Mold release film and method for producing laminate

Patent metadata

Field	Value
Publication number	US-11673295-B2
Application number	US-202016883302-A
Country	US
Kind code	B2
Filing date	May 26, 2020
Priority date	Nov 30, 2017
Publication date	Jun 13, 2023
Grant date	Jun 13, 2023

Abstract

Provided is a mold release film capable of transferring a concave-convex structure to the surface of an adhesive film.

First claim

The invention claimed is:

1. A mold release film comprising a concave-convex layer having a concave-convex structure on the surface of at least one surface side of a substrate,
wherein the concave-convex structure comprises a structure in which a convex portion in the concave-convex structure forms an irregular shape in a plan view,
and the concave-convex structure has an area ratio of the convex portion to the surface of the concave-convex structure of 10 to 90% and a maximum height difference in the concave-convex structure of 4.0 μm or more,
wherein the convex portion of the concave-convex structure is continuous in a plan view,
wherein the concave-convex layer comprises two or more kinds of acrylic polymers,
and wherein the two or more kinds of acrylic polymers form a phase separation structure.

2. The mold release film according to claim 1 , wherein at least one of the two or more kinds of acrylic polymers is a thermoplastic resin and/or a curable resin composition having a crosslinkable structure.

3. The mold release film according to claim 1 , wherein, in the concave-convex structure, a composition forming a concave portion is different from a composition forming a convex portion.

4. The mold release film according to claim 1 , wherein the concave-convex layer has an SP value (A) of a component A which occupies the largest part of components forming a concave portion of 8 to 21, and an SP value (B) of a component B which occupies the largest part of components forming a convex portion of 7 to 20, and the SP value (A)−the SP value (B)=0.01 to 10.

5. The mold release film according to claim 1 , wherein the concave-convex layer has a mass average molecular weight (Mw) of the component A which occupies the largest part of components forming a concave portion of 300 to 300,000, and a mass average molecular weight (Mw) of the component B which occupies the largest part of components forming a convex portion of 500 to 400,000.

6. The mold release film according to claim 1 , wherein the concave-convex layer is formed from a coating composition containing two or more kinds of acrylic polymers, oligomers, or monomers, and the coating composition has an SP value (A) of the component A which occupies the largest part of components forming a concave portion of 8 to 21, and an SP value (B) of the component B which occupies the largest part of components forming a convex portion of 7 to 20, and the SP value (A)−the SP value (B)=0.01 to 10.

7. The mold release film according to claim 1 , wherein the concave-convex layer is formed from a coating composition containing two or more kinds of acrylic polymers, oligomers, or monomers, and the coating composition has a mass average molecular weight (Mw) of the component A which occupies the largest part of components forming a concave portion of 300 to 300,000, and a mass average molecular weight (Mw) of the component B which occupies the largest part of components forming a convex portion of 500 to 400,000.

8. The mold release film according to claim 1 , comprising a release layer on the surface side of the concave-convex layer.

9. The mold release film according to claim 1 , comprising a functional layer between the substrate and the concave-convex layer.

10. The mold release film according to claim 1 , comprising an antistatic agent.

11. The mold release film according to claim 10 , wherein the substrate or the concave-convex layer, or both of them contain an antistatic agent and/or a layer containing an antistatic agent.

12. A laminate comprising a structure in which the mold release film according to claim 1 and an adhesive film are laminated.

13. The laminate according to claim 12 , wherein the concave-convex structure formed on the surface of the mold release film is transferred to the surface of the adhesive film.

14. The mold release film according to claim 1 , wherein the substrate is a biaxially stretched polyester film.

15. The mold release film according to claim 1 , wherein the component occupying the largest part of the components forming the concave portion is a component A selected from the group of acrylic polymers consisting of: poly (meth) acrylate.

16. The mold release film according to claim 1 , wherein the component occupying the largest part of the components forming the convex portion is incompatible with the component A and is selected from the group of acrylic polymers consisting of: poly (meth) acrylate.

17. The mold release film according to claim 1 , wherein in an image obtained by measuring the surface of the concave-convex structure on the mold release film surface by an optical interference method, in an image area of 703.13 μm×937.42 μm on the mold release film surface, the convex portions are connected from the peripheral edge of the image area to the opposite peripheral edge.

18. A roll-shaped laminate comprising a structure in which a support, an adhesive sheet composed of an adhesive layer, and the mold release film according to claim 1 are sequentially laminated,
wherein the concave-convex structure is transferred to one surface of the adhesive layer to be laminated with the mold release film by laminating the adhesive layer on the surface of the concave-convex layer of the mold release film, and the support is laminated on another surface of the adhesive sheet.

19. A mold release film comprising a concave-convex layer having a concave-convex structure on the surface of at least one surface side of a substrate,
wherein the concave-convex layer is a cured product of a concave-convex formed composition comprising a component A, a component B, a crosslinking initiator C, and a mixed solution Z composed of a solution X and a solution Y,
the component A and the component B both comprise an acrylic polymer,
a boiling point of the solution Y is higher than that of the solution X, and
the concave-convex structure comprises a structure in which a convex portion in the concave-convex structure forms an irregular shape in a plan view, and the concave-convex structure has an area ratio of the convex portion to the surface of the concave-convex structure of 10 to 90% and maximum height difference in the concave-convex structure of 4.0 μm or more, and
the convex portion of the concave-convex structure is continuous in a plan view, and
the maximum height difference in the concave-convex structure is the maximum value of the difference between the minimal value of the concave portion and the maximal value around the concave portion, or the difference between the maximal value of the convex portion and the minimal value around the convex portion.

20. The mold release film according to claim 19 , wherein in an image obtained by measuring the surface of the concave-convex structure on the mold release film surface by an optical interference method, in an image area of 703.13 μm×937.42 μm on the mold release film surface, the convex portions are connected from the peripheral edge of the image area to the opposite peripheral edge.

21. A method for producing a laminate comprising a structure in which a support, an adhesive sheet composed of an adhesive layer, and the mold release film of claim 1 are sequentially laminated, the method comprising:
transferring the concave-convex structure to one surface of the adhesive layer to be laminated with the mold release film by laminating the adhesive layer on the surface of the concave-convex layer of the mold release film, wherein the support is laminated on another surface of the adhesive sheet.

Assignees

• Mitsubishi Chem Corp

Inventors

• Sasaki Nobuaki
• Sato Yoshihide

Classifications

• B32B2264/104

  Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles · CPC title

• B32B2307/748

  Releasability · CPC title

• B32B2264/025

  Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title