Classifications

• • 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
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
  • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
  • G02B1/12—Optical coatings produced by application to, or surface treatment of, optical elements by surface treatment, e.g. by irradiation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
  • B05D1/265—Extrusion coatings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
• • 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
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
  • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
• • 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
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
• • 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
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
  • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
  • G02B1/14—Protective coatings, e.g. hard coatings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0037—Other properties
  • B29K2995/0072—Roughness, e.g. anti-slip
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0037—Other properties
  • B29K2995/0072—Roughness, e.g. anti-slip
  • B29K2995/0074—Roughness, e.g. anti-slip patterned, grained
• • 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
  • B32B2255/00—Coating on the layer surface
  • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
• • 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
  • B32B2255/00—Coating on the layer surface
  • B32B2255/26—Polymeric coating
• • 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
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/02—Synthetic macromolecular particles
  • B32B2264/0214—Particles made of materials belonging to B32B27/00
  • B32B2264/025—Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers
• • 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
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/412—Transparent
• • 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
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/702—Amorphous
• • 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
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/746—Slipping, anti-blocking, low friction
• • 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
  • B32B2457/00—Electrical equipment
  • B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
• • 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.]
  • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
  • Y10T428/2495—Thickness [relative or absolute]
• • 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.]
  • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
  • Y10T428/2495—Thickness [relative or absolute]
  • Y10T428/24967—Absolute thicknesses specified
  • Y10T428/24975—No layer or component greater than 5 mils thick

Definitions

• the present invention relates to articles such as polymeric films, e.g., multilayer optical films, with binder-deficient slip coatings and methods for making such articles.
• Polymer films have found application in myriad uses, e.g., from packaging to multilayer optical films.
• the manufacture of such films entails formation of single or multiply layered films and handling of such films by passing through roller apparatuses for application of additional layers, exposure to selected treatments to impart desired performance and properties, conversion to select size and configuration, storage, and transport.
• the polymer film is wound around rollers as it passes through various equipment and is often wound upon itself into roll form.
• polymeric films include so-called optical films that are used in a wide variety of applications, e.g., mirrors, polarizers, etc., that rely upon uniform film properties.
• optical films that are used in a wide variety of applications, e.g., mirrors, polarizers, etc., that rely upon uniform film properties.
• Such films exhibit desirable optical properties as selected based on the precise structure of features, e.g., thickness and arrangement of layers with differing refractive indices, etc.
• the surfaces of films may be marred as they are handled and used, degrading their suitability for the desired ultimate purpose. Accordingly, it is known in the art to provide layers on the outside of such films, sometimes referred to as “premask” or “skin” layers, to protect the films and facilitate handling and use.
• Skin layers can serve a variety of purposes, such as protection of the interior layers, for example, against scratching or abrasion, stiffening or strengthening or providing dimensional stability to the entire film, hosting additives such as ultraviolet light stabilizers, reducing surface reflection, providing an appropriately receptive surface for subsequent coatings, or others.
• premask is often used to refer to a surface layer, either produced with the rest of the film or added later by such means as lamination, extrusion coating, solvent coating, or other means, intended to protect the film temporarily against damage during handling, processing, converting and the like, and is further intended to be removed before final use of the film or of portions cut from the film.
• strippable skin can serve as a premask.
• a film can also be prepared with a skin layer, say, by coextrusion, and have a premask applied thereon, say, by lamination, whereupon the skin layer is no longer, temporarily, the film construction's external-most layer, but is intended at a later time once again to serve as the external layer, after removal of the premask.
• a challenge with polymer films is that when contacted to other films, e.g., such as when wound into roll form or arranged into a stack of sheets, the films may tend to adhere strongly if they are too close to having perfectly smooth surfaces. This is sometimes referred to as “blocking", making a roll difficult to unwind or a sheet difficult to remove from the stack. Alternatively, if a film surface is made too slippery, film on a roll may tend to slip upon itself, sideways, resulting in what is often referred to as roll "telescoping". Good roll formation with acceptable unwindability requires that the film surface strike a balance.
• portions of a sheet are roughened, e.g., by imparting knurled portions on the edges thereof, to make the sheets easier to handle and to impart a tendency to "stand off from articles into which they are contacted, e.g., other sheets in a stack or other portions of the same sheet when wound into roll form.
• the use of such measures frequently degrade the subject portions of the sheet, thereby reducing yields and incurring additional costs.
• a sheet of the invention comprises: (1) a core member comprising one or more layers and having a first major surface and (2) a slip control layer as described herein.
• the slip control layer is disposed on at least a portion of the first major surface and comprises: (i) a footing layer disposed on the first major surface of the core member, (iii) a binder layer disposed on the footing layer, and (iii) an array of particles disposed in the binder layer and footing layer and protruding therefrom.
• the average diameter of the particles is greater than the combined thickness of the foot layer and binder layer.
• the method of the invention for making such sheets comprises: (1) providing a core member comprising one or more layers and having a first major surface; (2) forming a footing layer on at least a portion of the first major surface; (3) applying a binder layer composition containing particles as described herein on at least a portion of the footing layer; then (5) tentering the assembly under sufficient heat to soften the footing layer such that particles sink into the footing layer perhaps so far so as to contact the first major surface of the core member, wherein the average diameter of the particles is greater than the combined thickness of the footing layer and the binder layer.
• Sheets of the invention can be easily handled, e.g.., during manufacture and subsequent converting. Exploitation of the invention can make possible surprising improvements in runability, reduced waste, and improved yields.
• Fig. 2 is an end view of a plurality of sheets of the invention arranged in a stack
• Fig. 3 is an end view of a portion of a sheet of the invention wound into roll form
• polymer will be understood to include polymers, copolymers (e.g., polymers formed using two or more different monomers), oligomers and combinations thereof, as well as polymers, oligomers, or copolymers that can be formed in a miscible blend by, for example, coextrusion or reaction, including transesterification. Both block and random copolymers are included, unless indicated otherwise.
• Weight percent, percent by weight, % by weight, and the like are synonyms that refer to the concentration of a substance as the weight of that substance divided by the weight of the composition and multiplied by 100.
• a sheet of the invention 10 comprises: (1) a core member 12 comprising one or more layers and having a first major surface 14 and (2) a slip control layer 16 disposed on at least a portion of the first major surface.
• the slip control layer comprises (i) a footing layer 18 disposed on the first major surface 14 of the base member, (iii) a binder layer 20 disposed on the footing layer, and (iii) an array of particles 22 disposed in the binder layer and footing layer and protruding from the surface of the slip control layer opposite the core member.
• the average diameter of the particles is typically greater than the combined thickness of the footing layer and binder layer though some particles may have diameters which are smaller.
• FIG. 2 A stack of three sheets of the invention 10a, 10b, and 10c is shown in Fig. 2. A portion of a sheet of the invention 10 wound upon itself in roll form on roll core 24 is shown in Fig. 3. Core Member
• the core member will be a single layer film, e.g., a polyester base film, and in other embodiments the core member may be a multilayer structure, e.g., a multilayer optical film.
• a multilayer structure e.g., a multilayer optical film.
• optical films with which the present invention may provide advantageous results include optical base films, multilayer optical films, diffuse reflecting polarizer films, prismatic brightness enhancement films, etc.
• polyesters selected from the group consisting of homopolymer and copolymer polyesters comprising terephthalate moieties, napthalate moieties, bibenzoate moieties, or combinations thereof.
• the footing layer may be similar to previously known “skin” layers.
• the footing layer is formulated to provide desired adhesion to the underlying major surface of the core member, the overlying binder layer, and the particles, in addition to other properties desired for the specific application.
• the footing layer is formulated to provide desired adhesion to the underlying major surface of the core member, the overlying binder layer, and the particles, in addition to other properties desired for the specific application.
• the core member e.g., a multilayer optical film, and footing layer are formed simultaneously via coextrusion.
• the footing layer may cover only a limited portion of the area of the first major surface of the core member or it may cover substantially all thereof.
• the binder layer 20 covers at least a portion of the footing layer 18. In embodiments where the sheet is used for desired optical properties, typically the binder layer is transparent.
• the binder layer is from about 100 to about 500 nanometers thick, and in some embodiments, the binder layer is from about 200 to about 300 nanometers thick.
• the binder layer 20 is formulated to provide desired adhesion to the underlying footing layer 18 and the particles 22, in addition to other properties desired for the specific application.
• Those skilled in the art will be able to readily select suitable components in accordance with the invention.
• the binder layer comprises an olefinic film former, e.g., polypropylene.
• the particles 22 protrude therefrom.
• protrude merely means that the particles define an elevation above the intermediate portions of the slip control layer that are defined by the footing layer and the binder layer.
• the particles may have residual portions of the binder layer precursor materials thereon or may be uncovered and still be considered to "protrude" from the slip control layer.
• the particles typically have a mean particle diameter from about 2 to about 30 microns, in some embodiments, from about 3 to about 10 microns. While it is preferred in some instances that the particles have a substantially uniform size, this is not necessary.
• the particles have a generally spherical shape, though particles having other regular or irregular shapes may be used if desired.
• the particles comprise polymeric materials.
• Illustrative particles suitable for use herein consist essentially of polymethylmethacrylate.
• Advantages of the invention include that only scant quantities of the binder layer and particles can be used to achieve desired improvements in sheet handling, reduced roll blockings etc.
• the particles constitute from about 5 to about 20 weight percent of the total weight of the particles plus binder layer.
• sheets can be made in accordance with the following process:
• the footing layer may be formed simultaneously with the core member, e.g., via co-extrusion. If desired, existing core members may be used in the present invention with a footing layer being formed thereon later.
• binder layer and particles are assembled on the sheet by application of a binder layer composition, e.g., an aqueous emulsion containing film forming polyer and particles, as described herein, on select portions of the footing layer.
• a binder layer composition e.g., an aqueous emulsion containing film forming polyer and particles, as described herein, on select portions of the footing layer.
• the composition is typically dried. This may be carried out in part or total prior to tentering the sheet or simultaneously therewith.
• the tentering step entails heating the assembly to sufficiently high temperature to soften the footing layer and facilitate stretching of the core member.
• Tentering of films such as core members entails stretching in one or more dimensions, typically under elevated temperatures, and is a well known operation and can be readily carried out by those skilled in the art.
• Sheets having been manufactured in accordance with the invention can then be more readily handled. For instance, in some embodiments the sheets will be cut to desired size and then stacked, one atop another. In accordance with the invention, the presence of the slip control layer with protruding particles described herein will prevent overlying sheets from wetting out and sticking more strongly to underlying sheets.
• the sheet may be wound into roll form with a plurality of layers.
• sheets such as optical films are manufactured they are wound into large rolls referred to as jumbos, which are then manipulated, stored, transported to subsequent manufacturing operations or customers, etc.
• the sheet When wound into a roll, the sheet is under tension and quantities of air are entrapped therein. Over time, the sheet may exhibit some relaxation in the machine or roll direction which impacts the tension through the roll. Also over time, the entrapped air may escape, causing the stability of the rolled sheet to change. Such changes may lead to wrinkling or other damage to portions of the roll that can render significant portions of the sheet unuseable. Sheets rolled in accordance with the present invention exhibit significant reduction or even elimination of such defects.
• the presence of the slip control layer with protruding particles as described herein will prevent overlying portions of sheet from wetting out and sticking more strongly to underlying portions of the sheet.
• jumbo rolls of expensive sheets such as optical films can be more easily and efficiently manufactured, stored, transported, and handled.

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• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)
• Adhesive Tapes (AREA)

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• 2013
  • 2013-08-20 KR KR1020157006631A patent/KR102190374B1/ko not_active Expired - Fee Related
  • 2013-08-20 EP EP13759905.6A patent/EP2888108A1/en not_active Withdrawn
  • 2013-08-20 CN CN201380044441.5A patent/CN104812575B/zh not_active Expired - Fee Related
  • 2013-08-20 JP JP2015528562A patent/JP6445435B2/ja active Active
  • 2013-08-20 TW TW102129882A patent/TWI584953B/zh not_active IP Right Cessation
  • 2013-08-20 WO PCT/US2013/055672 patent/WO2014031573A1/en not_active Ceased
  • 2013-08-20 SG SG11201501294YA patent/SG11201501294YA/en unknown
  • 2013-08-20 US US14/422,911 patent/US9915762B2/en active Active

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