Filler-filled film, sheet film, stacked film, bonded body, and method for producing filler-filled film

Patent metadata

Field	Value
Publication number	US-10065380-B2
Application number	US-201515523212-A
Country	US
Kind code	B2
Filing date	Oct 28, 2015
Priority date	Oct 28, 2014
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

There is provided a filler-filled film, a sheet film, a stacked film, a bonded body, and a method for producing a filler-filled film, the filler-filled film including: a film main body; a plurality of concavities formed on a surface of the film main body; and a filler put in each of the concavities. A diameter of an opening surface of the concavity is at least larger than a visible light wavelength, an arrangement pattern of the concavities has periodicity along a length direction of the film main body, and the difference between the rate of filling of the fillers in one end portion of the film main body and the rate of filling of the fillers in another portion of the film main body is less than 0.5%.

First claim

The invention claimed is:

1. A filler-filled film comprising:
a film main body;
a plurality of concavities formed on a surface of the film main body; and
a filler put in each concavity of the plurality of concavities,
wherein a diameter of an opening surface of each concavity of the plurality of concavities is at least larger than a visible light wavelength,
wherein an arrangement pattern of the plurality of concavities has periodicity along a length direction of the film main body,
wherein a surface shape of each filler is different from a surface shape of the concavity in which the filler is put, and
wherein a difference between a rate of filling of the fillers in one end portion of the film main body and the rate of filling of the fillers in another portion of the film main body is less than 0.5%.

2. The filler-filled film according to claim 1 , wherein the film main body is a long-length film.

3. The filler-filled film according to claim 1 , wherein the rate of filling of the fillers has periodicity along the length direction of the film main body.

4. The filler-filled film according to claim 1 , wherein each concavity of the plurality of concavities has substantially the same shape.

5. The filler-filled film according to claim 1 , wherein the number of fillers put in per unit area of the film main body is 50,000,000/cm 2 or less.

6. The filler-filled film according to claim 1 , wherein the filler is integrated with the film main body in each concavity of the plurality of concavities.

7. The filler-filled film according to claim 1 , wherein the film main body is formed of a hardenable resin or a plastic resin.

8. The filler-filled film according to claim 1 , wherein a respective filler with a size corresponding to a respective concavity is put in each concavity of the plurality of concavities.

9. The filler-filled film according to claim 1 , wherein the filler has a spherical shape.

10. The filler-filled film according to claim 1 , wherein a difference between filler filling rates in places of 0.1%, 25%, 50%, 75%, and 100% of a full length of the filler-filled film is 0.1% or less.

11. The filler-filled film according to claim 1 , wherein the number of consecutive losses of the plurality of concavities in the length direction of the film main body is 10 or less.

12. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for printed electronics or a field of application of printed electronics.

13. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for medical treatment or bioscience.

14. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for health care.

15. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for life science.

16. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for an optical element.

17. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for a battery or an energy-related field.

18. The filler-filled film according to claim 1 , wherein the filler-filled film is a filler-filled film for a vehicle-related field.

19. A sheet film produced by cutting the filler-filled film according to claim 1 into a plurality of sheets.

20. A stacked film, wherein the film according to claim 1 is stacked.

21. The film according to claim 1 , comprising a sticky layer formed on a back surface of the film main body.

22. A bonded body comprising:
the film according to claim 1 ; and
a matrix to which the film is bonded.

23. The filler-filled film according to claim 1 , comprising a coating layer formed on at least part of a surface of the film main body.

24. The filler-filled film according to claim 23 , wherein the coating layer is formed on at least part of a surface of each concavity of the plurality of concavities, a surface of a convexity between ones of the plurality of concavities, and an exposed surface of the filler.

25. The filler-filled film according to claim 23 , wherein the coating layer contains an inorganic material.

26. The filler-filled film according to claim 23 , wherein the coating layer is formed on the entire surface of at least one surface of the film main body.

27. A method for producing a filler-filled film, comprising:
preparing a circular cylindrical or circular columnar master in which a plurality of convexities are formed on a peripheral surface;
producing a film main body by conveying a long-length transfer destination film by a roll-to-roll system and at the same time transferring a shape of the peripheral surface of the master to the transfer destination film; and
putting a filler in each concavity of a plurality of concavities formed on a surface of the film main body,
wherein a diameter of an opening surface of each concavity of the plurality of concavities is at least larger than a visible light wavelength,
wherein a surface shape of each filler is different from a surface shape of the concavity in which the filler is put, and
wherein a difference between a rate of filling of the fillers in one end portion of the film main body and the rate of filling of the fillers in another portion of the film main body is less than 0.5%.

Assignees

• Dexerials Corp

Inventors

• Muramoto Yutaka
• Kikuchi Masanao

Classifications

• H10W90/701

  characterised by the relative positions of pads or connectors relative to package parts · CPC title

• B32B2255/20

  Inorganic coating · CPC title

• B32B2255/10

  on synthetic resin layer or on natural or synthetic rubber layer · CPC title

• B32B3/085

  spaced apart pieces on the surface of a layer · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title