WO2016084568A1 - ポリエステルフィルム - Google Patents
ポリエステルフィルム Download PDFInfo
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- WO2016084568A1 WO2016084568A1 PCT/JP2015/081140 JP2015081140W WO2016084568A1 WO 2016084568 A1 WO2016084568 A1 WO 2016084568A1 JP 2015081140 W JP2015081140 W JP 2015081140W WO 2016084568 A1 WO2016084568 A1 WO 2016084568A1
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Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
- C08L67/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
- C08L67/03—Polyesters derived from dicarboxylic acids and dihydroxy compounds the dicarboxylic acids and dihydroxy compounds having the carboxyl- and the hydroxy groups directly linked to aromatic rings
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2203/00—Applications
- C08L2203/16—Applications used for films
Definitions
- the present invention relates to a polyester film having a low heat shrinkage even at a high temperature.
- Polyester resins especially polyethylene terephthalate (hereinafter sometimes abbreviated as PET) and polyethylene 2,6-naphthalene dicarboxylate (hereinafter sometimes abbreviated as PEN) are mechanical properties, thermal properties, chemical resistance, electrical properties, It has excellent moldability and is used for various purposes.
- Polyester films made from polyester, especially biaxially oriented polyester films, are used in solar cell backsheets, water heater motor electrical insulation materials, and hybrid vehicles because of their excellent mechanical and electrical properties. Electrical insulation materials for car air conditioner motors and drive motors, magnetic recording materials, capacitor materials, packaging materials, building materials, photographic applications, graphic applications, thermal transfer applications, various industrial materials, flexible displays and organic It is used as an optical material such as a transparent electrode substrate for EL.
- JP-A-3-13315 JP 11-165350 A Japanese Patent Laid-Open No. 2005-216706
- substrate use of a transparent conductive film is calculated
- the flatness of the film is impaired if a heat setting treatment at a high temperature is performed.
- the PEN film is excellent in mechanical properties like the PET film, and is excellent in heat resistance as compared with the PET film.
- the PEN film has a problem that the PEN constituting the film has a rigid molecular structure, so that the processability is poor and the film breaks during processing.
- the present invention has the following configuration. That is, [I] A polyester film in which the proportion of polyethylene terephthalate in the polyester resin constituting the film is 60% by weight or more, and the heat shrinkage in the film longitudinal direction and width direction when heat-treated at 200 ° C. for 30 minutes. Polyester film which is 0.5% or less in any case. [II] At least one of the heat shrinkage rate in the longitudinal direction of the film and the heat shrinkage rate in the width direction when heat-treated at 200 ° C. for 30 minutes is 0.01% or more [I] The polyester film as described in. [III] The heat shrinkage rate in the longitudinal direction of the film and the heat shrinkage rate in the width direction when heat-treated at 220 ° C.
- the polyester resin constituting the film has a melting point (Tmf (° C.)) and one or more minute endothermic peak temperatures (Tmeta (° C.)) from [I] to [V ]
- the polyester resin constituting the film has two or more minute endothermic peaks (Tmeta (° C)), the lowest temperature Tmeta (Tmeta1) (° C) and the highest temperature Tmeta (Tmeta2) (° C). ) Satisfies the following relationship: [VI]. Tmf ⁇ 35 (° C.) ⁇ Tmeta1 (° C.) ⁇ Tmeta2 (° C.) ⁇ Tmf (° C.) [VIII]
- the polyester film is a laminated polyester film composed of at least three layers, and the melting point (Tmo (° C.)) of the polyester resin constituting the layer (A layer) constituting the outermost surface of the film is 260 ° C. or higher.
- the laminated polyester film is composed of three layers, the polyester constituting the melting point (Tmo (° C.)) of the polyester resin constituting the layer constituting the surface layer (A layer) and the layer constituting the inner layer (B layer)
- the polyester film according to [VIII] wherein the difference in melting point (Tmi (° C.)) of the resin is 5 ° C. or higher and 10 ° C. or lower.
- the polyester film according to [IX] wherein the ratio of the sum of the thicknesses of the layers constituting the surface layer (A layer) and the thicknesses of the layers constituting the inner layer (B layer) is from 1/8 to 1/4. .
- [XI] The polyester film according to any one of [I] to [X], which is used for a substrate for forming a transparent conductive film.
- the present invention it is possible to provide a film that achieves heat resistance, particularly low heat shrinkage at high temperatures, and is excellent in workability.
- the polyester film of the present invention is a polyester film in which the proportion of polyethylene terephthalate in the polyester resin constituting the film is 60% by weight or more.
- the polyester referred to here has a dicarboxylic acid component and a diol component.
- a structural component shows the minimum unit which can be obtained by hydrolyzing polyester.
- the proportion of polyethylene terephthalate is preferably 70% by weight or more, more preferably 80% by weight or more.
- the polyester film of the present invention needs to have a thermal shrinkage rate of 0.5% or less in both the film longitudinal direction and the width direction after heat treatment at 200 ° C. for 30 minutes. More preferably, the thermal shrinkage in the longitudinal direction and the width direction after the film of the present invention is treated at 200 ° C. for 30 minutes is 0.3% or less.
- the polyester film is a stretched film
- the molecular chain is in a tensioned state (orientated state) by stretching. Therefore, when heat is applied, the molecular chain tension is released, the film contracts, and the planarity may deteriorate.
- a process of heat treatment at a predetermined temperature after the stretching process is performed in order to stabilize the structure of the polyester molecular chain formed by stretching (hereinafter referred to as film structure). It is known to use a method of providing (the heat treatment temperature is referred to as a heat setting temperature). By carrying out a heat treatment step after the stretching step, a film having a certain degree of flatness and mechanical properties can be obtained.
- the degree of contraction of molecular chains in tension by stretching due to heat is not uniform. For this reason, a difference occurs in the thermal shrinkage even in the film plane, and the film is wrinkled and the flatness is impaired.
- a thermal load is applied to the film in a process (such as a curing process) after the ITO film is deposited. At this time, if the flatness of the film is impaired due to thermal shrinkage of the polyester film, the conductivity of the ITO film is lowered, which is not preferable.
- the higher the cure temperature the larger the ITO film crystal size and the better the ITO film conductivity.
- the crystal size is large, the film used as the substrate may be bent or followed up during deformation. It is inferior in property, and the ITO film is easily cracked.
- the curing temperature at which both the followability and the conductivity at the time of deformation of the ITO film are 200 ° C. or more and 220 ° C. or less. Therefore, by setting the thermal contraction rate in the longitudinal direction and the width direction of the film at 200 ° C. and 220 ° C., which are the temperatures, to 0.5% or less, the ITO film is kept at an appropriate temperature without impairing the flatness of the film This is preferable because the performance as a transparent conductive substrate is improved. More preferably, it is 0.3% or less.
- the thermal contraction rate of the film at 200 ° C. and 220 ° C. is small.
- the polyester film is used for an ITO vapor deposition substrate, it is at 200 ° C. and 220 ° C.
- the thermal shrinkage rate of the film is 0.01% or more in either the longitudinal direction or the width direction, the polyester film shrinks without expanding due to heat, so it is possible to suppress the occurrence of cracks in the ITO film.
- the performance as a transparent conductive substrate is improved, which is preferable.
- the thermal shrinkage of the film at 200 ° C. and 220 ° C. is 0.03% or more in either the longitudinal direction or the width direction.
- Method I a method of forming the polyester film under a specific condition
- Method II a method of setting the polyester resin constituting the film to a specific configuration
- Examples of the method include a combination of (method b), (method a) and (method b).
- the polyester film of the present invention is produced by forming a polyester film in which the ratio of polyethylene terephthalate in the polyester resin constituting the film is 60% by weight or more by the method described later and further annealing by the method described later (Method A). Can be suitably obtained.
- a method of obtaining a biaxially oriented polyester film by performing biaxial stretching after discharging a polyester containing 60% by weight or more of polyethylene terephthalate in an extruder and discharging it from a die to obtain an unrolled sheet the following conditions are satisfied.
- the thermal shrinkage rate at 200 ° C. can be reduced.
- the biaxially stretched film obtained in (2) is heat-set for 1 second to 30 seconds at a temperature (Th0 (° C.)) that satisfies the following formula (ii), and gradually cooled gradually Then, a polyester film is obtained by cooling to room temperature.
- the sequential biaxial separation is performed by separating the film longitudinal direction (MD) and the film width direction (direction perpendicular to the film longitudinal direction, TD) separately.
- MD film longitudinal direction
- TD film width direction
- stretching temperature (T1n) (degreeC) is less than Tg (degreeC)
- T1n (° C.) exceeds Tg + 40 (° C.), the film is frequently broken and the film may not be obtained by stretching. More preferably, Tg + 10 (° C.) ⁇ T1n (° C.) ⁇ Tg + 30 (° C.).
- step (3) It is preferable from the viewpoint of flatness that the step (3) is performed while holding both ends of the film. Further, a method of heat fixing while shrinking 1 to 10% with respect to the film width in the film width direction is preferable from the viewpoint of reducing the heat shrinkage rate.
- heat shrinkage generated in the film occurs at a temperature close to the temperature at which the film structure is formed as described above. Therefore, in order to suppress the heat shrinkage rate of the film at a high temperature exceeding 200 ° C., heat setting is performed. It is important to increase the temperature (Th0 (° C.)). On the other hand, when heat treatment is performed at a temperature at which the heat setting temperature (Th0 (° C.)) exceeds Tmf (° C.), the film cannot be melted to form a film. Further, if the heat treatment is performed at a temperature too close to Tmf (° C.), the planarity may be deteriorated.
- the polyester resin constituting the polyester film of the present invention preferably has a minute endothermic peak.
- the minute endothermic peak is preferably Tmf-35 (° C.) or more and Tmf (° C.) or less, more preferably Tmf-25 (° C.) or more and Tmf-10 (° C.) or less.
- annealing is performed by the following method (4) in order to make the structure of the polyester molecular chain in which the orientation in the film is formed stronger. It is preferable.
- the film obtained in (3) is annealed at a heat treatment temperature Th1 (° C.) satisfying the following formula (iii) for a period of 70 seconds to 600 seconds.
- a method of performing the annealing treatment there is a method of heat-treating the film in an oven installed between the film winding roll and the film winding roll (off-annealing).
- Tmf-35 ° C.
- Th1 ° C.
- Th0 thermo fixing temperature
- Th1 ° C.
- Th0 thermal fixing temperature
- Th1 (° C.) is lower than Th0 (heat set temperature) (° C.), particularly when Th1 (° C.) is sufficiently smaller than Th0 (heat set temperature) (° C.), the minute endothermic peak (Tmeta) is (3)
- Th0 heat set temperature
- Th0 heat set temperature
- Tmeta minute endothermic peak
- the polyester resin which comprises the polyester film of this invention has 2 or more Tmeta (degreeC).
- Tmeta (° C.) is 2 or more
- the low temperature T meta (T meta 1) (° C.) and the high temperature T meta (T meta 2) (° C.) are Tmf ⁇ 35 (° C.) ⁇ T meta 1 (° C.) ⁇
- Tmeta2 (° C.) ⁇ Tmf (° C.) is satisfied, a film with good flatness can be obtained, which is preferable.
- the heat setting treatment step (3) and the annealing treatment step (4) may be performed a plurality of times.
- the film that has undergone the heat setting treatment step (3) and the annealing treatment step (4) a plurality of times may have a Tmeta (° C.) of 3 or more.
- Tmeta (° C.) the lowest temperature Tmeta (° C) is Tmeta1 (° C)
- the highest temperature Tmeta (° C) is Tmeta2 (° C)
- the polyester film of the present invention is a laminated film composed of at least three layers, and a method (method b) in which the melting point (Tmo) of the resin constituting the layer (A layer) constituting the outermost surface of the film is 260 ° C. or more, It can be suitably obtained. It is preferable that the film has the above structure because the heat shrinkage rate of the film can be reduced and the flatness can be improved.
- the melting point of polyethylene terephthalate which is the main component of the polyester film of the present invention, is about 255 ° C. That is, the polyester constituting the A layer contains a high melting point component other than polyethylene terephthalate.
- the melting point (Tmo) of the resin constituting the layer (A layer) constituting the outermost surface of the film is more preferably 262 ° C. or higher.
- the inner layer (B layer) that does not constitute the surface layer is preferably polyethylene terephthalate.
- fusing point Tmf (degreeC) of the polyester resin which comprises the polyester film of this invention reflects melting
- the resin used for the A layer examples include polyethylene naphthalate (hereinafter sometimes referred to as PEN), polycyclohexylenedimethylene terephthalate (hereinafter sometimes referred to as PCHT), polyphenylene sulfide (hereinafter sometimes referred to as PPS), or These mixtures are mentioned. Further, in order to improve the adhesion between the A layer and the B layer, it is also a preferred embodiment to add a small amount of the resin constituting the B layer to the resin constituting the A layer within a range not impairing the effects of the invention of the present application. is there.
- PEN polyethylene naphthalate
- PCHT polycyclohexylenedimethylene terephthalate
- PPS polyphenylene sulfide
- the amount of the resin constituting the B layer added to the resin constituting the A layer is preferably 0.01% by weight or more and less than 15% by weight, more preferably 0.1% by weight with respect to the total amount of the resin constituting the A layer. % To 5% by weight.
- the ratio of the sum of the thicknesses of the layers constituting the surface layer (A layer) to the thicknesses of the layers constituting the inner layer (B layer) (sum of the thickness of A layer / B layer thickness) is 1/16 to 1/2 It is preferable that When it is smaller than 1/16, the thickness of the surface layer (A layer) is thin, the role of protecting the B layer is not sufficient, and the planarity and heat resistance may be inferior. If it exceeds 1/2, the stretchability may deteriorate.
- the ratio of the sum of the thicknesses of the layers constituting the surface layer (A layer) and the thicknesses of the layers (B layer) constituting the inner layer (sum of the thickness of the A layer / the thickness of the B layer) is more preferably 1/8. ⁇ 1/4.
- the thickness of the one side of A layer is 5 micrometers or more and 30 micrometers or less. Even when the above-mentioned stacking ratio is satisfied, when the thickness of one side of the A layer is less than 5 ⁇ m, the planarity may be inferior, and when it exceeds 30 ⁇ m, the stretchability and workability may be deteriorated.
- the polyester film of the present invention is a laminated film composed of at least three layers
- an extruder is used for each layer constituting the laminated film, the raw materials of each layer are melted, and these are provided between the extrusion apparatus and the die.
- a method of laminating in a molten state with a merging apparatus, guiding to a die, and extruding from the die onto a cast drum to process into a sheet is preferably used.
- the sheet is closely cooled and solidified by static electricity on a drum cooled to a surface temperature of 10 ° C. or higher and 40 ° C. or lower to produce an unstretched sheet.
- This unstretched sheet is formed by the methods (2) to (4) described above to obtain a polyester film.
- the melting point (Tmo (° C)) of the resin constituting the surface layer is higher than the melting point (Tmi (° C)) of the resin constituting the inner layer of the film.
- heat treatment is performed for 1 second to 30 seconds at a heat setting temperature (Th0 (° C.)) that satisfies the formula (iv), and after uniform cooling, it is cooled to room temperature. It is also a preferred embodiment that after obtaining a polyester film by annealing, annealing is performed for 70 seconds to 600 seconds at an annealing temperature Th1 (° C.) satisfying the following formula (v).
- the melting point (Tmo (° C.)) of the resin constituting the surface layer is higher than the melting point Tmf (° C.) of the polyester resin constituting the film. That is, since the surface layer can protect the resin of the inner layer as described above, the heat setting temperature can be increased, and the heat setting can be performed at a temperature close to Tmf (° C.) without melting the film.
- the film of the present invention obtained as described above has a low thermal shrinkage at high temperatures and is excellent in flatness.
- the film of the present invention preferably has a film unevenness difference of 300 ⁇ m or less when the film unevenness is measured with a non-contact laser microscope by the method described below. If the unevenness difference is 0 ⁇ m, it becomes a substantially flat surface, so the lower limit is 0 ⁇ m or more.
- the unevenness of the film surface exceeds 300 ⁇ m, it may be unfavorable because the film processability is deteriorated and the conductivity after ITO deposition is deteriorated.
- the smaller the unevenness difference the better the conductivity after ITO deposition.
- there are methods such as providing a heat setting step after biaxial stretching of the film and further providing a step of annealing at a temperature lower than the heat setting temperature after the heat setting step. . More preferably, it is 150 micrometers or less, Most preferably, it is 80 micrometers or less.
- the polyester film of the present invention preferably has a plane orientation coefficient of 0.145 or more and 0.165 or less.
- the plane orientation coefficient is obtained from the refractive index of the film by the method described later.
- the plane orientation coefficient of a biaxially stretched film made of PET, PEN, or the like is increased by arranging benzene rings included in molecular chains in parallel with the film plane. Since benzene rings are rigid in the molecular chain, when the plane orientation coefficient exceeds 0.165, there are many benzene rings arranged in parallel to the film plane, so the film is likely to break during processing such as bending or cutting the film. There is a case.
- the plane orientation coefficient is less than 0.145, the mechanical strength may be inferior because no orientation is obtained by biaxial stretching.
- the polyester resin of the present invention contains phosphoric acid and an alkali metal phosphate because the polyester film of the present invention has excellent heat and moisture resistance.
- the method for adding a phosphoric acid and an alkali metal phosphate to the polyester resin include adding phosphoric acid and an alkali metal phosphate during polymerization of the polyester resin.
- the polyester film of the present invention is a laminated film having an A layer and a B layer, phosphoric acid and phosphoric acid are contained in both the A layer and the B layer, in which only the A layer contains phosphoric acid and an alkali metal phosphate.
- An embodiment in which an alkali metal salt is contained is preferable because of excellent heat and heat resistance.
- the heat resistance of the polyester film of the present invention is good, it can be suitably used as an ITO vapor deposition substrate used in a display used in a harsher environment, for example, a display of a car navigation system.
- the film obtained by the present invention is excellent in processability and flatness and has a small thermal shrinkage at high temperature, and can be suitably used as a transparent electrode deposition substrate such as ITO.
- a 1st RUN differential scanning calorimetry chart (the vertical axis is thermal energy and the horizontal axis is temperature) is obtained.
- the peak top temperature at the crystal melting peak which is the endothermic peak, is determined, and this is defined as the melting point (° C.).
- the temperature at the peak top having the largest peak area is defined as the melting point.
- Tmf Melting point (° C) of the polyester resin constituting the polyester film
- a differential scanning calorimeter “Robot DSC-RDC220” manufactured by Seiko Denshi Kogyo Co., Ltd. and a disk session “SSC / 5200” for data analysis were used. Perform the measurement in the following manner. The sample is weighed in a sample pan by 5 mg, and the sample is heated from 25 ° C. to 320 ° C. at a heating rate of 20 ° C./min (1stRUN). A 1st RUN differential scanning calorimetry chart (the vertical axis is thermal energy and the horizontal axis is temperature) is obtained.
- the peak top temperature at the crystal melting peak which is the endothermic peak, is determined, and this is defined as the melting point (° C.).
- the temperature at the peak top having the largest peak area is defined as the melting point.
- Tmeta1, Tmeta2) (° C) of the polyester resin constituting the polyester film
- the minute endothermic peak temperature Tmeta (° C.) is determined by using a differential scanning calorimeter “Robot DSC-RDC220” manufactured by Seiko Denshi Kogyo according to JIS K 7122 (1999), and a disk session “SSC / 5200” for data analysis. ”To measure. 5 mg of the film is weighed in a sample pan and heated from 25 ° C. to 320 ° C. at a temperature rising rate of 20 ° C./min (1stRUN).
- a 1st RUN differential scanning calorimetry chart (the vertical axis is thermal energy and the horizontal axis is temperature) is obtained.
- Tmeta the endothermic peak temperature before the crystal melting peak
- the data analysis unit enlarges the vicinity of the peak and reads the peak.
- Tmeta1 the minute endothermic peak having the highest temperature
- Tmeta2 the lowest minute endothermic peak
- the graph reading method of the minute endothermic peak uses the peak detection function of the analysis software, and among the temperatures detected as peaks, the endothermic peak detected at a temperature below the melting point is defined as Tmeta.
- Tg Glass transition temperature (° C) of the polyester resin constituting the polyester film
- the differential scanning calorimeter “Robot DSC-RDC220” manufactured by Seiko Denshi Kogyo Co., Ltd. was used, and the disk session “SSC / 5200” was used for data analysis. Conduct measurements.
- a marked line is attached to the film so that the length measurement portion is approximately 100 mm, and the length of the marked line is measured under the condition of 23 ° C. and is defined as L0. Thereafter, a 2 g weight is put in a hot air oven heated to a predetermined temperature (200 ° C. or 220 ° C.), the film is hung, and left for 30 minutes. The film is taken out from the oven and cooled to 23 ° C., and then the length of the marked line is measured and set to L1.
- the shrinkage ratio of the film is determined by the following formula (vi). The measurement is performed by cutting out five points at random so that the film longitudinal direction or the film width direction is 150 mm.
- An average value is calculated for each of the longitudinal direction and the width direction, and is defined as the thermal shrinkage rate of the film.
- (Vi) (Film heat shrinkage) (L0 ⁇ L1) / L0 ⁇ 100 F.
- Film flatness Evaluation is performed using a non-contact three-dimensional measuring apparatus NH-SP3 manufactured by Mitaka Kogyo Co., Ltd. as a non-contact laser microscope. NH software manufactured by Ryoko Co., Ltd. is used for the analysis. Cut the film into 120 mm ⁇ 120 mm. Each side is made parallel to the film longitudinal direction or the width direction. The four sides of the cut out film are fixed with a tape on a measuring table kept horizontal. The surface shape of the film is measured in the three-dimensional shape measurement mode.
- the X-axis direction is the film longitudinal direction
- the Y-axis direction is the film width direction.
- the measurement pitch is 100 ⁇ m in the X-axis direction, 500 ⁇ m in the Y-axis direction, the measurement range is 100 mm ⁇ 100 mm, and the Z-axis magnification is 20 times.
- the difference (the height difference H ( ⁇ m)) between the highest point and the lowest point in the Z-axis direction is calculated. Five points are randomly cut out from the film into the above shape, and the average value is calculated and evaluated as follows. 0 ⁇ H ⁇ 80 Evaluation A 80 ⁇ H ⁇ 150 Evaluation B 150 ⁇ H ⁇ 300 Evaluation C 300 ⁇ H Evaluation D Evaluation A is most excellent in flatness.
- the thickness of each layer was determined by the following method.
- the film cross section is cut out with a microtome in a direction parallel to the film width direction.
- the cross section is observed with a scanning electron microscope at a magnification of 5000 times to determine the thickness ratio of each layer.
- the thickness of each layer is calculated from the obtained lamination ratio and the above-described film thickness.
- Terminal carboxyl group amount The terminal carboxyl group amount was measured by the following method according to the method of Malice. (Reference: M. J. Malice, F. Huizinga, Anal. Chim. Acta, 22 363 (1960)) 2 g of a measurement sample (polyester resin (raw material) or separated P1 layer of the laminate) was dissolved in 50 mL of o-cresol / chloroform (weight ratio 7/3) at a temperature of 80 ° C., and 0.05 N KOH / The solution was titrated with a methanol solution, and the terminal carboxyl group concentration was measured and indicated by the value of equivalent / polyester 1t (eq./t).
- the indicator at the time of titration used phenol red, and the place where it changed from yellowish green to light red was set as the end point of titration. If there is insoluble matter such as inorganic particles in the solution in which the measurement sample is dissolved, the solution is filtered to measure the weight of the insoluble matter, and the value obtained by subtracting the weight of the insoluble matter from the measurement sample weight The following correction was made.
- L Film-forming properties Count the number of times the film breaks in one hour during film formation, A is less than 1 time, B is 1 to 3 times, C is 3 to 5 times, A value of 5 or more is evaluated as D. A is the best film-forming property, and D is the worst.
- the direction having the maximum refractive index in the film is regarded as the longitudinal direction
- the direction orthogonal to the longitudinal direction is regarded as the width direction.
- the direction of the maximum refractive index in the film may be obtained by measuring the refractive index in all directions of the film with a refractometer, and the slow axis direction may be determined by a phase difference measuring device (birefringence measuring device) or the like. It may be obtained by deciding.
- the film cut out in the same manner is treated with a pressure cooker manufactured by Tabai Espec Co., Ltd. under high-humidity heat conditions of a temperature of 125 ° C. and a relative humidity of 100% RH, and then the elongation at break is measured.
- n 5 and it measures about each of the longitudinal direction of a film, and the width direction, and let the average value be the breaking elongation E1.
- the elongation retention is calculated by the following equation (a).
- the treatment time is changed by one hour, and the treatment time at which the elongation retention is 50% or less is defined as the elongation half-life.
- PET-A Polymerization was carried out from terephthalic acid and ethylene glycol by a conventional method using antimony trioxide as a catalyst to obtain melt-polymerized PET.
- the resulting melt-polymerized PET had a glass transition temperature of 81 ° C., a melting point of 255 ° C., an intrinsic viscosity of 0.62, and a terminal carboxyl group content of 20 eq. / T.
- melt-polymerized PET was solid-phase polymerized by a conventional method to obtain PET-A.
- the obtained PET-A had a glass transition temperature of 82 ° C., a melting point of 255 ° C., an intrinsic viscosity of 0.85, and a terminal carboxyl group content of 11 eq. / T.
- PEN-A A transesterification reaction was carried out from dimethyl 2,6-naphthalenedicarboxylate and ethylene glycol using manganese acetate as a catalyst. After the transesterification reaction, PEN-A was obtained by a conventional method using antimony trioxide as a catalyst. The obtained PEN-A had a glass transition temperature of 124 ° C., a melting point of 265 ° C., an intrinsic viscosity of 0.62, and a terminal carboxyl group concentration of 25 eq. / T.
- PET-B Polymerization was performed using terephthalic acid and ethylene glycol as raw materials and antimony trioxide as a catalyst. Simultaneously with antimony trioxide, a solution of phosphoric acid and sodium dihydrogen phosphate dihydrate dissolved in ethylene glycol was added. Phosphoric acid was added in an amount corresponding to 2.0 mol / t with respect to PET, and sodium dihydrogen phosphate dihydrate was added in an amount corresponding to 1.7 mol / t with respect to PET.
- PET-C had a glass transition temperature of 81 ° C., a melting point of 255 ° C., an intrinsic viscosity of 0.68, and a terminal carboxyl group content of 20 eq. / T.
- PET-C was solid-phase polymerized by a conventional method to obtain PET-B.
- the obtained PET-B had a glass transition temperature of 82 ° C., a melting point of 255 ° C., an intrinsic viscosity of 0.85, and a terminal carboxyl group content of 11 eq. / T.
- PEN-B A transesterification reaction was carried out using dimethyl 2,6-naphthalenedicarboxylate and ethylene glycol as raw materials and manganese acetate as a catalyst. After the transesterification reaction, polymerization was carried out using antimony trioxide as a catalyst. Simultaneously with antimony trioxide, a solution of phosphoric acid and sodium dihydrogen phosphate dihydrate dissolved in ethylene glycol was added. Phosphoric acid was added so as to be equivalent to 2.0 mol / t with respect to PET, and sodium dihydrogen phosphate dihydrate was added so as to correspond to 1.7 mol / t with respect to PET, and the polymerization reaction was allowed to proceed. Got. The obtained PEN-B had a glass transition temperature of 124 ° C., a melting point of 265 ° C., an intrinsic viscosity of 0.62, and a terminal carboxyl group concentration of 20 eq. / T.
- Example 1 As a resin constituting the surface layer, 100 parts by mass of PEN-A was dried in a vacuum at 160 ° C. for 2 hours, and then charged into the extruder 1. Further, 100 parts by mass of PET-A as a resin constituting the inner layer was vacuum-dried at 160 ° C. for 2 hours, and then charged into the extruder 2. Each raw material is melted in the extruder at the temperature shown in the table, and the resin introduced into the extruder 1 is merged by the merging device so as to become both surface layers of the film, and extruded onto a casting drum having a surface temperature of 25 ° C. A laminated sheet having a layer structure was produced.
- the sheet is preheated with a heated roll group, and then stretched 3.2 times in the longitudinal direction (MD direction) at a temperature of 95 ° C., and then cooled with a roll group at a temperature of 25 ° C. to be a uniaxially stretched film.
- MD direction longitudinal direction
- roll group a temperature of 25 ° C.
- the obtained uniaxially stretched film was stretched 3.5 times in the width direction (TD direction) perpendicular to the longitudinal direction in a heating zone at a temperature of 110 ° C. in the tenter while holding both ends with clips.
- heat setting was performed for 10 seconds at a temperature of 240 ° C. in a heat treatment zone in the tenter.
- the film was shrunk in the film width direction by 5% with respect to the film width. Subsequently, after cooling gradually uniformly in a cooling zone, it wound up and obtained the laminated polyester film. Furthermore, the obtained film is annealed in a hot air oven installed between the film winding roll and the film winding roll at a temperature of 220 ° C. so that the time for heat treatment of the film is 5 minutes. And a film having a thickness of 100 ⁇ m was obtained. Each characteristic of the film is shown in the table. The film had a low heat shrinkage at 200 ° C. and a particularly good flatness.
- Example 2-4 Film formation was performed in the same manner as in Example 1 except that the resin composition and film formation conditions were changed as shown in the table. The properties of the film are shown in the table. The film had a low heat shrinkage at 200 ° C. and a particularly good flatness.
- Example 5 A film having a thickness of 100 ⁇ m was obtained in the same manner as in Example 1 except that the heat setting temperature and off-annealing temperature of the film were changed as shown in the table. Each characteristic of the film is shown in the table. Since the heat setting temperature was near the film melting point, only one Tmeta was observed. This film was found to be a film that has a low thermal shrinkage rate at 220 ° C. in addition to a 200 ° C. heat shrinkage rate and is excellent in flatness.
- Example 6-8 Film formation was performed in the same manner as in Example 5 except that the resin composition and film formation conditions were changed as shown in the table. The properties of the film are shown in the table. The film had a low heat shrinkage at 220 ° C. and a particularly good flatness.
- Example 9-14 and 22 A film was formed in the same manner as in Example 1 except that the lamination ratio of the film and the thickness of the film were changed as shown in the table. The properties of the film are shown in the table.
- Example 9 since the lamination ratio of the surface layer (A layer) was large, although it was slightly inferior in film formability and workability, it could withstand practical use.
- Example 11 since the lamination ratio of the surface layer (A layer) is small and the thickness is thin, the function of protecting the inner layer (B layer) is lowered and the planarity is inferior.
- Example 13 since the thickness of one side of the surface layer (A layer) was thin, the function of protecting the inner layer (B layer) was lowered, and although it was slightly inferior in flatness, it could withstand practical use. In Example 22, since the thickness of one side of the surface layer (A layer) was thick, although it was slightly inferior in film formability and workability, it could withstand practical use.
- Example 15-17 Film formation was performed in the same manner as in Example 5 except that the resin composition and the off-annealing temperature of the film were changed as shown in the table. The properties of the film are shown in the table. Since the off-annealing temperature was lower than that of Example 5, the heat shrinkage rate at 220 ° C. was slightly inferior, but the flatness showed excellent characteristics.
- Example 18 The resin constituting the film was only polyethylene terephthalate, and a single film was formed according to the film forming conditions as shown in the table. The properties of the film are shown in the table.
- Example 18 the heat yield at 200 ° C. was excellent, but the flatness was slightly inferior to that in Example 1, but it could withstand practical use.
- Example 21 since the heat setting temperature and the annealing temperature are the same, the heat shrinkage rate is excellent. Although it was slightly inferior in flatness, it could withstand practical use.
- Example 19 A film was obtained in the same manner as in Example 1 except that the composition of the resin constituting the A layer was as described in the table. The properties of the film are shown in the table. It turned out that melting
- Example 20 A film was obtained in the same manner as in Example 1 except that the resin used for the A layer was PCHT.
- PCHT Eastman Chemical Co., Ltd., copolyester 13319 was used.
- the properties of the film are shown in the table. The film was excellent in heat shrinkage and flatness.
- Example 23-25 A film was obtained in the same manner as in Example 1 except that the resin used for the A layer was PEN-B and the resin used for the B layer was PET-B. The properties of the film are shown in the table. It was a film excellent in heat shrinkage, flatness, and heat and humidity resistance.
- Comparative Examples 1 and 2 The resin constituting the film was only polyethylene terephthalate, and a single film was formed according to the film forming conditions as shown in the table. The properties of the film are shown in the table. In Comparative Example 1, since the temperature of Tmeta1 is low and is lower than Tmf-35 ° C., the heat shrinkage rate is inferior. In Comparative Example 2, since the heat setting temperature was high and Tmf was equivalent, the film forming property was poor and a film could not be obtained.
- Comparative Examples 3 and 4 The resin constituting the film was PEN only, and the film was formed under the stretching conditions described in the table. The properties of the obtained film are shown in the table. In Comparative Example 3, only heat setting was performed, and in Comparative Example 4, off-annealing was performed after the heat setting step. Since it is not a film containing PET as a main component and has a large plane orientation coefficient (fn), it is greatly inferior in workability.
- Example 5 A film was formed in the same manner as in Example 1 except that the composition of the resin constituting the A layer and the film forming conditions were changed as described in the table. The film properties are shown in the table.
- the polyester film of the present invention not only has excellent flatness and workability, but also has excellent heat resistance. Therefore, the polyester film of the present invention has little change in film shape even in a high-temperature environmental process such as transparent electrode deposition, and can be suitably used as an optical device substrate.
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Abstract
Description
[I]フィルムを構成するポリエステル樹脂に占めるポリエチレンテレフタレートの割合が60重量%以上であるポリエステルフィルムであって、200℃で30分間熱処理を行った場合のフィルム長手方向、幅方向の熱収縮率がいずれも0.5%以下であるポリエステルフィルム。
[II]200℃で30分間熱処理を行った場合のフィルム長手方向の熱収縮率、幅方向の熱収縮率のうち、少なくともいずれか一方の熱収縮率が0.01%以上である[I]に記載のポリエステルフィルム。
[III]220℃で30分間熱処理を行った場合のフィルム長手方向の熱収縮率、幅方向の熱収縮率がいずれも0.5%以下であり、かつ、少なくともいずれか一方の熱収縮率が0.01%以上である[I]または[II]に記載のポリエステルフィルム。
[IV]非接触式レーザー顕微鏡でフィルムの凹凸を測定した際に、フィルムの凹凸差が300μm以下である[I]~[III]のいずれかに記載のポリエステルフィルム。
[V]面配向係数が0.145以上0.165以下である[I]から[IV]のいずれかに記載のポリエステルフィルム。
[VI]フィルムを構成するポリエステル樹脂が、融点(Tmf(℃))を有しており、かつ、微少吸熱ピーク温度(Tmeta(℃))を1つ以上有している[I]から[V]のいずれかに記載のポリエステルフィルム。
[VII]フィルムを構成するポリエステル樹脂が、微少吸熱ピーク(Tmeta(℃))を2以上有しており、最も低い温度のTmeta(Tmeta1)(℃)と最も高い温度のTmeta(Tmeta2)(℃)が以下の関係を満たす[VI]に記載のポリエステルフィルム。
Tmf-35(℃)≦Tmeta1(℃)<Tmeta2(℃)≦Tmf(℃)
[VIII]前記ポリエステルフィルムが、少なくとも3層からなる積層ポリエステルフィルムであり、フィルムの最表面を構成する層(A層)を構成するポリエステル樹脂の融点(Tmo(℃))が260℃以上である[I]から[VII]のいずれかに記載のポリエステルフィルム。
[IX]前記積層ポリエステルフィルムが3層からなり、表層を構成する層(A層)を構成するポリエステル樹脂の融点(Tmo(℃))と、内層を構成する層(B層)を構成するポリエステル樹脂の融点(Tmi(℃))の差が5℃以上10℃以下である[VIII]に記載のポリエステルフィルム。
[X]表層を構成する層(A層)の厚みの和と、内層を構成する層(B層)の厚みの比が1/8以上1/4以下である[IX]に記載のポリエステルフィルム。
[XI]透明導電膜の製膜基板に用いられる[I]から[X]のいずれかに記載のポリエステルフィルム。
本発明のポリエステルフィルムは、フィルムを構成するポリエステル樹脂に占めるポリエチレンテレフタレートの割合が60重量%以上であるポリエステルフィルムである。
(1)溶融したポリエステルを口金から吐出して未延伸シートを作製する際に、表面温度10℃以上40℃以下に冷却されたドラム上で静電気により密着冷却固化し、未延伸シートを作製する。
(2)(1)で得られた未延伸シートを、下記(i)式を満たす温度T1n(℃)にて、フィルムの長手方向(MD)とフィルムの幅方向(TD)に面積倍率10.0倍以上16.0倍以下に二軸延伸する。
(i)Tg(℃)≦T1n(℃)≦Tg+40(℃)
Tg:ポリエステルフィルムを構成するポリエステル樹脂のガラス転移温度(℃)
(3)(2)で得られた二軸延伸フィルムを、下記(ii)式を満足する温度(Th0(℃))で、1秒間以上30秒間以下の熱固定処理を行ない、均一に徐冷後、室温まで冷却することによって、ポリエステルフィルムを得る。
(ii)Tmf-35(℃)≦Th0(℃)≦Tmf(℃)
Tmf:ポリエステルフィルムを構成するポリエステル樹脂の融点(℃)
(1)を満たす条件によって未延伸シートを得ることにより実質的に非晶のポリエステルフィルムを得ることができ、(2)以降の工程においてフィルムに配向を付与せしめ易くし、熱収縮率が小さく、機械特性に良好なフィルムを得やすくすることができる。
(2)を満たす条件によって二軸延伸フィルムを得ることにより、フィルムに適度な配向を付与せしめ、機械特性の良好なフィルムとすることができる。
(3)を満たす条件によって結晶配向を完了させることにより、配向が形成されたポリエステル分子鎖の構造が安定し、熱収縮率が低く、平面性が良好なフィルムとすることができる。
(iii)Tmf-35(℃)≦Th1(℃)≦Th0(熱固定温度)(℃)
(3)を満たす条件で熱固定したフィルムを、さらに(4)を満たす条件でアニールすることで、フィルム内の配向が形成されたポリエステル分子鎖の構造をより強固なものとすることができ、200℃を超えるような高温での熱収縮率を大幅に低減させることができる。
(iv)Tmf-10(℃)≦Th0(熱固定温度)(℃)≦Tmf(℃)
(v)Tmf-35(℃)≦Th1(℃)≦Th0(熱固定温度)(℃)
本構成の積層フィルムにおいて、表層を構成する樹脂の融点(Tmo(℃))は、フィルムを構成するポリエステル樹脂の融点Tmf(℃)よりも高い。即ち、上述のように表層が内層の樹脂を保護することができるため、熱固定温度を高くすることが可能となり、フィルムを溶かすこと無くTmf(℃)に近い温度で熱固定することができる。(iv)式を満たす場合、熱固定温度がTmf(℃)に近いため、熱固定温度を反映するTmeta(℃)は融点ピークに重なり、観察することができない。一方で、二軸延伸後にフィルム構造をより高温で形成することが可能となるため、(4)のアニール工程の温度を、フィルム構造を破壊することなく高温化することができる。その結果、高温下でも安定なフィルム構造とすることができ、高温での熱収縮率を低減することが可能となる。
A.各層を構成する樹脂の融点(Tmo、Tmi)(℃)
試料を、JIS K 7121(1999)に基づいた方法により、セイコー電子工業(株)製示差走査熱量測定装置“ロボットDSC-RDC220”を、データ解析にはディスクセッション“SSC/5200”を用いて、下記の要領にて、測定を実施する。
サンプルパンに試料を5mgずつ秤量し、試料を25℃から320℃まで20℃/分の昇温速度で加熱する(1stRUN)。1stRUNの示差走査熱量測定チャート(縦軸を熱エネルギー、横軸を温度とする)を得る。当該1stRunの示差走査熱量測定チャートの、吸熱ピークである結晶融解ピークにおけるピークトップの温度を求め、これを融点(℃)とする。2以上の結晶融解ピークが観測される場合は、最もピーク面積の大きいピークトップの温度を融点とする。
試料を、JIS K 7121(1999)に基づいた方法により、セイコー電子工業(株)製示差走査熱量測定装置“ロボットDSC-RDC220”を、データ解析にはディスクセッション“SSC/5200”を用いて、下記の要領にて、測定を実施する。
サンプルパンに試料を5mgずつ秤量し、試料を25℃から320℃まで20℃/分の昇温速度で加熱する(1stRUN)。1stRUNの示差走査熱量測定チャート(縦軸を熱エネルギー、横軸を温度とする)を得る。当該1stRunの示差走査熱量測定チャートの、吸熱ピークである結晶融解ピークにおけるピークトップの温度を求め、これを融点(℃)とする。2以上の結晶融解ピークが観測される場合は、最もピーク面積の大きいピークトップの温度を融点とする。
微少吸熱ピーク温度Tmeta(℃)は、JIS K 7122(1999)に準じて、セイコー電子工業(株)製示差走査熱量測定装置”ロボットDSC-RDC220”を、データ解析にはディスクセッション”SSC/5200”を用いて測定する。サンプルパンにフィルムを5mg秤量し、25℃から320℃まで20℃/分の昇温速度で加熱する(1stRUN)。1stRUNの示差走査熱量測定チャート(縦軸を熱エネルギー、横軸を温度とする)を得る。得られた示差走査熱量測定チャートにおける結晶融解ピーク前の微少吸熱ピーク温度でもってTmeta(℃)とする。微小な吸熱のピークが観測しにくい場合は、データ解析部にてピーク付近を拡大して、ピークを読みとる。微小吸熱ピークが複数存在する場合、温度が最も高い微小吸熱ピークをTmeta1(℃)、最も低い微小吸熱ピークをTmeta2(℃)とする。
JIS K 7121(1999)に準じて、セイコー電子工業(株)製示差走査熱量測定装置”ロボットDSC-RDC220”を、データ解析にはディスクセッション”SSC/5200”を用いて、下記の要領にて、測定を実施する。
JIS K 7105(1999)に準じて、アタゴ(株)製アッベ式屈折率計を用いて20℃での屈折率を求める。フィルムの表面の長手方向屈折率(Nmd),幅方向屈折率(Nd),厚み方向屈折率(Nz)を測定し、面配向係数(fn)を算出する。
fn=(Nmd+Ntd)/2-Nz
E.フィルムの熱収縮率(%)
JIS C 2318(1997)に準じて、フィルムの熱収縮率を測定する。フィルムを幅10mm、長さ150mmの短冊状に切り出す。測長部分がおおよそ100mmになるようにフィルムに標線をつけて標線の長さを23℃の条件下にて測定し、L0とする。その後、所定の温度(200℃または220℃)に熱した熱風オーブン内に2gのおもりをつけてフィルムを吊し、30分間放置する。フィルムをオーブンから取りだして23℃まで冷却した後、標線の長さを測定し、L1とする。下記(vi)式によりフィルムの収縮率を求める。測定は、フィルム長手方向またはフィルム幅方向が150mmの長さになるようにランダムに5箇所切り出して測定する。長手方向、幅方向それぞれに平均値を算出し、フィルムの熱収縮率とする。
(vi)(フィルム熱収縮率)=(L0-L1)/L0×100
F.フィルムの平面性
非接触式レーザー顕微鏡として三鷹光器(株)製の非接触三次元測定装置NH-SP3を用いて評価する。解析には(株)菱光社製NHソフトを用いる。フィルムを120mm×120mmにフィルムを切り出す。各辺は、フィルム長手方向または幅方向に平行になるようにする。切り出したフィルムの4辺を、水平に保たれた測定台にテープで固定する。3次元形状測定モードにて、フィルムの表面形状を測定する。X軸方向はフィルム長手方向、Y軸方向はフィルム幅方向とする。測定ピッチは、X軸方向は100μm、Y軸方向は500μmとして、測定範囲は100mm×100mmの範囲とし、Z軸倍率は20倍とする。Z軸方向の最も高い点と最も低い点の差(高低差H(μm))を算出する。フィルムからランダムに5箇所を上記形状に切り出し、その平均値を算出し、以下のように評価する。
0≦H<80 評価A
80≦H<150 評価B
150≦H≦300 評価C
300<H 評価D
評価Aが最も平面性に優れている。
フィルム厚みは、ダイヤルゲージを用い、JIS K7130(1992年)A-2法に準じて、フィルムを10枚重ねた状態で任意の5ヶ所について厚さを測定した。その平均値を10で除してフィルム厚みとした。
フィルムが積層フィルムである場合、下記の方法にて、各層の厚みを求めた。フィルム断面を、フィルム幅方向に平行な方向にミクロトームで切り出す。該断面を走査型電子顕微鏡で5000倍の倍率で観察し、積層各層の厚み比率を求める。求めた積層比率と上記したフィルム厚みから、各層の厚みを算出する。
高分子計器(株)製試験片打抜機を用い、JIS K-6251に記載の5号型ダンベル形状に積層フィルムを打ち抜く。フィルムを50枚重ねて打ち抜いた際に端面の割れ、剥がれが起きている枚数Mを数え、打ち抜き性を評価する。
0≦M≦9:打ち抜き性A
10≦M≦20:打ち抜き性B
21≦M≦30:打ち抜き性C
31≦M:打ち抜き性D
Aが最も優れ、Dが最も劣っている。
オルトクロロフェノール100mlにポリエステル組成物を溶解させ(溶液濃度C=1.2g/dl)、その溶液の25℃での粘度を、オストワルド粘度計を用いて測定する。また、同様に溶媒の粘度を測定する。得られた溶液粘度、溶媒粘度を用いて、下記(c)式により、[η](dl/g)を算出し、得られた値でもって固有粘度(IV)とする。
(c)ηsp/C=[η]+K[η]2・C
(ここで、ηsp=(溶液粘度(dl/g)/溶媒粘度(dl/g))―1、Kはハギンス定数(0.343とする)である。)。
末端カルボキシル基量については、Mauliceの方法に準じて、以下の方法にて測定した。(文献:M.J.Maulice,F. Huizinga, Anal.Chim.Acta,22 363(1960))
測定試料(ポリエステル樹脂(原料)または積層体のP1層のみを分離したもの)2gをo-クレゾール/クロロホルム(重量比7/3)50mLに温度80℃にて溶解し、0.05NのKOH/メタノール溶液によって滴定し、末端カルボキシル基濃度を測定し、当量/ポリエステル1t(eq./t)の値で示した。なお、滴定時の指示薬はフェノールレッドを用いて、黄緑色から淡紅色に変化したところを滴定の終点とした。なお、測定試料を溶解させた溶液に無機粒子などの不溶物がある場合は、溶液を濾過して不溶物の重量測定を行い、不溶物の重量を測定試料重量から差し引いた値を測定試料重量とする補正を実施した。
製膜中にフィルムが1時間に破れる回数を数え、1回未満であるものをA、1回以上3回未満であるものをB、3回以上5回未満であるものをC、5回以上であるものをDとして評価する。Aが最も製膜性がよく、Dが最も劣る。
積層フィルムを1cm×20cmの大きさに、長辺がフィルムの長手方向・幅方向に平行となるようにそれぞれ切り出し、ASTM-D882(1997)に基づいて、チャック間5cm、引っ張り速度300mm/分にて引っ張ったときの破断伸度を測定する。なお、サンプル数はn=5とし、また、フィルムの長手方向、幅方向のそれぞれについて測定した後、それらの平均値を求め、これをフィルムの破断伸度E0とする。
(d) 伸度保持率(%)=E1/E0×100
得られた伸度半減期から、フィルムの耐湿熱性を以下のように判定した。
伸度半減期が30時間以上の場合:A
伸度半減期が20時間以上30時間未満の場合:B
伸度半減期が20時間未満の場合:C
表層を構成する樹脂として、PEN-A100質量部とし、160℃で2時間真空乾燥した後押出機1に投入した。また、内層を構成する樹脂としてPET-A100質量部を160℃で2時間真空乾燥した後、押出機2に投入した。押出機内でそれぞれの原料を表に記載の温度で溶融させ、合流装置で押出機1に投入した樹脂がフィルムの両表層となるように合流させ、表面温度25℃のキャスティングドラム上に押し出し、3層構造をもつ積層シートを作製した。続いて該シートを加熱したロール群で予熱した後、95℃の温度で長手方向(MD方向)に3.2倍延伸を行った後、25℃の温度のロール群で冷却して一軸延伸フィルムを得た。得られた一軸延伸フィルムの両端をクリップで把持しながらテンター内の110℃の温度の加熱ゾーンで長手方向に直角な幅方向(TD方向)に3.5倍延伸した。さらに引き続いて、テンター内の熱処理ゾーンで240℃の温度で10秒間の熱固定を施した。熱固定の工程で、フィルムをフィルム幅方向にフィルム幅に対して5%収縮させた。次いで、冷却ゾーンで均一に徐冷後、巻き取って、積層ポリエステルフィルムを得た。さらに、得られたフィルムをフィルム巻きだしロールとフィルム巻き取りロールの間に設置された熱風オーブンにて、220℃の温度にて、フィルムが熱処理される時間が5分となるようにアニール処理を施し、厚さ100μmのフィルムを得た。フィルムの各特性を表に示す。200℃熱収縮率が低く、かつ平面性も特に良好なフィルムであった。
樹脂の組成、製膜条件を表の通りに変えた以外は、実施例1と同様に製膜を行った。フィルムの特性を表に示す。200℃熱収縮率が低く、かつ平面性も特に良好なフィルムであった。
フィルムの熱固定温度、オフアニール温度を表に記載の通りに変えた以外は、実施例1と同様にして厚さ100μmのフィルムを得た。フィルムの各特性を表に示す。熱固定温度がフィルム融点近傍であったため、Tmetaが1つしか観察されなかった。このフィルムは、200℃熱収縮率に加え、220℃の熱収縮率が低く、平面性に優れるフィルムであることがわかった。
樹脂の組成、製膜条件を表の通りに変えた以外は、実施例5と同様に製膜を行った。フィルムの特性を表に示す。220℃熱収縮率が低く、かつ平面性も特に良好なフィルムであった。
フィルムの積層比、フィルムの厚みを表の通りに変えた以外は、実施例1と同様にして製膜を行った。フィルムの特性を表に示す。実施例9では表層(A層)の積層比が大きいため、製膜性、加工性にやや劣るものの、実用に耐え得るものであった。実施例11では、表層(A層)の積層比が小さく厚みが薄いため、内層(B層)を保護する機能が低下し、平面性に劣る。実施例13では、表層(A層)の片側の厚みが薄いため、内層(B層)を保護する機能が低下し、平面性にやや劣るものの、実用に耐え得るものであった。実施例22では、表層(A層)の片側の厚みが厚いため、製膜性、加工性にやや劣るものの、実用に耐え得るものであった。
樹脂の組成、フィルムのオフアニール温度を表に記載の通りに変えた以外は、実施例5と同様に製膜を行った。フィルムの特性を表に示す。実施例5に比べてオフアニール温度が低いため、220℃熱収縮率はやや劣るものの、平面性は優れた特性を示した。
フィルムを構成する樹脂をポリエチレンテレフタレートのみとし、製膜条件を表の通りとして単膜のフィルムを製膜した。フィルムの特性を表に示す。実施例18では200℃熱収に優れるが、平面性が実施例1に比べてやや劣るものの実用には耐え得るものであった。実施例21では、熱固定温度とアニール温度が同一であるため、熱収縮率に優れる。平面性にやや劣っているものの、実用には耐え得るものであった。
A層を構成する樹脂の組成を表に記載の通りとした以外は、実施例1と同様にしてフィルムを得た。フィルムの特性を表に示す。A層の融点が260℃に満たず、平面性にやや劣ることがわかった。
A層に用いる樹脂をPCHTとした以外は、実施例1と同様にしてフィルムを得た。PCHTは、イーストマンケミカル社製copolyester13319を用いた。フィルムの特性を表に示す。熱収縮率、平面性に優れるフィルムであった。
A層に用いる樹脂をPEN-Bとし、B層に用いる樹脂をPET-Bとした以外は、実施例1と同様にしてフィルムを得た。フィルムの特性を表に示す。熱収縮率、平面性、耐湿熱性に優れるフィルムであった。
フィルムを構成する樹脂をポリエチレンテレフタレートのみとし、製膜条件を表の通りとして単膜のフィルムを製膜した。フィルムの特性を表に示す。比較例1では、Tmeta1の温度が低く、Tmf-35℃未満であるため、熱収縮率に劣る。比較例2では、熱固定温度が高く、Tmf同等であるため、製膜性が悪くフィルムを得ることができなかった。
フィルムを構成する樹脂をPENのみとし、表に記載の延伸条件で製膜した。得られたフィルムの特性を表に示す。比較例3では、熱固定のみ行い、比較例4では、熱固定工程後にオフアニールを実施した。PETを主成分とするフィルムでは無く、面配向係数(fn)が大きいため、加工性に大きく劣る。
A層を構成する樹脂の組成、製膜条件を表に記載の通りに変えた以外は、実施例1と同様にしてフィルムを製膜した。フィルム特性を表に示す。
Claims (11)
- フィルムを構成するポリエステル樹脂に占めるポリエチレンテレフタレートの割合が60重量%以上であるポリエステルフィルムであって、200℃で30分間熱処理を行った場合のフィルム長手方向、幅方向の熱収縮率がいずれも0.5%以下であるポリエステルフィルム。
- 200℃で30分間熱処理を行った場合のフィルム長手方向、幅方向の熱収縮率のうち、少なくともいずれか一方の熱収縮率が0.01%以上である請求項1に記載のポリエステルフィルム。
- 220℃で30分間熱処理を行った場合のフィルム長手方向の熱収縮率、幅方向の熱収縮率がいずれも0.5%以下であり、かつ、少なくともいずれか一方の熱収縮率が0.01%以上である請求項1または2に記載のポリエステルフィルム。
- 非接触式レーザー顕微鏡でフィルムの凹凸を測定した際に、フィルムの凹凸差が300μm以下である請求項1から3のいずれかに記載のポリエステルフィルム。
- 面配向係数が0.145以上0.165以下である請求項1から4のいずれかに記載のポリエステルフィルム。
- フィルムを構成するポリエステル樹脂が、融点(Tmf(℃))を有しており、かつ、微少吸熱ピーク温度(Tmeta(℃))を1つ以上有している請求項1から5のいずれかに記載のポリエステルフィルム。
- フィルムを構成するポリエステル樹脂が、微少吸熱ピーク(Tmeta(℃))を2以上有しており、最も低い温度のTmeta(Tmeta1)(℃)と最も高い温度のTmeta(Tmeta2)(℃)が以下の関係を満たす請求項6に記載のポリエステルフィルム。
Tmf-35(℃)≦Tmeta1(℃)<Tmeta2(℃)≦Tmf(℃) - 前記ポリエステルフィルムが、少なくとも3層からなる積層ポリエステルフィルムであり、フィルムの表面を構成する層(A層)を構成するポリエステル樹脂の融点(Tmo(℃))が260℃以上である請求項1から7のいずれかに記載のポリエステルフィルム。
- 前記積層ポリエステルフィルムが3層からなり、表層を構成する層(A層)を構成するポリエステル樹脂の融点(Tmo(℃))と、内層を構成する層(B層)を構成するポリエステル樹脂の融点(Tmi(℃))の差が5℃以上10℃以下である請求項8に記載のポリエステルフィルム。
- 表層を構成する層(A層)の厚みの和と、内層を構成する層(B層)の厚みの比が1/8以上1/4以下である請求項9に記載のポリエステルフィルム。
- 透明導電膜の製膜基板に用いられる請求項1から9のいずれかに記載のポリエステルフィルム。
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