  • the olefin monomer is either ethylene or propylene, but thermoplastic polyolefins may include higher molecular weight olefins.
  • polyolefins may also include polymers and copolymers of olefin monomers such as, but not limited to, ethylene, propylene, butene, isobutene, pentene, methyl pentene, hexene, heptene, octene, and decene.
  • olefin monomers such as, but not limited to, ethylene, propylene, butene, isobutene, pentene, methyl pentene, hexene, heptene, octene, and decene.
  • the adhesion layer is capable of adhering to the surface of a substrate and the release layer provides a three-dimensional release surface which reduces the tendency of the film to adhere to itself when stored on a roll.
  • the release surface can provide cushioning and protection to the surface of the substrate, without scratching the surface and may also allow protected surfaces to be handled more easily.
  • the release layer can be formulated to provide a significant portion of the strength and protective properties to the masking film, if desired.
  • the resins, additives and process variables of the contacting film surfaces are designed to eliminate any residue or stain transfer to the optical surfaces.
  • the loft of the protrusions may be varied by modifying the amount of vacuum pressure, fluid pressure, temperature, dwell time, aperture size in the forming structure and polymers used to make the film.
  • the thickness of an unembossed film is normally between 12.7 ⁇ and 152.4 ⁇ , but more typically within a range of 12.7 ⁇ and 76.2 ⁇ . After a deep embossing process, such a film will have three-dimensional features between 63.5 ⁇ and 1069 ⁇ .
  • the deep embossed film for use as a component of a masking film may have between about 4 and about 120 macro cells per inch.
  • cells of the film have any shape and may be arranged in many patterns. The shapes of the cells include, but are not limited to, circles, ovals, diamond, boat shaped, ridges, channels, triangles, quadrilaterals or increasing multi-sided figures.
  • An embossed film may be made by any suitable process which adds three-dimensional features to the film.
  • a web of thermoplastic film may be fed through the nip of a driven pull roll or the web may be fed through the nip of embossing rolls, for example, to form the embossing or deep embossing.
  • Other processes may be used to emboss the films with the desired properties and dimensions.
  • the film Prior to the embossing process, the film may be preheated to facilitate embossing the film and set the features into the film after cooling. For example, spaced apart heaters on either side of the film may be used to raise the temperature of the film above its softening point.
  • the heat softened film may then be passed into a nip formed by a metal embossing roll and a backup roll covered with an outer layer of a resilient material, such as a rubber, rubber-like material, or rubber silicone.
  • the backup roller may have a surface roughness to provide a matte surface on the film.
  • the backup roll may have a surface roughness of 5 to 150 microinch (0.127 to 3.81 ⁇ ).
  • a rubber roll may be used and have a surface roughness between 30 and 100 microinch (0.762 and 2.54 ⁇ ).
  • the film is produced with a matte surface on one side and an embossed surface on the other.
  • the film may then be passed into a nip formed by a polished metal roll, such as a high polish smooth chrome roll, and a rough backup roll.
  • a polished metal roll such as a high polish smooth chrome roll, and a rough backup roll.
  • This process will produce film with a matte surface and a smooth opposite surface, such a film has one release surface and may be laminated with an adhesion layer or may be laminated to other layers that provide a second release surface, for example.
  • An adhesion layer is a layer of material that has some adhesive properties to smooth or rough surfaces and may be formed into a coherent monolayer. In use, the adhesion layer is applied to the surface to be protected.
  • the masking films of the present disclosure achieve the desirable wetting and adhesion characteristics without an adhesive coating.
  • the adhesion layer comprises a smooth surface having a roughness of from 0 to 60 microinch (0 to 1.524 ⁇ ), or more preferably, between 0 and 30 microinch (0 and 0.762 ⁇ ).
  • the adhesion layer may comprise a polymer.
  • the polymer of the adhesive layer may be at least one polymer selected from polyethylene, low density polyethylene, linear low density polyethylene, high density polyethylene, medium density polyethylene, polypropylene, random copolymer polypropylene, polypropylene impact copolymers, metallocene polyolefin, metallocene linear low density polyethylene, plastomers, poly (ethylene-co-vinyl acetate), copolymers of an acrylic acid, poly (ethylene-co-acrylic acid), poly (ethylene-co-methyl acrylate), cyclic olefin polymers, polyamides, or poly (ethylene-co-n-butyl acrylate).
  • Embodiments of the masking film of the present disclosure comprise an adhesion layer comprising a metallocene polyolefin.
  • a “metallocene polyolefin” is a polyolefin produced by a metallocene catalyzed polymerization of olefin monomers.
  • the olefin monomer is either ethylene or propylene, but metallocene polymerizations may include a catalyst that may polymerize higher molecular weight olefins.
  • Metallocene polyolefins also include copolymers of olefins produced by a metallocene catalyzed polymerization process, such as copolymers of any combination of olefin monomers such as, but not limited to, ethylene, propylene, butene, isobutenes, pentene, methyl pentene, hexene, heptene, octene, and decene, for example, metallocene poly (ethylene-co-octene) copolymers.
  • Blends of metallocene polyolefins may also be used, as well as blends of metallocene polyolefins with other polymers.
  • Metallocene polyolefins differ from polyolefins prepared by different polymerization processes. Metallocene polyolefins may be characterized by narrow molecular weight distributions of less than 2.0, controlled polymer structure, higher thermal stability, higher clarity, and higher impact resistance. Based upon such properties, one skilled in the art may easily discern between metallocene polyolefins and polyolefins produced by other processes. Metallocene polyolefins are commercially available, for example, from Dow Chemical Corp. and other resin suppliers.
  • metallocene polyolefin having the desired properties may be used in embodiments of the masking film.
  • metallocene polyolefin selected from the group of polymers comprising metallocene polyethylenes, metallocene polypropylenes, and metallocene copolymers comprising monomer units derived from ethylene and propylene may be used in the adhesion layer of the masking film.
  • Such polymers provide a desired level of adhesive and cohesive properties.
  • Metallocene copolymers may also provide the desired properties to the adhesion layer of the masking films.
  • metallocene copolymers comprising monomer units derived from ethylene higher a-olefins having 3 to 12 carbon atoms, for example, a metallocene poly (ethylene-co-octene).
  • metallocene copolymers comprising monomer units derived from ethylene, propylene, butene, pentene, hexene, and octene.
  • the adhesion layer of the masking film may comprise a metallocene copolymer comprising monomer units derived primarily of polyethylene and additional monomer units derived from butene, pentene, hexene, octene, or a combination of these monomers. Blends of metallocene polyolefins may also be used.
  • Embodiments of the masking films include metallocene polyolefins having a molecular weight distribution (i.e., polydispersity) greater than 1.0 and less than 2.0, or in certain embodiments, metallocene polyolefins having a molecular weight distribution of less than 1.7 may be desired or even a molecular weight distribution greater than 1.0 and less than 1.5.
  • a molecular weight distribution i.e., polydispersity
  • the adhesion layer may comprise polymers comprising metallocene polyolefins as blocks of the polymer, wherein the other blocks may or may not comprise a metallocene polyolefin.
  • block copolymers are considered metallocene polyolefins as the term is used herein.
  • An embodiment of a two layer masking film comprises an adhesion layer and a release layer.
  • the adhesion layer comprises a blend of metallocene polyethylene and a low density polyethylene.
  • the release layer comprises low density polyethylene and has a release surface comprising a plurality of protrusions.
  • the adhesion layer may be from 5% to 30%, or in other embodiments from 15% to 25%, of the film based upon the total thickness of the masking film and the release layer may be the remaining 70% to 90%, or in other embodiments from 75% to 85%, of the total thickness of the masking film. In a more specific embodiment, the adhesion layer is 15% to 20% of the film.
  • the masking film may comprise any polymers that give the desired properties. However, in one embodiment, the adhesion layer consists essentially of 75% to 85% of a metallocene poly (ethylene-co-octene) copolymer and 15% to 25% of a low density polyethylene.
  • This embodiment has specific properties that allow rapid and sufficient wetting of low surface energy substrates such as, but not limited to substrates comprising glass, acrylates, cyclic olefin polymers (“COP”) films, or triacetyl cellulose (“TAC”) films.
  • substrates comprising glass, acrylates, cyclic olefin polymers (“COP”) films, or triacetyl cellulose (“TAC”) films.
  • COP cyclic olefin polymers
  • TAC triacetyl cellulose
  • the masking films have particular use in the manufacture of optical films for LCD displays such as optical grade light management film (polarizers) used in an LCD assembly.
  • the metallocene poly (ethylene-co-octene) copolymer may be replaced with a metallocene plastomer or other metallocene polyolefin.
  • TAC films are typically used as polarizer protective layers in the manufacture of LCD's. TAC polymers formed with the low stresses of solvent casting result in a unique polymer system that meets the requirements of extremely isotropic LCD coversheets. Such properties have allowed solvent cast TAC films to capture the vast majority of LCD coversheet applications.
  • the TAC is a soft film and when produced and rolled, the smooth front and back film surfaces have a tendency to stick or block together and generate poor wound roll quality. This may lead to defects in the LCD assembly.
  • the masking film of the present disclosure protects and allows easier handling of TAC films better than other combinations of constituents and structures of masking films. Thus, TAC films, when masked with films of this disclosure may be used more successfully and efficiently for LCD assemblies.
  • Embodiments of the masking film with different adhesion levels may be produced by incorporating the constituents in different percentages of certain polymers and co-polymers in the adhesion surface of the masking film.
  • Secondary polymers such as polyolefins (homopolymers or co-polymers), polyvinyl alcohol, polyvinyl chloride, nylon, polyesters, styrenes, polybutylenes, polymethylpentene, plastomers, poly (ethylene-co-vinyl acetate), poly (ethylene-co-acrylic acid), poly (ethylene-co-methyl acrylate), cyclic olefin polymers, polyamides, or poly (ethylene-co-n-butyl acrylate) and polyoximethylene, and mixtures thereof, can be blended with the primary polymer at varying ratios to provide the desired level of adhesion of the film.
  • Acid-modified co-polymers, anhydride-modified co-polymers and acid/acrylate-modified co-polymers also are useful. Films of polyethylene are particularly suited and therefore preferred. Films of low-density polyethylene homopolymers are even more particularly suited, and therefore more preferred, due to their relatively low tensile modulus which tends to conform better to surfaces.
  • the masking film may be any desired thickness. However, in certain applications, the total thickness of the masking film is from 60 ⁇ to 200 ⁇ .
  • FIG. 1 An embodiment of a masking film is shown in FIG. 1 .
  • the masking film 10 is shown on substrate 16 .
  • Masking film 10 comprises an adhesion layer 12 and a release layer 14 .
  • the adhesion layer 12 is formulated to provide adhesion to the substrate 16 , but also to be removed when no longer needed without damaging the substrate 16 or leaving any residue on the substrate 16 .
  • Adhesion layer 12 can be of any desired formulation now know in the art or later developed for the particular surface being protected. As is also known in the art, the adhesion layer is preferably made with a very smooth surface to facilitate intimate contact with the substrate surface.
  • the release layer 14 comprises a three-dimensional release surface 15 .
  • the release surface 15 comprises a plurality of protrusions 13 that are raised from the planar portion of release surface 15 .
  • the raised protrusions create a physical separation between the masking film 10 and an adjacent substrate in a stack.
  • the plurality of protrusions 13 protect the substrate 16 during handling and allow one substrate to be separated from another more easily.
  • the release layer comprises a formed film in which protrusions 13 are integral extensions of the release layer 14 .
  • the release surface 15 may comprise protrusions 13 that have an average height, as measured from the base surface 15 of the film, of greater than 50 microns. In certain embodiments, the average height of the protrusions may be greater than 100 microns. In certain embodiments, the release surface of the release layer comprises at least one of a plurality of protrusions, a plurality of three-dimensional apertures, a deeply embossed structure, or combinations thereof.
  • the three-dimensional protrusions 13 comprise apertured protrusions in the shape of cones or funnels and have an opening or aperture 11 in the apex of the protrusion 13 . It is understood, however, that the protrusions need not be apertured and, in fact, are preferably not apertured. The apertures create an opportunity for debris to collect or be trapped in the film. The debris can then scratch or otherwise damage the substrate surface. It will be appreciated and understood that the three dimensional film used as release layer 14 can be oriented in the direction opposite the direction shown in FIG. 1 , wherein the protrusions 13 would be oriented towards and in contact with adhesion layer 14 .
  • FIG. 1A shows another embodiment of a masking film 110 is adhered to a substrate 116 .
  • the masking film 110 comprises an adhesion layer 112 and a release layer 114 .
  • the release layer 114 has a release surface 115 comprising a plurality of three-dimensional protrusions 113 extending from the release surface 115 .
  • the release layer 114 may conveniently be formed by a deep embossing process.
  • the masking film 210 is shown adhered to a substrate 216 .
  • the masking film 210 comprises an adhesion layer 212 and a release layer 214 .
  • the release layer 214 in this embodiment comprises a multiplanar film.
  • the multiplanar film 214 has a protrusions 213 extending upward from a planar surface 215 of the film.
  • the multiplanar film has a plurality of protrusions 217 that, in the embodiment shown, terminate in apertures 218 at the apex of the protrusion.
  • the film used as the release layer 214 may be inverted such that the protrusions 213 are oriented toward and in contact with the adhesion layer 212 .
  • Embodiments also include masking films comprising more than two layers.
  • a specific embodiment of a masking film comprises an adhesion layer, a core layer, and a release layer. At least one core layer may be interposed between the adhesion layer and the release layer of the masking film.
  • the core layer(s) of such embodiment may comprise any polymer that improves the mechanical properties of the film, such as stiffness, modulus, tear resistance, etc.
  • the core layer may be formulated to reduce the potential damage of the smooth surface of the adhesion layer during manufacturing and use of the film, or to improve the film's modulus.
  • the masking film should have a modulus of greater than 15,000 psi (103.4 MPa).
  • the modulus of the masking film may be greater than 15,000 psi (103.4 MPa) and less than 350,000 psi (2413.17 MPa).
  • the release layer should have a modulus of 240,000 psi (1654.74 MPA) ( ⁇ 15%). The modulus in this range is desired to provide protection to the adhesion layer without affecting the wetting characteristics of the masking film.
  • the core layer may be any thermoplastic, thermoset, or elastic polymer, as described herein, for example, that provides the desired properties to the masking film.
  • the core layer may comprise a polymer selected from polyethylene, low density polyethylene, linear low density polyethylene, high density polyethylene, medium density polyethylene, polypropylene, random copolymer polypropylene, polypropylene impact copolymers, metallocene polyolefin, metallocene linear low density polyethylene, plastomers, poly (ethylene-co-vinyl acetate), copolymers of an acrylic acid, poly (ethylene-co-acrylic acid), poly (ethylene-co-methyl acrylate), cyclic olefin polymers, polyamides, poly (ethylene-co-n-butyl acrylate), polyvinyl chloride, nylon, polyester, and combinations thereof.
  • the core layer can aid in providing the desired opacity and/or color, stiffness and toughness to the multilayer masking film.
  • Embodiments of the masking film may comprise two release surfaces.
  • the films with two release surfaces may be monolayer or multilayer films.
  • FIG. 2 depicts an embodiment of a masking film 20 comprising a core layer 21 , a first release layer 22 and a second release layer 26 .
  • Each release layer 22 , 26 has a release surface 23 , 27 , respectively.
  • the release surfaces 23 , 27 comprise three-dimensional surfaces having a plurality of protrusions 24 , 28 , respectively.
  • the protrusions are integral extensions of the release layers.
  • the three-dimensional protrusions 24 , 28 are unapertured, but still have a characteristic cone shape of a vacuum formed, or hydroformed, film.
  • the masking film may omit the core layer 21 and may, for example, comprise two three-dimensional films laminated together such that the three-dimensional surfaces are oriented outwardly.
  • FIG. 3 depicts an embodiment of a single layer masking film 30 comprising two release surfaces 31 , 32 .
  • Release surface 31 comprises a three-dimensional surface having a plurality of embossments 33 .
  • Release surface 32 comprises a matte surface having a surface roughness of between 5 and 100 microinch (0.127 ⁇ and 2.54 ⁇ ).
  • a masking film 40 comprises a release layer 42 and an adhesion layer 44 .
  • the release layer 42 comprises a release layer 46 having a plurality of spaced apart raised ribs or ridges 48 .
  • Such films may be conveniently made by casting a molten polymer onto a forming drum having raised ribs or wires. As the polymer cools to form the film, the film surface will correspond to the ribs or wires, resulting in continuous raised ridges 48 in the film.
  • the release layer 42 can then be coated or laminated to an adhesion layer 44 .
  • the masking film 40 can be made by coextruding the release layer 42 and the adhesion layer 44 onto a forming structure having a plurality of spaced apart channels or grooves and then subjecting the coextrusion to a vacuum (as discussed above) to draw the polymer forming the release layer into the grooves. As the polymer cools, the film will form ridges corresponding to the location where the polymer was drawn into the groove. Care must be taken to ensure that the surface of the release layer 44 does not get drawn into the grooves so that the adhesion layer remains as smooth as possible. Other methods of making the films may also be used to advantage.
  • FIG. 4A depicts a cross sectional view of the release layer 42 of the embodiment of FIG. 4 .
  • the masking film is a monolayer film 42 having a release surface 46 comprising a plurality of spaced apart, three-dimensional raised ridges 48 formed integral with the release surface 46 as in FIG. 4 .
  • the masking film further comprises a second surface 43 opposite the release surface 46 .
  • Second surface 43 of release layer 42 has a plurality of air spaces 54 corresponding to the underside of the raised ribs 48 .
  • the ridges 48 in the embodiments of FIGS. 4 and 4A provide a significant rigidity to the films. This is advantageous for the embodiment of FIG. 4A in particular where the film may be used as a replacement for paper in a stack of substrates.
  • FIGS. 5 and 5A shows a masking film 50 comprising a release layer 52 and an adhesion layer 54 .
  • Release layer 52 comprises a release surface 56 having a plurality of polymeric beads 58 disposed thereon.
  • the beads 58 are not formed as integral extensions of the release layer 52 . Rather, the beads 58 comprise individual, discrete beads of polymeric material, such as polyethylene, applied to the surface of the film.
  • Polymer beads can be applied via an impact printing process (such a gravure printing), a non-impact printing process (such as ink jet printing), a glue application apparatus, or any other apparatus capable of ejecting or depositing discrete polymer beads in molten, semi-molten, or solid form.
  • an impact printing process such as a gravure printing
  • a non-impact printing process such as ink jet printing
  • a glue application apparatus or any other apparatus capable of ejecting or depositing discrete polymer beads in molten, semi-molten, or solid form.
  • discrete polymer beads may be applied to the surface of the release layer while the beads are in a solid form and the release layer is in a semi-molten or softened state.
  • the beads will be applied while the polymeric material is at, above or near the melting temperature. To keep the beads from spreading into the film layer, it may be advantageous to quench the polymer bead by contacting the surface of the release layer with a quenching roll.
  • the polymer beads 58 may comprise any polymer material that can be applied to the release layer 56 and remain sufficiently adhered to the release layer for the intended purpose.
  • the polymer beads may be of any size, shape, dimension, pattern or spacing desired for the particular use of the film.
  • FIG. 6 depicts an embodiment of a masking film 60 having a planar portion 61 and a plurality of protrusions 62 formed integral with the planar portion 61 .
  • the protrusions 62 extend on either side of the planar portion 61 .
  • the protrusions 62 are in registration on either side of the film, but this does not necessarily need to be the case.
  • FIG. 7 is a schematic illustration of one process that may be used to produce the masking films.
  • the polymers are mixed and melted in an extruder (not shown) and passed through a die 70 , where the polymer emerges in a molten stream or curtain 72 onto roll 74 .
  • roll 74 may comprise a smooth casting roll, a forming structure, or a textured casting roll.
  • Web 76 is brought together with web 72 at the nip formed between roll 74 and roll 78 . The two webs, 72 , 76 are laminated in the nip and then removed from roll 74 to produce the final film structure 80 .
  • the web 76 may be an apertured or unapertured three-dimensional film, an embossed film, a deep embossed film, an adhesive layer, etc.
  • the polymeric material intended for use as the adhesion layer 12 would be extruded from die 70 as molten web 72 onto roll 74 , which in this case would comprise a smooth surface chill roll.
  • Web 74 comprising three-dimensional apertured film 14 of FIG. 1 , would be brought into contact with the web 72 at the nip formed between pressure roll 78 and chill roll 74 .
  • the combination of heat and pressure at the nip would cause the apertured film 76 to become adhered to the adhesion layer 72 whereby the laminated film 10 of FIG. 1 would emerge as web 80 .
  • the web 72 could comprise a coextrusion of the materials for first release layer 22 and core layer 21 which would be cast onto roll 74 , which in such an embodiment would comprise a forming structure.
  • the second release layer 26 would be brought into the nip as web 76 .
  • the second release layer 26 would be formed and the final film 20 would emerge from roll 74 as web 80 .
  • FIG. 8 illustrates a schematic diagram of another process that may be used to produce certain of the embodiments.
  • a molten polymer web 82 is extruded from die 80 onto roll 84 .
  • roll 84 may comprise a forming structure, a smooth surface casting roll, a textured surface casting roll, an embossing roll, etc.
  • Nip roll 86 can preferably comprise a textured roll or embossing roll, but may also be a smooth roll if desired.
  • the process of FIG. 8 is particularly advantageous in making masking films such as the embodiments shown in FIGS. 3 , 4 A and 6 , for example.
  • FIG. 8 is particularly advantageous in making masking films such as the embodiments shown in FIGS. 3 , 4 A and 6 , for example.
  • the nip roll 86 may be a thin screen disposed on a support roll of rubber or other material, The thin screen would impart the surface topography to one side of the film while the surface of roll 84 would impart the surface topography to the opposite side of the film, preferably with the assistance of vacuum.
  • the masking films may be interleaved between stacks of substrates to protect the substrates during shipping, use, manufacture, or assembly.
  • the masking films may be particularly useful for use in stacks of substrates with smooth surfaces, such as glass or other optical media.
  • the masking film may be placed in between substrates to protect the substrates and allow the desired release characteristics.
  • a masking film that resists buildup of an electrostatic charge is desirable in many applications.
  • the masking film protects portions of the film not only from mechanical damage and chemical damage or contamination, but also from contamination from particulates, such as dust. Therefore, it is desired in certain applications, such as layered optical screens, that the masking films themselves do not transfer dust or other particles to the surface of the substrate.
  • an antistatic agent may be added to the adhesion layer and/or the release layer.
  • the adhesion layer or release layer will include an antistatic agent that will not migrate to the surface of the film and, thus having the potential of contaminating the surface of the substrate, such as an ionomer.
  • the adhesion layer in specific embodiments may comprise an ionomer.
  • An ionomer is a polymer having unique physical properties due to ionic interactions of discrete regions of the polymer components. Most ionomers are polymers in which a small but significant proportion of the constituent monomers have ionic groups. In certain embodiments, the ionomer may be a potassium ionomer.
  • any layer of the masking films of the present disclosure may comprise at least one anti-oxidant, colorant, pigment, clarifier, and/or nucleating agent.
  • any layer such as the adhesion layer, a core layer and/or release layer, may be co-extruded using any co-extrusion process known in the art.
  • co-extrusion allows for the relatively simple and easy manufacture of a multi-layered masking film composed of distinct layers, each performing specific functions.
  • co-extrusion of the improved multi-layered masking film of the present disclosure is preferred, it is again noted that the masking film can be mono-layered or multi-layered and that, regardless of form, the masking film can be produced using any other suitable method, if desired.
  • any of a variety of conventional methods can be utilized for applying the multi-layer (or monolayer) masking film to the textured surface of the substrate to be protected.
  • the multi-layer film is taken off from a roll and directly applied to the surface by means of a nip roll or similar system. In this manner, the smooth side of the multi-layer film is applied to and pressed against the textured substrate in one operation. If desired, the resulting lamination may be passed through compression rolls or the like for further processing.
  • Other suitable techniques for forming the laminations of this disclosure will be readily apparent to those skilled in the art upon reading the description herein.
  • Sample No. 4 is a monolayer film.
  • Sample no. 7 is a coextruded film. All other samples were prepared by laminating two films together. The sample films were measured for basis weight, haze and thickness (loft) and tested for adhesion. Properties and data are set forth in Table 2.
  • a series of monolayer polyethylene films were made having one smooth adhesion surface and an opposite release surface.
  • the films were made by casting the low density polyethylene/slip agent blend used in the earlier examples onto a smooth chill roll. Pressure was applied to the opposite side of the film with a textured or engraved embossing roll, as seen in FIG. 8 .
  • the textured embossing roll was made of rubber and had a surface texture with a roughness of 1.397 ⁇ (55 microinch).
  • the engraved embossing roll was also made of rubber and had an series of deep engraved grooves in a diamond shape pattern.
  • Each surface of the film was then tested for adhesion using a special developmental adhesion strength test method in a 180° peel test. Results are reported in Table 3.
  • a series of polyethylene films were made having a release surface on each side.
  • the films were made by casting the low density polyethylene/slip agent blend used in the earlier examples onto an engraved chill roll.
  • the chill roll had an engraved surface containing a series of deep engraved grooves in the shape of a diamond pattern.
  • Pressure was applied to the opposite side of the film with a textured embossing roll, as seen in FIG. 8 .
  • the textured embossing roll was made of rubber and had a surface texture with a roughness of 1.397 ⁇ (55 microinch).
  • Each surface of the film was then tested for adhesion. Results are reported in Table 4. As seen in Table 4, in this embodiment, the films did not adhere to the substrate.
  • a series of three-layer coextruded films were prepared having the composition set forth in Table 5 (layer 2 was the core layer and layers 1 and 3 are outer or “skin” layers).
  • the films were cast onto a forming screen having thin wires wrapped about the periphery and subjected to vacuum to form the film materials depicted in FIG. 4A .
  • the films were tested for a variety of physical properties. Results are reported in Table 6.

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CN103991263A (zh) 2014-08-20
US9993988B2 (en) 2018-06-12
US20140190612A1 (en) 2014-07-10
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CN102066512A (zh) 2011-05-18
WO2009158036A3 (en) 2010-04-15
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TW201008773A (en) 2010-03-01
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ES2659060T3 (es) 2018-03-13
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KR20170003715A (ko) 2017-01-09
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TWI503230B (zh) 2015-10-11
CN102066512B (zh) 2014-06-04

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