Adhesive sheet, and adhesive sheet production method

Patent metadata

Field	Value
Publication number	US-11053416-B2
Application number	US-201615763357-A
Country	US
Kind code	B2
Filing date	Sep 27, 2016
Priority date	Sep 28, 2015
Publication date	Jul 6, 2021
Grant date	Jul 6, 2021

Abstract

Provided a pressure sensitive adhesive sheet including a substrate or a release material having thereon a resin layer that contains a resin part (X) containing a carbon atom-containing resin having a carbon atom in a main chain of a constitutional unit as a main component, and a particle part (Y) consisting of fine particles containing silica particles, a surface (α) having pressure sensitive adhesiveness, the surface (α) having a concave portion and a flat face existing thereon, a prescribed section (P 1 ) having existing on the side of the surface (α) a concave portion having a prescribed maximum height difference, and a flat portion corresponding to a cut portion of the flat face existing in a region (P) and being substantially in parallel to a surface of the substrate or the release material in contact with the resin layer, and an absolute value of a ratio of an intensity ratio of a peak intensity derived from silicon atoms and a peak intensity derived from carbon atoms measured by EDX a for a prescribed region (S) that is positioned under one of the concave portion existing on the cross section, and the intensity ratio measured by EDX for a prescribed region (T) that is positioned under one of the flat portion existing on the cross section being 0.2 or less.

First claim

The invention claimed is:

1. A pressure sensitive adhesive sheet, comprising:
a substrate or a release material; and
a resin layer on the substrate or the release material, the resin layer comprising a resin part (X) comprising a carbon atom-containing resin having a carbon atom in a main chain of a constitutional unit as a main component, and a particle part (Y) consisting of fine particles which contain silica particles and have an average particle diameter of 0.01 to 100 at least a surface (α) of the resin layer opposite to the side having the substrate or the release material provided having pressure sensitive adhesiveness,
wherein:
a concave portion and a flat face exist on the surface (α);
in at least one cross section (P 1 ) of two cross sections of the pressure sensitive adhesive sheet resulting from freely-selecting a region (P) surrounded by a square having an edge length of 5 mm on the surface (α) and cutting the region (P) in a thickness direction of the pressure sensitive adhesive sheet with a plane surface going through each of two diagonal lines of the square and being perpendicular to the region (P) on the surface (α),
a concave portion having a maximum height difference of 40% or more of a total thickness of the resin layer, and a flat portion corresponding to a cut portion of the flat face existing in the region (P) and being substantially in parallel to a surface of the substrate or the release material in contact with the resin layer exist on the side of the surface (α) of the cross section (P 1 ); and
an absolute value of a ratio (S EDX /T EDX ) of a value (S EDX ) of an intensity ratio Si/C of a peak intensity (Si) derived from silicon atoms and a peak intensity (C) derived from carbon atoms measured by energy dispersive X-ray analysis for a prescribed region (S) that is positioned under in the thickness direction with respect to one of the concave portion existing on the cross section (P 1 ), and a value (T EDX ) of the intensity ratio Si/C measured by energy dispersive X-ray analysis for a prescribed region (T) that is positioned under in the thickness direction with respect to one of the flat portion existing on the cross section (PI) and has the same length in a horizontal direction as the region (S) is 0.2 or less.

2. The pressure sensitive adhesive sheet according to claim 1 , wherein the value (S EDX ) of the intensity ratio Si/C in the prescribed region (S) is 0.01 or less.

3. A pressure sensitive adhesive sheet, comprising:
a substrate or a release material; and
a resin layer on the substrate or the release material, the resin layer comprising a resin part (X) comprising a carbon atom-containing resin having a carbon atom in a main chain of a constitutional unit as a main component, and a particle part (Y) consisting of fine particles which contain silica particles and have an average particle diameter of 0.01 to 100 μm, at least a surface (α) of the resin layer opposite to the side having the substrate or the release material provided having pressure sensitive adhesiveness,
wherein:
a concave portion and a flat face exist on the surface (α);
in at least one cross section (P 1 ) of two cross sections of the pressure sensitive adhesive sheet resulting from freely-selecting a region (P) surrounded by a square having an edge length of 5 mm on the surface (α) and cutting the region (P) in a thickness direction of the pressure sensitive adhesive sheet with a plane surface going through each of two diagonal lines of the square and being perpendicular to the region (P) on the surface (α),
a concave portion having a maximum height difference of 40% or more of a total thickness of the resin layer, and a flat portion corresponding to a cut portion of the flat face existing in the region (P) and being substantially in parallel to a surface of the substrate or the release material in contact with the resin layer exist on the side of the surface (α) of the cross section (P 1 ); and
a value (S EDX ) of an intensity ratio Si/C of a peak intensity (Si) derived from silicon atoms and a peak intensity (C) derived from carbon atoms measured by energy dispersive X-ray analysis for a prescribed region (S) that is positioned under in a thickness direction with respect to one of the concave portion existing on the cross section (P 1 ) is 0.01 or less.

4. The pressure sensitive adhesive sheet according to claim 3 , wherein an absolute value of a ratio (S EDX /T EDX ) of the value (S EDX ) and a value (T EDX ) of the intensity ratio Si/C measured by energy dispersive X-ray analysis for a prescribed region (T) that is positioned under in a thickness direction with respect to one of the flat portion existing on the cross section (P 1 ) and has the same length in a horizontal direction as the region (S) is 0.150 or less.

5. The pressure sensitive adhesive sheet according to claim 1 , wherein the value (T EDX ) of the intensity ratio Si/C of the prescribed region (T) is more than 0.01.

6. The pressure sensitive adhesive sheet according to claim 1 , wherein plural concave portions each having a maximum height difference of 40% or more of a total thickness of the resin layer and being different in shape from each other exist on the side of the surface (α) of the cross section (P 1 ).

7. The pressure sensitive adhesive sheet according to claim 1 , wherein the flat face has an irregular shape on observation from the side of the surface (α).

8. The pressure sensitive adhesive sheet according to claim 1 , wherein plural flat portions exist on the side of the surface (α) of the cross section (P 1 ).

9. The pressure sensitive adhesive sheet according to claim 8 , wherein positions of the plural flat portions existing on the side of the surface (α) on the cross section (P 1 ) have no periodicity.

10. The pressure sensitive adhesive sheet according to claim 8 , wherein differences between distances of each of the plural flat portions existing on the side of the surface (α) on the cross section (P 1 ) to the substrate or the release material are less than 5% with respect to an average value of the distances.

11. The pressure sensitive adhesive sheet according to claim 1 , wherein the concave portion has a maximum height difference of 0.5 μm or more.

12. The pressure sensitive adhesive sheet according to claim 1 , wherein one or more flat faces (f 1 ) having such an area that a region surrounded by a circle having a diameter of at least 100 μm is selectable exist on the surface (α) of the resin layer.

13. The pressure sensitive adhesive sheet according to claim 1 , wherein one or more flat faces (f 2 ) having an area of 0.2 mm 2 or more exist on the surface (α) of the resin layer.

14. The pressure sensitive adhesive sheet according to claim 1 , wherein the concave portion is not formed using a release material having an emboss pattern.

15. The pressure sensitive adhesive sheet according to claim 13 , wherein a mass retention rate after heating the resin layer to 800° C. for 30 minutes is 3 to 90% by mass.

16. The pressure sensitive adhesive sheet according to claim 13 , wherein the carbon atom-containing resin in the resin part (X) comprises a pressure sensitive adhesive resin.

17. The pressure sensitive adhesive sheet according to claim 1 , wherein the resin part (X) further comprises at least one selected from the group consisting of a metal chelate crosslinking agent and an epoxy crosslinking agent.

18. The pressure sensitive adhesive sheet according to claim 1 , wherein a surface (β) of the resin layer on the side on which the substrate or the release material

Assignees

• Lintec Corp

Inventors

• Amino Yumiko
• Uemura Kazue
• Kato Kiichiro

Classifications

• C09J7/401

  characterised by the release coating composition · CPC title

• C09J2483/005

  in the release coating · CPC title

• C09J11/04

  inorganic · CPC title

• C09J2301/204

  the adhesive coating being discontinuous · CPC title

• C09J7/38 Primary

  Pressure-sensitive adhesives [PSA] · CPC title