WO2022209547A1 - セラミックグリーンシート製造工程用剥離フィルム - Google Patents
セラミックグリーンシート製造工程用剥離フィルム Download PDFInfo
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- WO2022209547A1 WO2022209547A1 PCT/JP2022/008846 JP2022008846W WO2022209547A1 WO 2022209547 A1 WO2022209547 A1 WO 2022209547A1 JP 2022008846 W JP2022008846 W JP 2022008846W WO 2022209547 A1 WO2022209547 A1 WO 2022209547A1
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- WIPO (PCT)
- Prior art keywords
- release
- ceramic green
- release agent
- release film
- green sheet
- Prior art date
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- 125000003438 dodecyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
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- 230000008030 elimination Effects 0.000 description 1
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- 230000007613 environmental effect Effects 0.000 description 1
- 125000001301 ethoxy group Chemical group [H]C([H])([H])C([H])([H])O* 0.000 description 1
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- 235000011187 glycerol Nutrition 0.000 description 1
- 238000007756 gravure coating Methods 0.000 description 1
- XXMIOPMDWAUFGU-UHFFFAOYSA-N hexane-1,6-diol Chemical compound OCCCCCCO XXMIOPMDWAUFGU-UHFFFAOYSA-N 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 125000002768 hydroxyalkyl group Polymers 0.000 description 1
- 125000001841 imino group Chemical group [H]N=* 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 229940035429 isobutyl alcohol Drugs 0.000 description 1
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 1
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- FQPSGWSUVKBHSU-UHFFFAOYSA-N methacrylamide Chemical compound CC(=C)C(N)=O FQPSGWSUVKBHSU-UHFFFAOYSA-N 0.000 description 1
- 229940098779 methanesulfonic acid Drugs 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
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- 238000006386 neutralization reaction Methods 0.000 description 1
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- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 238000005191 phase separation Methods 0.000 description 1
- FABOKLHQXVRECE-UHFFFAOYSA-N phenyl(tripropoxy)silane Chemical compound CCCO[Si](OCCC)(OCCC)C1=CC=CC=C1 FABOKLHQXVRECE-UHFFFAOYSA-N 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 229920001515 polyalkylene glycol Polymers 0.000 description 1
- 229920006267 polyester film Polymers 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- HJWLCRVIBGQPNF-UHFFFAOYSA-N prop-2-enylbenzene Chemical compound C=CCC1=CC=CC=C1 HJWLCRVIBGQPNF-UHFFFAOYSA-N 0.000 description 1
- 239000002683 reaction inhibitor Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 238000005204 segregation Methods 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 238000007764 slot die coating Methods 0.000 description 1
- 238000004528 spin coating Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 125000004964 sulfoalkyl group Chemical group 0.000 description 1
- 238000010345 tape casting Methods 0.000 description 1
- ISIJQEHRDSCQIU-UHFFFAOYSA-N tert-butyl 2,7-diazaspiro[4.5]decane-7-carboxylate Chemical compound C1N(C(=O)OC(C)(C)C)CCCC11CNCC1 ISIJQEHRDSCQIU-UHFFFAOYSA-N 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- UQMOLLPKNHFRAC-UHFFFAOYSA-N tetrabutyl silicate Chemical compound CCCCO[Si](OCCCC)(OCCCC)OCCCC UQMOLLPKNHFRAC-UHFFFAOYSA-N 0.000 description 1
- ZQZCOBSUOFHDEE-UHFFFAOYSA-N tetrapropyl silicate Chemical compound CCCO[Si](OCCC)(OCCC)OCCC ZQZCOBSUOFHDEE-UHFFFAOYSA-N 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- INUOIYMEJLOQFN-UHFFFAOYSA-N tributoxy(phenyl)silane Chemical compound CCCCO[Si](OCCCC)(OCCCC)C1=CC=CC=C1 INUOIYMEJLOQFN-UHFFFAOYSA-N 0.000 description 1
- RRHXZLALVWBDKH-UHFFFAOYSA-M trimethyl-[2-(2-methylprop-2-enoyloxy)ethyl]azanium;chloride Chemical compound [Cl-].CC(=C)C(=O)OCC[N+](C)(C)C RRHXZLALVWBDKH-UHFFFAOYSA-M 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
-
- 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
Definitions
- the present invention relates to a release film used in the process of manufacturing ceramic green sheets.
- a ceramic green sheet is molded and a plurality of the obtained ceramic green sheets are laminated. Firing is done.
- a ceramic green sheet is formed by coating a release film with a ceramic slurry containing a ceramic material such as barium titanate or titanium oxide.
- the release film generally, one comprising a base material and a release agent layer provided on one side of the base material is widely used.
- a release film is required to have a light releasability that allows a thin ceramic green sheet formed on the release film to be released from the release film without breakage or the like. Therefore, release agent layers containing polyorganosiloxane such as polydimethylsiloxane are widely used.
- Patent Document 1 proposes a release film having a release agent layer made of a thermosetting amino resin and a polyorganosiloxane containing a hydroxy group.
- the silicone component in the release agent composition may easily migrate to the surface of the ceramic green sheet in contact with the release agent layer.
- the adhesiveness and adhesion on that surface are lowered.
- a ceramic green sheet is manufactured using such a release film to which a silicone component easily migrates, and a multilayer ceramic product is manufactured using the ceramic green sheet, delamination may occur between the layers of the multilayer ceramic product due to changes over time and environmental conditions. easily occur.
- the positional accuracy of electrodes and the like deteriorates, making it impossible to obtain desired product performance. Therefore, there is a demand for a release film in which the silicone component is less transferred to the ceramic green sheet.
- the present invention has been made in view of such circumstances, and an object of the present invention is to provide a release film for a ceramic green sheet manufacturing process that can achieve both easy release property and suppression of migration of the silicone component. .
- the present invention provides a release film for a ceramic green sheet manufacturing process, comprising a base material and a release agent layer provided on one side of the base material, the release film comprising:
- the agent layer is formed from a release agent composition containing an amino resin (A), a hydroxyl group-containing acrylic resin (B), a polyorganosiloxane (C), and an acid catalyst (D).
- a release film for a ceramic green sheet manufacturing process is provided (Invention 1).
- the hydroxyl group-containing acrylic resin (B) has excellent compatibility with the amino resin (A), but has poor compatibility with the polyorganosiloxane (C).
- the polyorganosiloxane (C) is easily segregated on the surface of the release agent layer. Therefore, it is possible to develop light release properties with a small amount of polyorganosiloxane (C). Since the range in which the easy release property is maintained is expanded in this way and the amount of the polyorganosiloxane (C) blended can be easily adjusted, the amount of the silicone component migrating to the ceramic green sheet can be reduced, and the silicone component can be removed. It is possible to suppress migration.
- the content of the hydroxyl group-containing acrylic resin (B) in the release agent composition is 5 parts by mass or more and 200 parts by mass with respect to 100 parts by mass of the amino resin (A).
- the following are preferable (Invention 2).
- the polyorganosiloxane (C) preferably has at least one hydroxy group in one molecule (invention 3).
- the polyorganosiloxane (C) preferably has at least one organic group selected from a polyester group, a polyether group and a carbinol group (invention 4).
- the weight average molecular weight of the polyorganosiloxane (C) is preferably 500 or more and 20000 or less (Invention 5).
- the content of the polyorganosiloxane (C) in the release agent composition is 100 parts by mass in total of the amino resin (A) and the hydroxyl group-containing acrylic resin (B). is preferably 0.05 parts by mass or more and 10 parts by mass or less (Invention 6).
- the release agent composition preferably contains an alkoxysilane hydrolysis polycondensate (E) having a siloxane bond (Si—O—Si) as a skeleton (Invention 7 ).
- the acid catalyst (D) preferably contains at least one of a sulfonic acid-based catalyst and a phosphoric acid-based catalyst (Invention 8).
- the release agent composition preferably contains a polyol compound (F) having a molecular weight or weight average molecular weight of 50 or more and 10000 or less (Invention 9).
- the thickness of the release agent layer is preferably 0.02 ⁇ m or more and 0.5 ⁇ m or less (Invention 10).
- the arithmetic mean roughness (Ra) of the release agent layer side surface of the substrate is 1 nm or more and 50 nm or less, and the maximum protrusion height (Rp) of the surface is is preferably 10 nm or more and 1000 nm or less (Invention 11).
- the arithmetic mean roughness (Ra) of the surface of the substrate opposite to the release agent layer is 10 nm or more and 50 nm or less, and the maximum projection height of the surface ( Rp) is preferably 100 nm or more and 1000 nm or less (Invention 12).
- the release film for the ceramic green sheet manufacturing process according to the present invention it is possible to achieve both easy release property and suppression of migration of the silicone component.
- a release film for a ceramic green sheet manufacturing process according to the present embodiment (hereinafter sometimes simply referred to as "release film”) comprises a substrate and a release agent layer provided on one side of the substrate. be done.
- the surface of the release agent layer opposite to the substrate may be hereinafter referred to as the "release surface”.
- Substrate The substrate in the present embodiment is not particularly limited as long as the release agent layer can be laminated thereon.
- examples of such substrates include films made of polyesters such as polyethylene terephthalate and polyethylene naphthalate, polyolefins such as polypropylene and polymethylpentene, and plastics such as polycarbonate and polyvinyl acetate. , may be multiple layers of two or more layers of the same or different types.
- a polyester film is preferable, a polyethylene terephthalate film is particularly preferable, and a biaxially stretched polyethylene terephthalate film is more preferable.
- Polyethylene terephthalate film is less likely to generate dust during processing, use, etc., so that, for example, it is possible to effectively prevent defects such as ceramic slurry coating failure due to dust and the like.
- one or both sides of the base material may optionally be subjected to a surface treatment such as an oxidation method or roughening method, or a primer treatment.
- a surface treatment such as an oxidation method or roughening method, or a primer treatment.
- the oxidation method include corona discharge treatment, plasma discharge treatment, chromium oxidation treatment (wet), flame treatment, hot air treatment, ozone, and ultraviolet irradiation treatment.
- a thermal spraying method and the like can be mentioned.
- These surface treatment methods are appropriately selected according to the type of substrate film, but generally corona discharge treatment is preferably used from the viewpoint of effectiveness and operability.
- the arithmetic mean roughness (Ra) of the release agent layer side surface of the substrate is preferably 50 nm or less, particularly preferably 40 nm or less, and further preferably 30 nm or less.
- the arithmetic mean roughness (Ra) is 50 nm or less, the arithmetic mean roughness (Ra) and the maximum protrusion height (Rp) on the peeled surface are easily kept within the ranges described later, thereby forming It is possible to effectively suppress the occurrence of defects in the ceramic green sheets.
- the lower limit of the arithmetic mean roughness (Ra) of the release agent layer side surface of the base material is not particularly limited, and may be, for example, 1 nm or more, particularly 3 nm or more, and further. It may be 5 nm or more.
- the maximum protrusion height (Rp) on the release agent layer side surface of the substrate is preferably 1000 nm or less, particularly preferably 700 nm or less, and further preferably 500 nm or less.
- the lower limit of the maximum projection height (Rp) on the release agent layer side surface of the substrate is not particularly limited, and may be, for example, 10 nm or more, particularly 30 nm or more, and further. It may be 50 nm or more.
- the arithmetic mean roughness (Ra) of the surface of the substrate opposite to the release agent layer is preferably 10 nm or more, particularly preferably 15 nm or more, and further preferably 18 nm or more.
- the arithmetic mean roughness (Ra) is 10 nm or more, it becomes easy to suppress winding misalignment when the release film is wound up to form a roll.
- excessive increase in the effective contact area between the surface of the substrate opposite to the release agent layer and the release surface in contact therewith is suppressed, thereby effectively suppressing blocking.
- the charge amount of the release film fed out from the roll body can be reduced.
- the arithmetic mean roughness (Ra) of the surface of the substrate opposite to the release agent layer is preferably 50 nm or less, particularly preferably 40 nm or less, and more preferably 30 nm or less. Since the arithmetic mean roughness (Ra) is 50 nm or less, when the release film and the ceramic green sheet formed on the release film are wound into a roll and transported, stored, etc., It is effectively suppressed that the surface shape (particularly uneven shape) of the surface opposite to the release agent layer is transferred to the surface of the ceramic green sheet that is in contact with the surface. As a result, it becomes easy to maintain good smoothness of the ceramic green sheet.
- the maximum protrusion height (Rp) on the side of the base material opposite to the release agent layer is preferably 100 nm or more, particularly preferably 200 nm or more, and further preferably 300 nm or more.
- the maximum protrusion height (Rp) on the surface of the substrate opposite to the release agent layer is preferably 1000 nm or less, particularly preferably 700 nm or less, and further preferably 500 nm or less.
- the maximum protrusion height (Rp) is 1000 nm or less, the smoothness of the ceramic green sheet can be easily maintained well, as in the case where the arithmetic mean roughness (Ra) is 50 nm or less.
- the surface roughness of the base material described above can be measured by a known method using a surface roughness measuring instrument, for example, the surface roughness of the release surface in the test examples described later can be measured in the same manner. can do.
- the thickness of the substrate is not particularly limited. For example, it is preferably 10 ⁇ m or more, particularly preferably 15 ⁇ m or more, and further preferably 20 ⁇ m or more. Also, the thickness of the substrate is preferably 300 ⁇ m or less, particularly preferably 200 ⁇ m or less, and further preferably 125 ⁇ m or less.
- the release agent layer in the present embodiment is made of a release agent composition containing an amino resin (A), a hydroxyl group-containing acrylic resin (B), a polyorganosiloxane (C), and an acid catalyst (D). It is formed.
- the combination of the amino resin (A) and the hydroxyl group-containing acrylic resin (B) facilitates the segregation of the polyorganosiloxane (C) on the surface of the release agent layer.
- the hydroxyl group-containing acrylic resin (B) has excellent compatibility with the amino resin (A), but has poor compatibility with the polyorganosiloxane (C).
- the polyorganosiloxane (C) is easily segregated on the surface of the release agent layer in this way, it becomes possible to develop light release properties with a small amount of the polyorganosiloxane (C).
- the range in which the light release property is maintained is widened and the amount of the polyorganosiloxane (C) blended can be easily adjusted. It is possible to suppress migration of components. This makes it possible to increase the relative adhesion between the obtained ceramic green sheets.
- the release agent composition contains an amino resin (A).
- the amino resin (A) undergoes a condensation reaction in the presence of the acid catalyst (D). An original structure is formed.
- the amino resin (A) also reacts with hydroxyl groups, it also reacts with the hydroxyl group-containing acrylic resin (B), and the acrylic resin (B) is also incorporated into the three-dimensional structure.
- the above reaction can be caused, for example, by heating. Since the release agent layer includes the three-dimensional structure described above, it exhibits sufficient elasticity, so that the release film according to the present embodiment can exhibit excellent release properties.
- amino resin refers to a component capable of undergoing a condensation reaction, and does not necessarily have to be a polymer compound.
- the component may be one that has not undergone condensation reaction at all, or one that has undergone partial condensation reaction.
- the amino resin (A) known ones can be used, for example, melamine resin, urea resin, guanamine resin or aniline resin can be used. Among these, it is preferable to use a melamine resin whose condensation reaction rate is very high.
- melamine resin means an aggregate of one type of melamine compound, or a mixture containing multiple types of melamine compounds and/or polynuclear compounds formed by condensation of the melamine compounds. do.
- the melamine resin preferably contains a melamine compound represented by the following general formula (a) or a polynuclear compound obtained by condensing two or more of the melamine compounds.
- X preferably represents -H, -CH 2 -OH or -CH 2 -OR.
- These groups constitute reactive groups in the condensation reaction between the melamine compounds. Specifically, the —NH group formed by X becoming H can undergo a condensation reaction with —N—CH 2 —OH and —N—CH 2 —OR groups. .
- R preferably represents an alkyl group having 1 to 8 carbon atoms.
- the number of carbon atoms is preferably 1 to 6, particularly preferably 1 to 3.
- alkyl groups having 1 to 8 carbon atoms include methyl group, ethyl group, propyl group, butyl group, pentyl group, hexyl group, octyl group and the like, with methyl group being particularly preferred.
- the above Xs may be the same or different.
- the above Rs may be the same or different.
- Melamine compounds generally include the full ether type in which all Xs are —CH 2 —O—R, imino methylols in which at least one X is —CH 2 —OH and at least one X is H. a methylol form with no X in which at least one X is -CH 2 -OH and H, and an imino form with no X in which at least one X is H and -CH 2 -OH.
- Types exist. Any of these types of melamine compounds may be used in the release film according to the present embodiment.
- the weight average molecular weight of the amino resin (A) is preferably 150 or more, particularly preferably 300 or more, further preferably 500 or more. preferable. Thereby, the cross-linking speed is stabilized, and a smoother peeling surface can be formed. Moreover, the weight average molecular weight is preferably 10,000 or less, particularly preferably 5,000 or less, and further preferably 4,000 or less. As a result, the release agent composition has a moderately low viscosity, and the coating liquid of the release agent composition can be easily applied onto the substrate.
- the weight average molecular weight in this specification is a value converted to standard polystyrene measured by gel permeation chromatography (GPC).
- the release agent composition contains a hydroxyl group-containing acrylic resin (B).
- the hydroxyl-containing acrylic resin (B) consists of only a hydroxyl-containing acrylic monomer (hereinafter sometimes referred to as "hydroxyl-containing monomer”), or consists of a hydroxyl-containing monomer and other copolymerizable monomers. It can be preferably produced by copolymerization. Examples of the production method include known methods such as bulk polymerization, solution polymerization in an organic solvent, and emulsion polymerization in water.
- hydroxyl group-containing monomers examples include 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, polyethylene glycol mono (meth) Acrylate, polypropylene glycol mono(meth)acrylate, neopentyl glycol mono(meth)acrylate, glycerin mono(meth)acrylate, polycaprolactone-modified hydroxyl alkyl (meth)acrylate, polycaprolactone-modified poly(oxyalkylene) (meth)acrylate, etc. mentioned.
- a hydroxyl-containing monomer may be used individually by 1 type, and may be used in combination of 2 or more type.
- (meth)acrylate means both acrylate and methacrylate. The same applies to other similar terms.
- copolymerizable acrylic monomers include, for example, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl ( meth)acrylate, tert-butyl (meth)acrylate, 2-ethylhexyl acrylate, cyclohexyl (meth)acrylate, n-octyl (meth)acrylate, lauryl (meth)acrylate, isobornyl (meth)acrylate, stearyl (meth)acrylate, etc.
- Alkyl esters of (meth)acrylic acid Carboxyl group-containing monomers such as (meth)acrylic acid, maleic acid and maleic anhydride; N,N-dimethylaminoethyl (meth)acrylate, N,N-diethylaminoethyl (meth)acrylate , N,N-dimethylaminopropyl (meth)acrylate and other aminoalkyl (meth)acrylates; acrylamide, methacrylamide, or derivatives thereof; 2-(methacryloyloxy)ethyltrimethylammonium chloride, 2-(methacryloyloxy)ethyltrimethylammonium quaternary ammonium base-containing monomers such as bromides; (meth)acrylamido-alkanesulfonic acids such as 2-acrylamido-2-methylpropanesulfonic acid, sulfoalkyl (meth)acrylates such as 2-sulfoethyl (meth)
- copolymerizable monomers other than acrylic monomers include vinyl acetate, styrene, vinyltoluene, ⁇ -methylstyrene and the like. These may be used individually by 1 type, respectively, and may be used in combination of 2 or more types.
- the hydroxyl value of the hydroxyl-containing acrylic resin (B) is preferably 10 mgKOH/g or more, particularly preferably 15 mgKOH/g or more, further preferably 20 mgKOH/g or more. Thereby, the amino resin (A) and the hydroxyl group-containing acrylic resin (B) can be favorably reacted and cured. Moreover, the hydroxyl value is preferably 200 mgKOH/g or less, particularly preferably 150 mgKOH/g or less, and further preferably 100 mgKOH/g or less. Thereby, the amino resin (A) and the hydroxyl group-containing acrylic resin (B) can be well reacted and cured, and the stability of the blended coating liquid can be sufficiently maintained. In addition, in this specification, the value measured according to the neutralization titration method (JIS K0070) shall be adopted as the hydroxyl value of the acrylic resin.
- the glass transition temperature Tg of the hydroxyl group-containing acrylic resin (B) is preferably ⁇ 20° C. or higher, particularly preferably 30° C. or higher, and further preferably 50° C. or higher. As a result, the film cured by reacting with the amino resin (A) becomes highly elastic, making it easier to exhibit light releasability with respect to the ceramic green sheet. Also, the glass transition temperature Tg is preferably 150° C. or lower, particularly preferably 120° C. or lower, and further preferably 100° C. or lower. As a result, the amino resin (A) and the hydroxyl group-containing acrylic resin (B) are appropriately compatible with each other, and sufficient reactivity can be ensured. In addition, the glass transition temperature shall employ
- the weight average molecular weight of the hydroxyl group-containing acrylic resin (B) is preferably 500 or more, particularly preferably 3000 or more, further preferably 5000 or more.
- the cured film that reacts with the amino resin (A) becomes highly elastic, and the polyorganosiloxane (C) segregates on the surface of the release agent layer due to poor compatibility with the polyorganosiloxane (C). It becomes easy to peel off, and it becomes easy to express easy releasability with respect to a ceramic green sheet.
- the weight average molecular weight is preferably 200,000 or less, particularly preferably 150,000 or less, further preferably 100,000 or less.
- the polyorganosiloxane (C) and the hydroxyl group-containing acrylic resin (B) are less likely to be compatible with each other, and the polyorganosiloxane (C) is more likely to segregate on the opposite side of the substrate, resulting in a ceramic green sheet.
- the hydroxyl group-containing acrylic resin (B) in the present embodiment is preferably not substantially silicone-modified. This makes it easier to segregate the polyorganosiloxane (C) on the surface of the release agent layer.
- the amount of silicone modification is preferably 0.50 mmol/g or less, particularly preferably 0.20 mmol/g or less, further preferably 0.10 mmol/g or less, and 0 mmol/g. /g is most preferred.
- the content of the hydroxyl group-containing acrylic resin (B) in the release agent composition is preferably 5 parts by mass or more, particularly preferably 15 parts by mass or more, relative to 100 parts by mass of the amino resin (A). , and more preferably 25 parts by mass or more.
- the content is preferably 200 parts by mass or less, particularly preferably 150 parts by mass or less, and further preferably 120 parts by mass or less with respect to 100 parts by mass of the amino resin (A). preferable.
- the polyorganosiloxane (C) which is less compatible with the hydroxyl group-containing acrylic resin (B), tends to segregate on the surface of the release agent layer. With the polyorganosiloxane (C) of , it is possible to more effectively exhibit light releasability.
- the release agent composition contains polyorganosiloxane (C).
- the surface free energy of the formed release agent layer is moderately lowered.
- the peel force when the release film is peeled off from the ceramic green sheet formed on the release surface of the release film is moderately lowered, and good peelability is achieved.
- good releasability can be achieved even with a small amount of polyorganosiloxane (C), so migration of the silicone component to the ceramic green sheet can be suppressed.
- the polyorganosiloxane (C) is not particularly limited as long as it can impart desired releasability to the release agent layer.
- the polyorganosiloxane (C) preferably has at least one hydroxy group in one molecule. Since the polyorganosiloxane (C) has a hydroxyl group, the polyorganosiloxane (C) can undergo a condensation reaction with the amino resin (A) or the hydroxyl group-containing acrylic resin (B). It becomes easy to suppress migration of the polyorganosiloxane (C) to the ceramic green sheet.
- Structures other than the hydroxyl group in the polyorganosiloxane (C) are the above-mentioned peelability, the amino resin (A) between each other, the amino resin (A) and the hydroxyl group-containing acrylic resin (B), and the hydroxyl group-containing acrylic resin (B) are not particularly limited as long as they do not inhibit the reaction between them.
- polyorganosiloxane (C) a polymer of a silicon-containing compound represented by the following general formula (b) can be used.
- R 1 to R 8 each independently represent a hydroxy group, an organic group (including an organic group having a hydroxy group), or a group other than these groups.
- at least one of R 1 to R 8 is a hydroxy group or an organic group having a hydroxy group
- at least one of R 3 to R 8 is preferably these groups. That is, when polyorganosiloxane (C) has a hydroxy group or an organic group having a hydroxy group, the group is preferably present at the end of polyorganosiloxane (C).
- the polyorganosiloxane (C) undergoes a condensation reaction with the amino resin (A) or the hydroxyl group-containing acrylic resin (B) and is easily fixed in a three-dimensional structure. Migration of siloxane (C) is effectively suppressed.
- the organic group examples include a polyester group, a polyether group and a carbinol group.
- the polyorganosiloxane (C) in the present embodiment is at least one of a polyester group, a polyether group and a carbinol group. It is preferred to have Since the polyorganosiloxane (C) has at least one of a polyester group, a polyether group and a carbinol group, the polyorganosiloxane (C), the amino resin (A) and the hydroxyl group-containing acrylic resin in the release agent composition (B) is easily mixed well.
- the polyorganosiloxane (C) is more compatible with the amino resin (A) than the hydroxyl group-containing acrylic resin (B), and both the amino resin (A) and the hydroxyl group-containing acrylic resin (B) are mixed.
- the condensation reaction between the polyorganosiloxane (C) and the amino resin (A) or the hydroxyl group-containing acrylic resin (B) as described above proceeds well, and the migration of the polyorganosiloxane (C) is effectively suppressed. be done.
- an "organic group” shall not contain the alkyl group mentioned later.
- Examples of groups other than hydroxy groups and organic groups include alkyl groups having 1 to 12 carbon atoms.
- Examples of alkyl groups having 1 to 12 carbon atoms include methyl group, ethyl group, propyl group, butyl group, pentyl group, hexyl group, octyl group and the like, with methyl group being particularly preferred.
- R 1 to R 8 may be the same or different. Moreover, when there are a plurality of R 1 and R 2 , R 1 and R 2 may be the same or different.
- the weight average molecular weight of the polyorganosiloxane (C) is preferably 20,000 or less, particularly preferably 10,000 or less, further preferably 5,000 or less. As a result, the compatibility between the polyorganosiloxane (C) and the amino resin (A) is excellent, and a release agent layer having an excellent surface condition can be easily formed. Furthermore, it becomes easy to suppress migration of the polyorganosiloxane (C) from the release agent layer to the ceramic green sheet.
- the weight average molecular weight of the polyorganosiloxane (C) is preferably 500 or more, particularly preferably 1000 or more, further preferably 2000 or more. As a result, the polyorganosiloxane (C) can easily lower the surface free energy on the release surface of the release agent layer, and the desired release property can be easily achieved.
- the content of the polyorganosiloxane (C) in the release agent composition is preferably 0.05 parts by mass or more with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B). , more preferably 0.10 parts by mass or more, particularly preferably 0.30 parts by mass or more, and further preferably 0.50 parts by mass or more.
- the release film according to the present embodiment can easily achieve desired release properties with respect to the ceramic green sheet.
- the content of the polyorganosiloxane (C) is preferably 10 parts by mass or less with respect to the total 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B), and 7 parts by mass or less.
- the release agent composition contains an acid catalyst (D).
- an acid catalyst (D) By including the acid catalyst (D) in the release agent composition, amino resin (A) with each other, hydroxyl group-containing acrylic resin (B) with each other, amino resin (A) and hydroxyl group-containing acrylic resin (B), and polyorganosiloxane (The reaction between C) and the alkoxysilane hydrolysis polycondensate (E), which will be described later, proceeds efficiently to form a release agent layer exhibiting sufficient elasticity.
- Examples of the acid catalyst (D) are not particularly limited as long as they have catalytic action for the above reaction, but it is particularly preferable to use at least one of a sulfonic acid-based catalyst and a phosphoric acid-based catalyst. . Since these catalysts have relatively high catalytic activity, they facilitate curing of the release agent layer at lower temperatures.
- Examples of sulfonic acid catalysts include p-toluenesulfonic acid, methanesulfonic acid, dodecylbenzenesulfonic acid, etc. Among these, p-toluenesulfonic acid is preferably used.
- a full-ether type melamine resin is mainly used as the amino resin (A)
- a sulfonic acid-based catalyst from the viewpoint of allowing the condensation reaction of the melamine resin to proceed efficiently.
- phosphoric acid-based catalysts include phosphoric acid and phosphorous acid.
- an imino-methylol type melamine resin is mainly used as the amino resin (A)
- the acid catalyst (D) other than those mentioned above include hydrochloric acid, sulfuric acid, nitric acid, and the like.
- the content of the acid catalyst (D) in the release agent composition is preferably 0.5 parts by mass or more with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B). In particular, it is preferably 0.7 parts by mass or more, more preferably 1.0 parts by mass or more.
- the content is preferably 30 parts by mass or less, particularly preferably 20 parts by mass or less, with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B). Furthermore, it is preferably 10 parts by mass or less.
- the release agent composition also preferably contains an alkoxysilane hydrolysis polycondensate (E) having a siloxane bond (Si—O—Si) as a skeleton.
- the release agent composition contains the alkoxysilane hydrolysis polycondensate (E)
- the alkoxysilane hydrolysis polycondensate (E) is combined with the hydroxyl group-containing acrylic resin (B) and the hydroxyl group-containing polyorganosiloxane (C).
- a harder film is formed, and it becomes easier to exhibit easy peelability with respect to the ceramic green sheet.
- the effect of suppressing migration of the silicone component becomes more excellent.
- the alkoxysilane hydrolysis polycondensate (E) is not particularly limited as long as it does not significantly impair the releasability of the release film.
- a preferred alkoxysilane hydrolysis polycondensate (E) is obtained by hydrolyzing a mixture of tetraalkoxysilane and/or its oligomer and phenylalkoxysilane and/or its oligomer, followed by further polycondensation reaction. is preferred.
- the tetraalkoxysilane is preferably represented by the formula Si(OR) 4
- the oligomer of the tetraalkoxysilane is represented by the formula Si n O n ⁇ 1 (OR) 2n+2 . It is preferable to be In these formulas, each R is preferably an alkyl group having 1 to 6 carbon atoms, and n is preferably an integer of 2 to 10.
- tetraalkoxysilane examples include tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, and tetrabutoxysilane. At least one of silane and tetraethoxysilane is preferred.
- the tetraalkoxysilane oligomer is preferably obtained by hydrolyzing and condensing the alkoxysilane monomer as described above.
- methyl silicate 51 which is an average tetramer oligomer of tetramethoxysilane
- ethyl silicate 40 which is an average pentamer oligomer of tetraethoxysilane
- the phenylalkoxysilane is preferably represented by the formula Ph n Si(OR) 4-n .
- Ph represents a phenyl group
- R each independently represents an alkyl group having 1 to 6 carbon atoms
- n represents an integer of 1 to 2.
- the phenylalkoxysilane oligomer is preferably a 2- to 10-mer of the phenylalkoxysilane represented by the above formula, and more preferably a 2- to 3-mer.
- phenylalkoxysilane examples include phenyltrimethoxysilane, phenyltriethoxysilane, phenyltripropoxysilane, and phenyltri-n-butoxysilane. Among them, at least one of phenyltrimethoxysilane and phenyltriethoxysilane is preferably used from the viewpoint of excellent reactivity.
- the phenylalkoxysilane a diphenyldialkoxysilane in which two phenyl groups are bonded to a silicon atom may be used.
- the alkoxy group is preferably a methoxy group or an ethoxy group.
- the hydrolysis and polycondensation reaction of a mixture of tetraalkoxysilane and/or its oligomer and phenylalkoxysilane and/or its oligomer can be carried out by known methods.
- the ratio of tetraalkoxysilane and/or its oligomer to phenylalkoxysilane and/or its oligomer in the mixture is preferably 1:1 to 1:0.1 in mass ratio.
- the content of the alkoxysilane hydrolysis polycondensate (E) in the release agent composition is 2 parts by mass or more with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B). is preferred, particularly preferably 5 parts by mass or more, and more preferably 10 parts by mass or more. As a result, the effect of suppressing migration of the silicone component becomes more excellent.
- the content of the alkoxysilane hydrolysis polycondensate (E) is preferably 50 parts by mass or less with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B), particularly It is preferably 40 parts by mass or less, more preferably 30 parts by mass or less. As a result, the release agent layer can be cured well, and good peelability and the ability to suppress migration of the silicone component can be easily achieved.
- antistatic properties are also improved by using the alkoxysilane hydrolysis polycondensate (E).
- the alkoxysilane hydrolysis polycondensate (E) as described above would not provide antistatic properties when used as a material for a release agent layer.
- the present inventors have found that by using the alkoxysilane hydrolysis polycondensate (E), the level of antistatic property required for release films for ceramic green sheet manufacturing processes can be obtained. discovered that it is possible to realize For example, the surface resistivity of the release film according to this embodiment can be equivalent to that of a polyethylene terephthalate film that is an insulator.
- the state of the electrification series of the components contained in the release agent layer due to the alkoxysilane hydrolysis polycondensate (E). may be changed.
- the electrification series means an order in which, when two kinds of substances are rubbed, those that tend to be positively charged are placed higher and those that tend to be negatively charged are placed lower. The further apart the positions in the electrification series are, the easier it is to be electrified when the two substances are rubbed.
- the positions of the amino resin (A) and the hydroxyl group-containing acrylic resin (B) in the triboelectric series are relatively distant from the substrate material (eg, polyethylene terephthalate film). Therefore, in the release agent layer containing the amino resin (A), when the release film is unwound from the roll body, the release film is very likely to be electrified by release.
- the substrate material eg, polyethylene terephthalate film
- the position in the electrification series of the alkoxysilane hydrolysis polycondensate (E) is often used as a substrate for release films for producing ceramic green sheets compared to the amino resin (A) and the hydroxyl group-containing acrylic resin (B). It is close to polyethylene terephthalate, which is widely used.
- the release agent composition in the present embodiment contains such an alkoxysilane hydrolysis polycondensate (E), so that when the release agent layer is formed, the amino resin (A) or the hydroxyl group-containing acrylic resin ( An alkoxysilane hydrolysis polycondensate (E) is bound to B).
- the thus obtained bonded product has a triboelectric array position much closer to polyethylene terephthalate than the amino resin (A) and the hydroxyl group-containing acrylic resin (B) before bonding.
- the release agent composition in this embodiment contains polyorganosiloxane (C), and the position of this polyorganosiloxane (C) in the electrification series is also relatively close to that of polyethylene terephthalate.
- the amino resin (A), the hydroxyl group-containing acrylic resin (B), or the alkoxysilane hydrolysis polycondensate (E) may react and bond. Therefore, the position of the electrification array of the crosslinked structure formed by bonding these is very close to the position of polyethylene terephthalate.
- the distance between the components contained in the release agent layer and the substrate is greater than that of the conventional release agent layer. , the separation of the electrification series is greatly relaxed, and as a result, separation electrification is difficult to occur.
- the content described above is not the only reason why the release film using the alkoxysilane hydrolysis polycondensate (E) is difficult to charge, and there may be other additional reasons. However, such an additional reason excludes the possibility that the alkoxysilane hydrolysis polycondensate (E) acts as a general antistatic agent. Some compounds corresponding to the alkoxysilane hydrolysis polycondensate (E) are generally used as antistatic agents. When the alkoxysilane hydrolysis polycondensate (E) is used as an antistatic agent, a large number of hydroxy groups possessed by the alkoxysilane hydrolysis polycondensate (E) are present on the surface of the member in which it is used.
- the surface resistance value of the surface is lowered, and the antistatic effect is exhibited.
- most of the hydroxyl groups possessed by the alkoxysilane hydrolysis polycondensate (E) are the amino resin (A), the hydroxyl group-containing acrylic resin (B ) or the reaction with polyorganosiloxane (C) and disappears. Therefore, in the release agent layer using the alkoxysilane hydrolysis polycondensate (E), it is presumed that the alkoxysilane hydrolysis polycondensate (E) does not function as a general antistatic agent.
- the release agent composition may contain other components such as a polyol compound (F), a dispersant, a cross-linking agent, a reaction inhibitor, an adhesion improver, and a lubricant.
- F polyol compound
- the polyol compound (F) is not particularly limited, and various known compounds can be used. By containing the polyol compound (F) in the release agent composition, it becomes easy to adjust the elastic modulus of the release agent layer to a desired range, and curing when the release agent composition is cured to form the release agent layer. It becomes easy to improve the property. From this point of view, it is preferable to use a polyol compound (F) having a molecular weight or a weight average molecular weight of 50 or more. Further, it is preferable to use one having a weight average molecular weight of 10,000 or less, particularly preferably 5,000 or less, and more preferably 3,000 or less.
- polyol compound (F) examples include 1,6-hexanediol, 3-methyl-1,5-pentanediol, neopentyl glycol, 2-methyl-1,5-pentanediol, 2,2-diethyl- Aliphatic diols such as 1,3-propanediol, 1,9-nonanediol, 1,10-decanediol, butylethylpropanediol and butylethylpentanediol; Alicyclic diols such as 1,4-cyclohexanedimethanol; Trimethylolpropane, pentaerythritol, ditrimethylolpropane, dipentaerythritol, dimer diol, hydrogenated dimer diol, trimer triol, hydrogenated trimer triol, castor oil, castor oil modified polyol, alkylene oxide adduct of bisphenol compound or derivative thereof
- polymer polyols such as polyether polyols, polyester polyols, polycarbonate polyols, acrylic polyols and polyolefin polyols.
- polyether polyols include polyalkylene glycols such as polyethylene glycol (including ethylene glycol), polypropylene glycol (including propylene glycol), polytetramethylene glycol, and monomers such as ethylene oxide-propylene oxide copolymers. Examples thereof include (alkylene oxide-other alkylene oxide) copolymers containing multiple alkylene oxides as a body component. These may be used alone or in combination of two or more.
- the content of the polyol compound (F) in the release agent composition is 100 parts by mass in total of the amino resin (A) and the hydroxyl group-containing acrylic resin (B).
- it is preferably 0.1 parts by mass or more, particularly preferably 0.5 parts by mass or more, further preferably 1 part by mass or more.
- the content is preferably 100 parts by mass or less, particularly preferably 70 parts by mass or less, with respect to a total of 100 parts by mass of the amino resin (A) and the hydroxyl group-containing acrylic resin (B).
- it is preferably 40 parts by mass or less.
- the surface free energy of the release surface of the release agent layer is preferably 17 mJ/m 2 or more, particularly 19 mJ/m 2 or more. is preferred, and more preferably 21 mJ/m 2 or more. Also, the surface free energy is preferably 40 mJ/m 2 or less, particularly preferably 35 mJ/m 2 or less, further preferably 30 mJ/m 2 or less.
- the release agent layer is formed from the release agent composition containing the components described above, so that the surface free energy on the release surface can be easily adjusted to the above range. become a thing. When the surface free energy is within the above range, the release film according to the present embodiment can easily exhibit better release properties with respect to the molded ceramic green sheet.
- the method for measuring the surface free energy is as shown in the test examples described later.
- the thickness of the release agent layer is preferably 0.02 ⁇ m or more, particularly preferably 0.03 ⁇ m or more, and further preferably 0.04 ⁇ m or more. This makes it easier to cure the release agent layer well, and along with that, it becomes easier to achieve the desired release properties.
- the thickness is preferably 0.5 ⁇ m or less, particularly preferably 0.4 ⁇ m or less, further preferably 0.3 ⁇ m or less.
- the arithmetic mean roughness (Ra) of the release surface is preferably 50 nm or less, particularly preferably 40 nm or less, and further It is preferably 30 nm or less.
- the lower limit of the arithmetic mean roughness (Ra) is not particularly limited, and may be, for example, 1 nm or more, particularly 3 nm or more, or even 5 nm or more.
- the maximum protrusion height (Rp) of the release surface is preferably 1000 nm or less, particularly preferably 700 nm or less, and further preferably 500 nm or less.
- the lower limit of the maximum protrusion height (Rp) is not particularly limited, and may be, for example, 10 nm or more, particularly 30 nm or more, or even 50 nm or more.
- the release force required to release the release film from the ceramic green sheet formed on the release surface is preferably 20 mN/50 mm or less, particularly 18 mN/50 mm or less. is preferable, and more preferably 15 mN/50 mm or less.
- the release film according to the present embodiment by including the amino resin (A) and the hydroxyl group-containing acrylic resin (B) as main components in the release agent layer, compared with the case where only the amino resin (A) is the main component As a result, the polyorganosiloxane (C) tends to segregate on the surface, and as a result, it is possible to exhibit light release properties with a small amount of polyorganosiloxane (C), and the peel strength can be easily set to a low level as described above. be able to.
- the lower limit of the peel force is not particularly limited, but in order to prevent unintended peeling of the ceramic green sheet, it is preferably 5 mN/50 mm or more, particularly preferably 8 mN/50 mm or more, and further preferably 10 mN/50 mm. It is preferable that it is above.
- the details of the method for measuring the peel force described above are as described in the test examples described later.
- the production method of the release film in the present embodiment is not particularly limited as long as it includes forming a release agent layer from the release agent composition described above. For example, after coating one side of the substrate with a coating liquid containing the aforementioned release agent composition and optionally an organic solvent, the resulting coating film is dried and heated to cure the release agent composition. to form a release agent layer, thereby obtaining a release film.
- Specific coating methods described above include, for example, gravure coating, bar coating, spray coating, spin coating, knife coating, roll coating, and die coating.
- the organic solvent is not particularly limited, and various solvents can be used.
- hydrocarbon compounds such as toluene, hexane and heptane, isopropyl alcohol, isobutyl alcohol, acetone, ethyl acetate, methyl ethyl ketone, methyl isobutyl ketone and mixtures thereof are used.
- the release agent composition coated as described above is preferably heat-cured.
- the heating temperature in this case is preferably 100° C. or higher, particularly preferably 110° C. or higher. Moreover, the heating temperature is preferably 150° C. or lower, particularly preferably 140° C. or lower.
- the heating time for thermosetting is preferably 10 seconds or longer, and particularly preferably 15 seconds or longer. Also, the heating time is preferably 120 seconds or less, particularly preferably 90 seconds or less.
- the release film in the present embodiment is preferably used for manufacturing a ceramic green sheet.
- a ceramic slurry containing a ceramic material such as barium titanate or titanium oxide is applied to the release surface of the release agent layer.
- the above coating can be performed using, for example, a slot die coating method, a doctor blade method, or the like.
- binder components contained in the ceramic slurry include butyral-based resins and acrylic-based resins.
- solvents contained in the ceramic slurry include organic solvents and aqueous solvents.
- a ceramic green sheet can be formed by drying the applied ceramic slurry after applying the slurry to the release surface. After molding the ceramic green sheets, the ceramic green sheets are separated from the release film.
- the release agent layer is formed from a release agent composition optionally containing an amino resin (A), a hydroxyl group-containing acrylic resin (B), a polyorganosiloxane (C), and other materials. Because of this, the release film has excellent releasability from the ceramic green sheet. Therefore, the ceramic green sheet can be peeled off with an appropriate peeling force without causing cracks, breakage, or the like.
- the amount of polyorganosiloxane (C) used can be reduced, so that the amount of silicone component transferred to the ceramic green sheet can be reduced.
- another layer may be provided on the surface of the substrate opposite to the release agent layer, or between the substrate and the release agent layer.
- Methylated melamine resin manufactured by Nippon Carbide Co., Ltd., product name "MW-30", weight average molecular weight: 508 as an amino resin (A) 75 parts by mass (solid content conversion value, the same applies hereinafter), and a hydroxyl group-containing acrylic resin ( 25 parts by mass of a hydroxyl group-containing acrylic resin (B1) (manufactured by DIC, product name “Acrydic A-807-BA)” as B), and both terminal carbinol-modified polydimethylsiloxane (C1) as polyorganosiloxane (C) ; manufactured by Shin-Etsu Chemical Co., Ltd., product name "KF-6001", weight average molecular weight: 2400) 2 parts by mass, a mixed solvent of isopropyl alcohol, methyl ethyl ketone and cyclohexanone (mixing ratio is isopropyl alcohol: methyl ethyl ket
- a biaxially stretched polyethylene terephthalate film (thickness: 31 ⁇ m) was prepared as a base material.
- the substrate had an arithmetic average roughness (Ra) of 24 nm and a maximum protrusion height (Rp) of 451 nm on one surface (hereinafter sometimes referred to as "first surface”).
- the substrate had an arithmetic average roughness (Ra) of 25 nm and a maximum protrusion height (Rp) of 465 nm on the other surface (hereinafter sometimes referred to as "second surface”).
- the coating liquid of the release agent composition obtained as described above was applied onto the first surface of the substrate using a bar coater, and the resulting coating film was heated at 125°C for 30 seconds. It was dried and cured to form a release agent layer. As a result, a release film having a release agent layer laminated on one side of the substrate was obtained.
- the thickness of the release agent layer of the release film was 0.07 ⁇ m when measured as described in Test Example 2 described later.
- Example 2 A release film was obtained in the same manner as in Example 1, except that the amount of the amino resin (A) was changed to 50 parts by mass and the amount of the hydroxyl group-containing acrylic resin (B) was changed to 50 parts by mass.
- Example 3 A release film was obtained in the same manner as in Example 1, except that the hydroxyl-containing acrylic resin (B) was changed to the hydroxyl-containing acrylic resin (B2) (manufactured by DIC, product name: "Acrydic WMU-504").
- Example 4 A release film was obtained in the same manner as in Example 1, except that the hydroxyl-containing acrylic resin (B) was changed to the hydroxyl-containing acrylic resin (B3) (manufactured by DIC, product name: "Acrydic WAU-139").
- Example 5 The procedure of Example 1 was repeated except that polyorganosiloxane (C) was changed to carbinol-modified polydimethylsiloxane (C2; manufactured by Shin-Etsu Chemical Co., Ltd., product name "KF-6002", weight average molecular weight: 4600). to obtain a release film.
- Example 6 The procedure of Example 1 was repeated except that polyorganosiloxane (C) was changed to carbinol-modified polydimethylsiloxane (C3; manufactured by Shin-Etsu Chemical Co., Ltd., product name "KF-6003", weight average molecular weight: 8000). to obtain a release film.
- Example 7 Example 1, except that the polyorganosiloxane (C) was changed to a side chain carbinol-modified polydimethylsiloxane (C4; manufactured by Shin-Etsu Chemical Co., Ltd., product name “X-22-4039”, weight average molecular weight: 5300). A release film was obtained in the same manner.
- Example 8 A release film was obtained in the same manner as in Example 1, except that the amount of polyorganosiloxane (C) was changed to 4 parts by mass.
- Methylated melamine resin (manufactured by Nippon Carbide Co., Ltd., product name "MW-30", weight average molecular weight: 508) 75 parts by mass as amino resin (A), and hydroxyl group-containing acrylic resin (B) as hydroxyl group-containing acrylic resin ( B1) 25 parts by mass (manufactured by DIC, product name “Acrydic A-807-BA)” and both end carbinol-modified polydimethylsiloxane (C1; manufactured by Shin-Etsu Chemical Co., Ltd., product name) as polyorganosiloxane (C) "KF-6001", weight average molecular weight: 2400) 2.2 parts by mass, alkoxysilane hydrolysis polycondensate (E) (E1; manufactured by Colcoat Co., product name "N-103X”) 10 parts by mass, It was diluted with a mixed solvent of isopropyl alcohol, methyl ethyl ketone and
- Example 10 A release film was obtained in the same manner as in Example 9, except that the alkoxysilane hydrolysis polycondensate (E) was changed to "PS-903" (E2) manufactured by Colcoat.
- Methylated melamine resin (manufactured by Nippon Carbide Co., Ltd., product name "MW-30", weight average molecular weight: 508) 75 parts by mass as amino resin (A), and hydroxyl group-containing acrylic resin (B) as hydroxyl group-containing acrylic resin ( B1) 25 parts by mass (manufactured by DIC, product name “Acrydic A-807-BA)” and both end carbinol-modified polydimethylsiloxane (C1; manufactured by Shin-Etsu Chemical Co., Ltd., product name) as polyorganosiloxane (C) "KF-6001", weight average molecular weight: 2400) 2.2 parts by mass, and ethylene glycol as a polyol compound (F) (F1; manufactured by Nippon Shokubai Co., Ltd., product name "(mono) ethylene glycol", molecular weight: 62) 10 parts by mass was diluted with a mixed solvent of isoprop
- Example 12 A release film was obtained in the same manner as in Example 11 except that the polyol compound (F) was changed to propylene glycol (F2; manufactured by Sankyo Chemical Co., Ltd., product name "propylene glycol", molecular weight: 76).
- Example 13 A release film was obtained in the same manner as in Example 11, except that the amount of polyorganosiloxane (C) was changed to 4.4 parts by mass.
- Methylated melamine resin (manufactured by Nippon Carbide Co., Ltd., product name "MW-30", weight average molecular weight: 508) 75 parts by mass as amino resin (A), and hydroxyl group-containing acrylic resin (B) as hydroxyl group-containing acrylic resin ( B1) 25 parts by mass (manufactured by DIC, product name “Acrydic A-807-BA)” and both end carbinol-modified polydimethylsiloxane (C1; manufactured by Shin-Etsu Chemical Co., Ltd., product name) as polyorganosiloxane (C) "KF-6001", weight average molecular weight: 2400) 2.4 parts by mass, alkoxysilane hydrolysis polycondensate (E) (E1; manufactured by Colcoat Co., product name "N-103X”) 10 parts by mass, and polyol 10 parts by mass of ethylene glycol (F1; manufactured by Nippon Shokubai Co., Ltd., product name “
- Example 15 A release film was obtained in the same manner as in Example 1, except that the thickness of the release agent layer was changed to 0.04 ⁇ m.
- the substrate has an arithmetic average roughness (Ra) of 13 nm on the first surface, a maximum protrusion height (Rp) of 210 nm, and an arithmetic average roughness (Ra) on the second surface of 13 nm,
- Ra arithmetic average roughness
- Rp maximum protrusion height
- Ra arithmetic average roughness
- the substrate has an arithmetic average roughness (Ra) of 7 nm on the first surface, a maximum protrusion height (Rp) of 70 nm, and an arithmetic average roughness (Ra) of the second surface of 28 nm,
- Ra arithmetic average roughness
- Rp maximum protrusion height
- Ra arithmetic average roughness
- Example 1 A release film was obtained in the same manner as in Example 1, except that the hydroxyl group-containing acrylic resin (B) was not blended.
- Comparative Example 3 The procedure was the same as in Comparative Example 2, except that polyorganosiloxane (C) was changed to carbinol-modified polydimethylsiloxane (C3; manufactured by Shin-Etsu Chemical Co., Ltd., product name "KF-6003", weight average molecular weight: 8000). to obtain a release film.
- thermosetting addition reaction type silicone resin manufactured by Shin-Etsu Chemical Co., Ltd., product name “KS-847H”
- a platinum catalyst manufactured by Shin-Etsu Chemical Co., Ltd., product name “CAT-PL- 50T” was added and mixed to obtain a coating liquid of a release agent composition having a solid content concentration of 1.5% by mass.
- the obtained coating liquid was applied on the first surface of the same substrate as in Example 1 using a bar coater, and the obtained coating film was heated at 125° C. for 30 seconds to dry and cure. , to form a release agent layer. As a result, a release film having a release agent layer laminated on one side of the substrate was obtained.
- the thickness of the release agent layer of the release film was 0.09 ⁇ m when measured as described in Test Example 2 below.
- the guide roll of the device was arranged with a space of 500 mm (test piece length) or more between itself and the floor, the roll axis was parallel to the floor, and it was locked without rotating with respect to the device.
- the surface of the prepared base film on which the release agent was to be applied was directed to the guide roll, and the surface opposite to the side to which the release agent was to be applied was directed outward, and the base film was adhered and fixed to the roll side surface of the guide roll.
- the release films obtained in Examples and Comparative Examples were cut into a size of 100 mm in width and 500 mm in length. Thus, a test piece for chargeability measurement was obtained. Then, after neutralizing the test piece using a static elimination brush, the test piece was charged using a static meter (manufactured by Kasuga Denki Co., Ltd., product name “KSD-1000”, measurement mode: High). (range of -2 kV to +2 kV).
- test piece which was confirmed to be not charged, was passed over a guide roll covered with a base film while holding one end to which no weight was attached by hand, and the test piece was rotated with respect to the guide roll. It was balanced with a hand holding one end of the specimen so that it would not move.
- the charge amount (kV) of the test piece removed from the guide roll was measured using the static electricity meter. Based on the value of the charge amount, the chargeability during feeding was evaluated according to the following criteria. Table 2 shows the results. A: The absolute value of the charge amount was 20 kV or less. B: The absolute value of the charge amount was over 20 kV and 25 kV or less. C: The absolute value of the charge amount was over 25 kV.
- the ceramic slurry was applied to the release surfaces of the release films obtained in Examples and Comparative Examples using a die coater over a width of 250 mm and a length of 10 m, and then dried in a dryer at 80°C for 1 minute. . Thus, a ceramic green sheet having a thickness of 3 ⁇ m was formed on the release film.
- the laminate of the ceramic green sheet and the release film obtained as described above was illuminated with a fluorescent lamp from the release film side, and the degree of repelling at both ends of the ceramic green sheet was visually confirmed. was used to evaluate the slurry coatability.
- the results are shown in Table 2 as slurry coatability in the production of "thin film (3 ⁇ m)" ceramic green sheets. A... Repellency was not confirmed. B: Slight (less than 0.5 mm) cissing was confirmed. C: Repelling of 0.5 mm or more was confirmed.
- the barium titanate powder which is the material of the ceramic slurry, was changed to the product name "BT-02" (average particle size: 200 nm) manufactured by Sakai Chemical Industry Co., Ltd., and the thickness of the ceramic green sheet to be formed was changed to 1 ⁇ m.
- Slurry coatability was evaluated in the same manner as above, except for the change. The results are also shown in Table 2 as slurry coatability in the production of "ultrathin (1 ⁇ m)" ceramic green sheets.
- the acrylic pressure-sensitive adhesive tape was peeled off from the release film at a peel angle of 180° and a peel speed of 300 mm/min, and the force (peeling force; mN/20 mm) required for peeling was measured. Table 2 shows the results.
- Test Example 9 (Measurement of peel strength against ceramic green sheet) A ceramic green sheet "extremely thin (1 ⁇ m)" was formed on the release surface of the release film by the same procedure as in Test Example 7. The obtained laminate of the ceramic green sheet and release film was allowed to stand in an atmosphere of 23° C. and 50% RH for 24 hours, and then cut into a width of 20 mm to obtain a measurement sample.
- the surface of the measurement sample on the ceramic green sheet side is attached and fixed to a flat plate, and a tensile tester (manufactured by Shimadzu Corporation, product name "AG-IS500N”) is used at a peel angle of 90 ° and a peel speed of 300 mm / min.
- the release film was peeled off from the ceramic green sheet, and the force (peeling force; mN/50 mm) required for peeling was measured. Table 2 shows the results.
- Test Example 10 Evaluation of adhesion between ceramic green sheets
- a ceramic green sheet "thin film (3 ⁇ m)" was formed on the release surface of the release film by the same procedure as in Test Example 7.
- the two ceramic green sheets thus obtained were stacked so that the surface of the green sheet that was in contact with the release agent layer and the surface of the green sheet that was not in contact with the release agent layer were put together, and the pressure was 50 kg/cm 2 and 50°C. After applying pressure (pressurized area: 25 cm 2 ) under the conditions of , the state of the interface between the two ceramic green sheets was visually observed through the release film. Then, the adhesion between the ceramic green sheets was evaluated based on the following criteria.
- A The ceramic sheets were in close contact with each other by 50% or more of the pressurized area.
- C The ceramic sheets adhered to each other less than 30% of the pressurized area.
- PVB resin solution was obtained.
- This PVB resin solution was uniformly applied to the release surfaces of the release films obtained in Examples and Comparative Examples using a 35 ⁇ m applicator, and then dried in a dryer at 60° C. for 1 minute. As a result, a release film laminated with PVB resin sheets having a thickness of 4 ⁇ m was obtained.
- Silicon atoms (Si) and carbon atoms measured by X-ray photoelectron spectroscopy (XPS) on the surface of the PVB resin sheet that was in contact with the release surface of the release film after peeling the release film from the PVB resin sheet Based on (C) and the amount of oxygen atoms (O) (XPS count number), the silicon atom ratio (atomic %) was calculated by the following formula. Table 2 shows the results. Silicon atomic ratio (atomic %) [(Si element amount) / ⁇ (C element amount) + (O element amount) + (Si element amount) ⁇ ] ⁇ 100
- the silicone migration property was evaluated according to the following criteria.
- Table 2 shows the results.
- the silicon atomic ratio is 0 If the amount is 5 atomic % or more, pinholes may occur during slurry coating, or lamination deviation may occur in the process of laminating the ceramic green sheets, resulting in defective laminated ceramic products.
- the release films obtained in Examples had a low release force against the ceramic green sheet and a small amount of migration of the silicone component.
- the release films obtained in the examples had good performance in terms of slurry coatability, release agent layer curability, release surface smoothness (surface roughness), handling properties, and blocking resistance. I found out.
- the release film for the ceramic green sheet manufacturing process of the present invention is suitable for molding ceramic green sheets.
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Abstract
Description
本実施形態に係るセラミックグリーンシート製造工程用剥離フィルム(以下単に「剥離フィルム」という場合がある。)は、基材と、当該基材の片面側に設けられた剥離剤層とを備えて構成される。なお、剥離剤層における基材とは反対側の面を、以下「剥離面」という場合がある。
本実施形態における基材は、剥離剤層を積層することができる限り、特に限定されない。かかる基材としては、例えば、ポリエチレンテレフタレートやポリエチレンナフタレート等のポリエステル、ポリプロピレンやポリメチルペンテン等のポリオレフィン、ポリカーボネート、ポリ酢酸ビニルなどのプラスチックからなるフィルムが挙げられ、単層であってもよいし、同種または異種の2層以上の多層であってもよい。これらの中でもポリエステルフィルムが好ましく、特にポリエチレンテレフタレートフィルムが好ましく、さらには二軸延伸ポリエチレンテレフタレートフィルムが好ましい。ポリエチレンテレフタレートフィルムは、加工時、使用時等において、埃等が発生しにくいため、例えば、埃等によるセラミックスラリー塗工不良等を効果的に防止することができる。
本実施形態における剥離剤層は、アミノ樹脂(A)と、水酸基含有アクリル樹脂(B)と、ポリオルガノシロキサン(C)と、酸触媒(D)とを含有する剥離剤組成物から形成されたものである。
本実施形態に係る剥離フィルムおいて、剥離剤組成物はアミノ樹脂(A)を含有する。剥離剤組成物から剥離剤層を形成する際、アミノ樹脂(A)は酸触媒(D)の存在下で縮合反応を行うため、得られる剥離剤層中には、アミノ樹脂(A)による三次元構造が形成される。また、アミノ樹脂(A)は水酸基とも反応するため、水酸基含有アクリル樹脂(B)とも反応し、上記三次元構造にはアクリル樹脂(B)も組み込まれる。上記の反応は、例えば加熱することにより生じさせることができる。剥離剤層は、上述した三次元構造を含むため、十分な弾性を示すものとなり、これにより、本実施形態に係る剥離フィルムは優れた剥離性を発揮することができる。なお、本明細書においては、「アミノ樹脂」という語句は、縮合反応を生じ得る成分を指し、必ずしも高分子化合物でなくてもよい。ここにおいて、当該成分は、全く縮合反応を生じていないものであってもよく、または部分的に縮合反応が生じたものであってもよい。
本実施形態に係る剥離フィルムおいて、剥離剤組成物は水酸基含有アクリル樹脂(B)を含有する。
本実施形態に係る剥離フィルムおいて、剥離剤組成物はポリオルガノシロキサン(C)を含有する。剥離剤組成物がポリオルガノシロキサン(C)を含有することにより、形成される剥離剤層の表面自由エネルギーが適度に低下したものとなる。これにより、剥離フィルムの剥離面上に成形されたセラミックグリーンシートから剥離フィルムを剥離する際の剥離力が適度に低下し、良好な剥離性が達成される。前述した通り、本実施形態では、ポリオルガノシロキサン(C)を少量にしても良好な剥離性を達成することができるため、セラミックグリーンシートに対するシリコーン成分の移行抑制を図ることができる。
本実施形態に係る剥離フィルムにおいて、剥離剤組成物は酸触媒(D)を含有する。剥離剤組成物が酸触媒(D)を含むことにより、アミノ樹脂(A)同士、水酸基含有アクリル樹脂(B)同士、アミノ樹脂(A)と水酸基含有アクリル樹脂(B)、およびポリオルガノシロキサン(C)と後述するアルコキシシラン加水分解重縮合物(E)との間の反応が効率的に進行し、十分な弾性を示す剥離剤層が形成される。
本実施形態に係る剥離フィルムにおいて、剥離剤組成物は、シロキサン結合(Si-O-Si)を骨格として有するアルコキシシラン加水分解重縮合物(E)を含有することも好ましい。剥離剤組成物が当該アルコキシシラン加水分解重縮合物(E)を含有すると、アルコキシシラン加水分解重縮合物(E)が水酸基含有アクリル樹脂(B)および水酸基を含有するポリオルガノシロキサン(C)と反応することで、更に硬い被膜を形成し、セラミックグリーンシートに対して軽剥離性をより発揮し易くなる。また、シリコーン成分の移行抑制効果がより優れたものとなる。
剥離剤組成物は、上記成分の他、ポリオール化合物(F)、分散剤、架橋剤、反応抑制剤、密着向上剤、滑り剤等のその他の成分を含有してもよい。
本実施形態に係る剥離フィルムでは、剥離剤層の剥離面の表面自由エネルギーが、17mJ/m2以上であることが好ましく、特に19mJ/m2以上であることが好ましく、さらには21mJ/m2以上であることが好ましい。また、当該表面自由エネルギーは、40mJ/m2以下であることが好ましく、特に35mJ/m2以下であることが好ましく、さらには30mJ/m2以下であることが好ましい。本実施形態に係る剥離フィルムでは、剥離剤層が、前述した成分を含有する剥離剤組成物により形成されたものであることにより、剥離面における表面自由エネルギーを上述のような範囲に調整し易いものとなる。そして、表面自由エネルギーが上記範囲であることで、本実施形態に係る剥離フィルムが、成形されるセラミックグリーンシートに対してより良好な剥離性を発揮し易いものとなる。なお、表面自由エネルギーの測定方法は、後述する試験例に示すとおりである。
本実施形態に係る剥離フィルムでは、剥離面の算術平均粗さ(Ra)が、50nm以下であることが好ましく、特に40nm以下であることが好ましく、さらには30nm以下であることが好ましい。これにより、剥離面が優れた平滑性を有するものとなり、成形されるセラミックグリーンシートにおけるピンホールや厚みむら等の欠陥の発生を効果的に抑制することができる。なお、上記算術平均粗さ(Ra)の下限値については特に限定されず、例えば、1nm以上であってもよく、特に3nm以上であってもよく、さらには5nm以上であってもよい。
本実施形態における剥離フィルムの製造方法は、前述した剥離剤組成物から剥離剤層を形成することを含む限り、特に制限されない。例えば、基材の一方の面に、前述した剥離剤組成物および所望により有機溶剤を含有する塗布液を塗工した後、得られた塗膜を乾燥および加熱することで剥離剤組成物を硬化させて剥離剤層を形成し、これにより剥離フィルムを得ることが好ましい。
本実施形態における剥離フィルムは、セラミックグリーンシートを製造するために使用することが好ましい。この場合、最初に、剥離剤層の剥離面に対し、チタン酸バリウムや酸化チタンなどのセラミック材料を含有するセラミックスラリーを塗工する。
アミノ樹脂(A)としてのメチル化メラミン樹脂(日本カーバイド社製,製品名「MW-30」,重量平均分子量:508)75質量部(固形分換算値,以下同じ)と、水酸基含有アクリル樹脂(B)としての水酸基含有アクリル樹脂(B1)(DIC社製,製品名「アクリディックA-807-BA)25質量部と、ポリオルガノシロキサン(C)としての両末端カルビノール変性ポリジメチルシロキサン(C1;信越化学工業社製,製品名「KF-6001」,重量平均分子量:2400)2質量部とを、イソプロピルアルコールとメチルエチルケトンとシクロヘキサノンとの混合溶媒(混合比は、イソプロピルアルコール:メチルエチルケトン:シクロヘキサノン=40:40:20)で希釈した。この希釈液に、酸触媒(D)としてのpートルエンスルホン酸(信越化学工業社製,製品名「PS-80」)4質量部を希釈して添加し、均一に撹拌することで、固形分濃度1.8質量%の剥離剤組成物の塗布液を得た。
アミノ樹脂(A)の配合量を50質量部、水酸基含有アクリル樹脂(B)の配合量を50質量部に変更する以外は、実施例1と同様にして剥離フィルムを得た。
水酸基含有アクリル樹脂(B)を水酸基含有アクリル樹脂(B2)(DIC社製,製品名「アクリディックWMU-504」)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
水酸基含有アクリル樹脂(B)を水酸基含有アクリル樹脂(B3)(DIC社製,製品名「アクリディックWAU-139」)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)を両末端カルビノール変性ポリジメチルシロキサン(C2;信越化学工業社製,製品名「KF-6002」,重量平均分子量:4600)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)を両末端カルビノール変性ポリジメチルシロキサン(C3;信越化学工業社製,製品名「KF-6003」,重量平均分子量:8000)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)を側鎖カルビノール変性ポリジメチルシロキサン(C4;信越化学工業社製,製品名「X-22-4039」,重量平均分子量:5300)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)の配合量を4質量部に変更する以外は、実施例1と同様にして剥離フィルムを得た。
アミノ樹脂(A)としてのメチル化メラミン樹脂(日本カーバイド社製,製品名「MW-30」,重量平均分子量:508)75質量部と、水酸基含有アクリル樹脂(B)としての水酸基含有アクリル樹脂(B1)(DIC社製,製品名「アクリディックA-807-BA)25質量部と、ポリオルガノシロキサン(C)としての両末端カルビノール変性ポリジメチルシロキサン(C1;信越化学工業社製,製品名「KF-6001」,重量平均分子量:2400)2.2質量部と、アルコキシシラン加水分解重縮合物(E)(E1;コルコート社製,製品名「N-103X」)10質量部とを、イソプロピルアルコールとメチルエチルケトンとシクロヘキサノンとの混合溶媒(混合比は、イソプロピルアルコール:メチルエチルケトン:シクロヘキサノン=40:40:20)で希釈した。この希釈液に、酸触媒(D)としてのp-トルエンスルホン酸(信越化学工業社製,製品名「PS-80」)4.4質量部を希釈して添加し、均一に撹拌することで、固形分濃度1.8質量%の剥離剤組成物の塗布液を得た。当該塗布液を使用する以外は、実施例1と同様にして、剥離フィルムを得た。
アルコキシシラン加水分解重縮合物(E)をコルコート社製の「PS-903」(E2)に変更する以外は、実施例9と同様にして剥離フィルムを得た。
アミノ樹脂(A)としてのメチル化メラミン樹脂(日本カーバイド社製,製品名「MW-30」,重量平均分子量:508)75質量部と、水酸基含有アクリル樹脂(B)としての水酸基含有アクリル樹脂(B1)(DIC社製,製品名「アクリディックA-807-BA)25質量部と、ポリオルガノシロキサン(C)としての両末端カルビノール変性ポリジメチルシロキサン(C1;信越化学工業社製,製品名「KF-6001」,重量平均分子量:2400)2.2質量部と、ポリオール化合物(F)としてのエチレングリコール(F1;日本触媒社製,製品名「(モノ)エチレングリコール」,分子量:62)10質量部とを、イソプロピルアルコールとメチルエチルケトンとシクロヘキサノンとの混合溶媒(混合比は、イソプロピルアルコール:メチルエチルケトン:シクロヘキサノン=40:40:20)で希釈した。この希釈液に、酸触媒(D)としてのpートルエンスルホン酸(信越化学工業社製,製品名「PS-80」)4.4質量部を希釈して添加し、均一に撹拌することで、固形分濃度1.8質量%の剥離剤組成物の塗布液を得た。当該塗布液を使用する以外は、実施例1と同様にして、剥離フィルムを得た。
ポリオール化合物(F)をプロピレングリコール(F2;三協化学社製,製品名「プロピレングリコール」,分子量:76)に変更する以外は、実施例11と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)の配合量を4.4質量部に変更する以外は、実施例11と同様にして剥離フィルムを得た。
アミノ樹脂(A)としてのメチル化メラミン樹脂(日本カーバイド社製,製品名「MW-30」,重量平均分子量:508)75質量部と、水酸基含有アクリル樹脂(B)としての水酸基含有アクリル樹脂(B1)(DIC社製,製品名「アクリディックA-807-BA)25質量部と、ポリオルガノシロキサン(C)としての両末端カルビノール変性ポリジメチルシロキサン(C1;信越化学工業社製,製品名「KF-6001」,重量平均分子量:2400)2.4質量部と、アルコキシシラン加水分解重縮合物(E)(E1;コルコート社製,製品名「N-103X」)10質量部と、ポリオール化合物(F)としてのエチレングリコール(F1;日本触媒社製,製品名「(モノ)エチレングリコール」,分子量:62)10質量部とを、イソプロピルアルコールとメチルエチルケトンとシクロヘキサノンとの混合溶媒(混合比は、イソプロピルアルコール:メチルエチルケトン:シクロヘキサノン=40:40:20)で希釈した。この希釈液に、酸触媒(D)としてのpートルエンスルホン酸(信越化学工業社製,製品名「PS-80」)4.8質量部を希釈して添加し、均一に撹拌することで、固形分濃度1.8質量%の剥離剤組成物の塗布液を得た。当該塗布液を使用する以外は、実施例1と同様にして、剥離フィルムを得た。
剥離剤層の厚さを0.04μmに変更する以外は、実施例1と同様にして剥離フィルムを得た。
基材を、第1の面の算術平均粗さ(Ra)が13nmであり、最大突起高さ(Rp)が210nmであり、第2の面の算術平均粗さ(Ra)が13nmであり、最大突起高さ(Rp)が224nmである二軸延伸ポリエチレンテレフタレートフィルム(厚さ:31μm)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
基材を、第1の面の算術平均粗さ(Ra)が7nmであり、最大突起高さ(Rp)が70nmであり、第2の面の算術平均粗さ(Ra)が28nmであり、最大突起高さ(Rp)が498nmである二軸延伸ポリエチレンテレフタレートフィルム(厚さ:31μm)に変更する以外は、実施例1と同様にして剥離フィルムを得た。
水酸基含有アクリル樹脂(B)を配合しない以外は、実施例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)の配合量を4質量部に変更する以外は、比較例1と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)を両末端カルビノール変性ポリジメチルシロキサン(C3;信越化学工業社製,製品名「KF-6003」,重量平均分子量:8000)に変更する以外は、比較例2と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)を側鎖カルビノール変性ポリジメチルシロキサン(C4;信越化学工業社製,製品名「X-22-4039」,重量平均分子量:5300)に変更する以外は、比較例2と同様にして剥離フィルムを得た。
ポリオルガノシロキサン(C)の配合量を15質量部に変更する以外は、比較例3と同様にして剥離フィルムを得た。
熱硬化付加反応型シリコーン樹脂(信越化学工業社製,製品名「KS-847H」)100質量部をトルエンで希釈した後、さらに白金触媒(信越化 学工業社製,製品名「CAT-PL-50T」)2質量部を添加・混合し、固形分濃度が1.5質量%である剥離剤組成物の塗布液を得た。
実施例で使用したアミノ樹脂(A)および水酸基含有アクリル樹脂(B)のそれぞれを酢酸エチルで固形分60質量%になるように希釈した液2gに対して、希釈していないポリオルガノシロキサン(C)0.02gをそれぞれに混合した。それら混合液の外観変化を目視で確認し、以下の基準にて剥離剤組成物の相溶性を評価した。結果を表2に示す。
A…アミノ樹脂(A)およびポリオルガノシロキサン(C)の混合液は透明であり、かつ水酸基含有アクリル樹脂(B)およびポリオルガノシロキサン(C)の混合液は白濁した。
B…アミノ樹脂(A)およびポリオルガノシロキサン(C)の混合液は白濁し、かつ水酸基含有アクリル樹脂(B)およびポリオルガノシロキサン(C)の混合液も白濁した。
C…上記A,B以外
実施例および比較例で得られた剥離フィルムの剥離剤層の厚さ(μm)を、分光エリプソメーター(J.A.Woollam社製,製品名「M-2000」)を使用して測定した。結果を表2に示す。
実施例および比較例で得られた剥離フィルムについて、メチルエチルケトンを含ませたウエス(小津産業社製,製品名「BEMCOT AP-2」)によって、剥離剤層の表面を荷重200g/cm2で往復10回研磨した。その後、剥離面を目視で観察し、以下の判断基準により剥離剤層の硬化性を評価した。結果を表2に示す。
A…剥離剤層の溶解・脱落がなかった。
B…剥離剤層の一部溶解が見られた。
C…剥離剤層が完全に溶解し、基材から脱落した。
実施例および比較例で得られた剥離フィルムについて、剥離剤層の剥離面に対する各種液滴の接触角を測定し、その値をもとに北崎・畑理論により、表面自由エネルギー(mJ/m2)を求めた。接触角は、接触角計(協和界面科学社製,製品名「DM-701」)を使用し、静滴法によってJIS R3257:1999に準じて測定した。液滴については、「分散成分」としてジヨードメタン、「双極子成分」として1-ブロモナフタレン、「水素結合成分」として蒸留水を使用した。結果を表2に示す。
実施例および比較例で得られた剥離フィルムの基材側の面を、両面粘着テープでガラス板に固定した後、剥離面における算術平均粗さ(Ra;nm)および最大突起高さ(Rp;nm)を、光干渉式表面形状観察装置(Vecco社製,製品名「WYKO-1100」)を使用して、PSIモードにて50倍率の条件にて測定した。なお、測定は、RaおよびRpについてそれぞれ10回行い、その平均値を剥離面のRaおよびRpとした。結果を表2に示す。
実施例および比較例で得られた剥離フィルムを用意するとともに、実施例および比較例のそれぞれで使用された基材と同じフィルム(以下「基材フィルム」という場合がある。)を用意した。
A…帯電量の絶対値が、20kV以下であった。
B…帯電量の絶対値が、20kV超、25kV以下であった。
C…帯電量の絶対値が、25kV超であった。
チタン酸バリウム粉末(BaTiO3;堺化学工業社製,製品名「BT-03」,平均粒子径:300nm)100質量部と、バインダーとしてのポリビニルブチラール樹脂(積水化学工業社製,製品名「エスレックB・K BM-2」)8質量部と、可塑剤としてのフタル酸ジオクチル(関東化学社製,製品名「フタル酸ジオクチル 鹿1級」)4質量部とを、トルエンおよびエタノールの混合液(質量比6:4)135質量部に添加し、ジルコニアビーズの存在下でボールミルにて混合して分散させた後、ビーズを除去することで、セラミックスラリーを調製した。
A…ハジキが確認されなかった。
B…僅か(0.5mm未満)なハジキが確認された。
C…0.5mm以上のハジキが確認された。
実施例および比較例で得られた剥離フィルムの剥離面に対し、アクリル粘着テープ(日東電工社製,製品名「31Bテープ」)を重さ2kgのローラーを使用し、1往復させて貼付した。その状態で、室温23度、湿度50%の雰囲気下に24時間静置した。次に、作製したサンプルの剥離フィルム側を両面粘着テープにより剛板に固定した。そして、引張試験機を用いて180°の剥離角度、300mm/分の剥離速度で剥離フィルムからアクリル粘着テープを剥離し、剥離するのに必要な力(剥離力;mN/20mm)を測定した。結果を表2に示す。
試験例7と同じ手順により剥離フィルムの剥離面上にセラミックグリーンシート「極薄(1μm)」を成形した。得られたセラミックグリーンシートと剥離フィルムとの積層体を、23℃、50%RHの雰囲気下に24時間静置した後、20mm幅に裁断し、これを測定サンプルとした。
試験例7と同じ手順により剥離フィルムの剥離面上にセラミックグリーンシート「薄膜(3μm)」を成形した。得られた2枚のセラミックグリーンシートを、剥離剤層と接触していたグリーンシート面と、剥離剤層と接触していないグリーンシート面とが合わさるように重ねて、50kg/cm2、50℃の条件で加圧(加圧面積:25cm2)した後、剥離フィルムを通して、2枚のセラミックグリーンシートの界面の状態を目視観察した。そして、以下の基準に基づき、セラミックグリーンシート同士の密着性を評価した。
A…セラミックシート同士が加圧面積の50%以上密着していた。
B…セラミックシート同士が加圧面積の30%以上50%未満密着していた。
C…セラミックシート同士が加圧面積の30%未満密着していた。
実施例および比較例で得られた剥離フィルムをロール状にする際のハンドリング性について評価した。具体的には、400mm幅、2000mの剥離フィルムを、外径3インチのABS樹脂コアに、巻き取り張力15kg/m、巻き取り速度150m/minで巻き取った。その巻き取り工程において、接触した剥離フィルム同士の滑り性、ロール状にする際の空気抜けの良さ、および剥離フィルムの巻きズレの生じ難さについて、以下の判断基準により評価した。結果を表2に示す。
A…接触した剥離フィルム同士の滑り性が良く、かつ剥離フィルムをロール状にするときの空気抜けが良く、剥離フィルムの巻きズレを防止できた。
B…接触した剥離フィルム同士の滑り性が若干悪く、かつ剥離フィルムをロール状に巻いたときの空気の抜けが若干悪く、巻きズレが若干生じるものの支障はなかった。
C…接触した剥離フィルム同士の滑り性が悪く、かつ剥離フィルムをロール状に巻いたときの空気の抜けが悪く、巻きズレが顕著に生じた。
実施例および比較例で得られた剥離フィルムを、幅400mm、長さ5000mのロール状に巻き上げた。この剥離フィルムロールを23±5℃、湿度50±10%の環境下に30日間保管した。その後、剥離フィルムロールから剥離フィルムを繰り出そうとしたときの様子について、以下の判断基準により耐ブロッキング性を評価した。結果を表2に示す。
A…ブロッキングが全く発生しておらず、剥離フィルムを良好に繰り出すことができた。
B…ブロッキングが生じている傾向にあったものの、剥離フィルムを繰り出すことができた。
C…ブロッキングが生じていることにより、剥離フィルムを繰り出すことができなかった。
ポリビニルブチラール(PVB)系バインダー樹脂(積水化学社製,製品名:「BL-S」)を、トルエンとエタノールとの混合溶媒(混合比50:50)にて希釈し、固形分濃度20質量%のPVB樹脂溶液を得た。このPVB樹脂溶液を、実施例および比較例で得られた剥離フィルムの剥離面に35μmアプリケーターを用いて均一に塗工し、その後、乾燥機にて60℃で1分間乾燥させた。これにより、厚さ4μmのPVB樹脂シートが積層された剥離フィルムを得た。
ケイ素原子比率(原子%)=[(Si元素量)/{(C元素量)+(O元素量)+(Si元素量)}]×100
A…ケイ素原子比率が0.5原子%未満
B…ケイ素原子比率が0.5原子%以上、1.0原子%未満
C…ケイ素原子比率が1.0原子%以上
なお、ケイ素原子比率が0.5原子%以上である場合、スラリー塗工時にピンホールが発生したり、セラミックグリーンシートを積層する工程で積層ズレが生じたりして、得られる積層セラミック製品において製品不良となるおそれがある。
[水酸基含有アクリル樹脂(B)]
B1:水酸基含有アクリル樹脂(DIC社製,製品名「アクリディックA-807-BA,水酸基価:22.0-27.0mgKOH/g,Tg:65℃,重量平均分子量:65000)
B2:水酸基含有アクリル樹脂(DIC社製,製品名「アクリディックWMU-504」,水酸基価:53.0-61.0mgKOH/g,Tg:60℃,重量平均分子量:9000)
B3:水酸基含有アクリル樹脂(DIC社製,製品名「アクリディックWAU-139」,水酸基価:47.0-53.0mgKOH/g,Tg:50℃,重量平均分子量:8000)
[ポリオルガノシロキサン(C)]
C1:両末端カルビノール変性ポリジメチルシロキサン
(信越化学工業社製,製品名「KF-6001」,重量平均分子量:2400)
C2:両末端カルビノール変性ポリジメチルシロキサン
(信越化学工業社製,製品名「KF-6002」,重量平均分子量:4600)
C3:両末端カルビノール変性ポリジメチルシロキサン
(信越化学工業社製,製品名「KF-6003」,重量平均分子量:8000)
C4:側鎖カルビノール変性ポリジメチルシロキサン
(信越化学工業社製 ,製品名「X-22-4039」,重量平均分子量:5300)
[アルコキシシラン加水分解重縮合物(E)]
E1:コルコート社製,製品名「N-103X」
E2:コルコート社製,製品名「PS-903」
[ポリオール化合物(F)]
F1:エチレングリコール(日本触媒社製,製品名「(モノ)エチレングリコール」,分子量:62)
F2:プロピレングリコール(三協化学社製,製品名「プロピレングリコール」,分子量:76)
Claims (12)
- 基材と、前記基材の片面側に設けられた剥離剤層とを備えたセラミックグリーンシート製造工程用剥離フィルムであって、
前記剥離剤層が、アミノ樹脂(A)と、水酸基含有アクリル樹脂(B)と、ポリオルガノシロキサン(C)と、酸触媒(D)とを含有する剥離剤組成物から形成された
ことを特徴とするセラミックグリーンシート製造工程用剥離フィルム。 - 前記剥離剤組成物中における前記水酸基含有アクリル樹脂(B)の含有量が、前記アミノ樹脂(A)100質量部に対して、5質量部以上、200質量部以下であることを特徴とする請求項1に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記ポリオルガノシロキサン(C)が、1分子中に少なくとも1個のヒドロキシ基を有することを特徴とする請求項1または2に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記ポリオルガノシロキサン(C)が、ポリエステル基、ポリエーテル基およびカルビノール基から選ばれる少なくとも1種の有機基を有することを特徴とする請求項1~3のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記ポリオルガノシロキサン(C)の重量平均分子量が、500以上、20000以下であることを特徴とする請求項1~4のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記剥離剤組成物中における前記ポリオルガノシロキサン(C)の含有量が、前記アミノ樹脂(A)および前記水酸基含有アクリル樹脂(B)の合計100質量部に対して、0.05質量部以上、10質量部以下であることを特徴とする請求項1~5のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記剥離剤組成物が、シロキサン結合(Si-O-Si)を骨格として有するアルコキシシラン加水分解重縮合物(E)を含有することを特徴とする請求項1~6のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記酸触媒(D)が、スルホン酸系触媒およびリン酸系触媒の少なくとも1種を含むことを特徴とする請求項1~7のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記剥離剤組成物が、分子量または重量平均分子量が50以上、10000以下のポリオール化合物(F)を含有することを特徴とする請求項1~8のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記剥離剤層の厚さが、0.02μm以上、0.5μm以下であることを特徴とする請求項1~9のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記基材における前記剥離剤層側の面の算術平均粗さ(Ra)が、1nm以上、50nm以下であり、前記面の最大突起高さ(Rp)が、10nm以上、1000nm以下であることを特徴とする請求項1~10のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
- 前記基材における前記剥離剤層と反対側の面の算術平均粗さ(Ra)が、10nm以上、50nm以下であり、前記面の最大突起高さ(Rp)が、100nm以上、1000nm以下であることを特徴とする請求項1~11のいずれか一項に記載のセラミックグリーンシート製造工程用剥離フィルム。
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JP2019166706A (ja) * | 2018-03-23 | 2019-10-03 | リンテック株式会社 | セラミックグリーンシート製造工程用剥離フィルム |
JP2020026135A (ja) * | 2018-08-10 | 2020-02-20 | 東洋紡株式会社 | セラミックグリーンシート製造用離型フィルム |
WO2020196223A1 (ja) * | 2019-03-26 | 2020-10-01 | リンテック株式会社 | 剥離シート |
WO2020203654A1 (ja) * | 2019-03-29 | 2020-10-08 | リンテック株式会社 | セラミックグリーンシート製造工程用剥離フィルム |
JP2020189945A (ja) * | 2019-05-23 | 2020-11-26 | 信越化学工業株式会社 | 剥離紙又は剥離フィルム用樹脂組成物、剥離紙及び剥離フィルム |
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