Adhesive sheet and adhesive sheet production method

Patent metadata

Field	Value
Publication number	US-2019085215-A1
Application number	US-201615762909-A
Country	US
Kind code	A1
Filing date	Sep 27, 2016
Priority date	Sep 28, 2015
Publication date	Mar 21, 2019
Grant date	—

Abstract

Provided is a pressure sensitive adhesive sheet including a resin layer on a substrate or a release material, at least a surface (α) of the resin layer on the side opposite to the side thereof on which the substrate or the release material is provided having pressure sensitive adhesiveness, wherein a concave portion and plural flat faces having an irregular shape exist in a region (Dc) surrounded by an arbitrarily predetermined circle on the surface (α) of the resin layer; and with respect to one or more flat faces (S) among the plural flat faces, the one or more flat faces (S) excluding flat faces having a cumulative relative frequency of 30% or less determined by adding the relative frequency from the respective flat faces with a smaller area, an rMAX value of the flat faces (S) calculated from specified operations is 0.60 or less

First claim

1 . A pressure sensitive adhesive sheet, comprising
a resin layer on a substrate or a release material, wherein at least a surface (α) of the resin layer on the side opposite to the side thereof on which the substrate or the release material is provided has pressure sensitive adhesiveness, a concave portion and plural flat faces having an irregular shape exist in a region (Dc) surrounded by a circle having a diameter of 8 mm that is arbitrarily selected on the surface (α) of the resin layer; and with respect to one or more flat faces (S) among the plural flat faces, the one or more flat faces (S) excluding flat faces having a cumulative relative frequency of 30% or less determined by adding relative frequency from the respective flat faces with a smaller area, in placing the region (Dc) containing the one or more flat faces (S) on an orthogonal coordinate system in which a direction orthogonal to the horizontal Feret's diameter direction is the vertical Feret's diameter direction, an r MAX value of the one or more flat faces (S) calculated from the following operations (i) to (iii) is 0.60 or less: Operation (i): with respect to all of the one or more flat faces (S) contained in the region (Dc), a ratio of an area of the flat face (S) to an area of a circumscribed rectangle of flat face (S), which circumscribes the flat face (S) by two pairs of straight lines parallel to the horizontal Feret's axis and the vertical Feret's axis [{area of flat face (S)}/{area of circumscribed rectangle of flat face (S)}] is calculated for every flat face (S), and r(0°) that is an average value of the obtained ratios is calculated; Operation (ii): with respect to each of all of the one or more flat faces (S) in each region obtained by rotating the region (Dc) at θ, where θ=15°, 30°, 45°, 60°, 75°, or 90°, in the counterclockwise direction centering on, as a center of the rotation, the center of the circle of the region (Dc) used in the operation (i) in the orthogonal coordinate system, a ratio of an area of the flat face (S) to an area of a circumscribed rectangle of flat face (S), which circumscribes the flat face (S) by two pairs of straight lines parallel to the horizontal Feret's axis and the vertical Feret's axis [{area of flat face (S)}/{area of circumscribed rectangle of flat face (S)}] is calculated for every flat face (S), and r(θ) that is an average value of the obtained ratios is calculated with respect to every case at θ=15°, 30°, 45°, 60°, 75°, and 90°; and Operation (iii): a maximum value of the seven values of r(θ), where θ=0°, 15°, 30°, 45°, 60°, 75°, and 90°, as calculated in the operations (i) and (ii) is defined as the r MAX value of the one or more flat faces (S).

2 . The pressure sensitive adhesive sheet according to claim 1 , wherein in the region (Dc) surrounded by a circle having a diameter of 8 mm that is arbitrarily selected on the surface (α) of the resin layer, one or more flat faces (f1) having an area where a range surrounded by a circle having a diameter of at least 100 μm is selectable exist.

3 . The pressure sensitive adhesive sheet according to claim 1 , wherein in the region (Dc) surrounded by a circle having a diameter of 8 mm that is arbitrarily selected on the surface (α) of the resin layer, one or more flat faces (f2) having an area of 0.2 mm 2 or more exist.

4 . The pressure sensitive adhesive sheet according to claim 1 , wherein a skewness Sk value relative to a normal distribution curve between the area and the frequency of each of the one or more flat faces (S) is 1.0 or more.

5 . The pressure sensitive adhesive sheet according to claim 4 , wherein a kurtosis Ku value relative to a normal distribution curve between the area and the frequency of each of the one or more flat faces (S) is 1.8 or more.

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

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

8 . The pressure sensitive adhesive sheet according to claim 1 , wherein the resin layer contains a resin part (X) containing a resin as a main component, and a particle part (Y) consisting of fine particles.

9 . The pressure sensitive adhesive sheet according to claim 8 , wherein a mass retention rate after heating the resin layer at 800° C. for 30 minutes is 3 to 90% by mass.

10 . The pressure sensitive adhesive sheet according to claim 8 , wherein the resin contained in the resin part (X) contains a pressure sensitive adhesive resin.

11 . The pressure sensitive adhesive sheet according to claim 8 , wherein the resin part (X) further contains at least one crosslinking agent selected from the group consisting of a metal chelate crosslinking agent and an epoxy crosslinking agent.

12 . The pressure sensitive adhesive sheet according to claim 8 , wherein the fine particles are one or more selected from the group consisting of silica particles, metal oxide particles, and smectite.

13 . 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 is provided has pressure sensitive adhesiveness.

14 . The pressure sensitive adhesive sheet according to claim 1 , wherein the resin layer has a multilayer structure in which a layer (Xβ) mainly containing a resin part (X), a layer (Y 1 ) containing a particle part (Y) in an amount of 15% by mass or more, and a layer (Xα) mainly containing the resin part (X) are laminated in this order from the side on which the substrate or the release material is provided.

15 . The pressure sensitive adhesive sheet according to claim 14 , wherein
the layer (Xβ) is a layer formed by a composition (xβ) containing a resin and having a content of fine particles of less than 15% by mass, the layer (Y 1 ) is formed by a composition (y) containing fine particles in an amount of 15% by mass or more, and the layer (Xα) is a layer formed by a composition (xα) containing a resin and having a content of fine particles of less than 15% by mass.

16 . A method for producing the pressure sensitive adhesive sheet according to claim 1 , the method comprising:
forming a coating film (x′) formed by a composition (x) containing a resin and having a content of fine particles of less than 15% by mass, and a coating film (y′) formed by a composition (y) having the fine particles in an amount of 15% by mass or more; and drying the coating film (x′) and the coating film (y′) simultaneously.

17 . A method for producing the pressure sensitive adhesive sheet according to claim 15 , the method comprising:
forming, on the substrate or the release material, a coating film (xβ′) formed by the composition (xβ) containing the resin and having a content of the fine particles of less than 15% by mass, a coating film (y′) formed by the composition (y) containing the fine particles in an amount of 15% by mass or more, and a coating film (xα′) formed by the composition (xα) containing the resin and having a content of the fine particles of less than 15% by mas, by laminating in this order; and drying the coating film (xβ′), the coating film (y′), and the coating film (xα′) simultaneously.

18 . A method for producing the pressure sensitive adhesive sheet according to claim 15 , the method comprising:
forming, on the layer (Xβ) mainly containing the resin part (X) that is provided on the substrate or the release material, a coati

Assignees

• Lintec Corp

Inventors

• Uemura Kazue
• Matsuoka Yusuke
• Kase Takamasa
• Kato Kiichiro

Classifications

• C08K3/36

  Silica · CPC title

• B32B27/36

  comprising polyesters · CPC title

• C09J11/04

  inorganic · CPC title

• C08K3/22

  of metals · CPC title

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title