GAS BARRIER FILM LAMINATE

• US 20100015431A1
• Filed: 11/15/2007
• Published: 01/21/2010
• Est. Priority Date: 11/16/2006
• Status: Active Grant

• Current Assignee: Mitsubishi Chemical Corporation (Mitsubishi Chemical Group Corp.)
• Original Assignee: Mistubishi Plastics Incorporated
• Inventors: Matsui, Tsutomu, Yoshida, Shigenobu
• Granted Patent: US 8,343,623 B2
• Time in Patent Office: Days
• US Class Current: 428/323
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/4845 Radiation curing adhesives, e.g. UV light curing adhesives
• CPC Class Codes: B29C 65/485 Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
• CPC Class Codes: B29C 65/4875 being spherical, e.g. particles or powders
• CPC Class Codes: B29C 66/001 Joining in special atmospheres
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72321 consisting of metals or their alloys
• CPC Class Codes: B29C 66/72324 consisting of inorganic materials not provided for in B29C66/72321 - B29C66/72322
• CPC Class Codes: B29C 66/72325 Ceramics
• CPC Class Codes: B29C 66/72341 for gases
• CPC Class Codes: B29C 66/73161 Roughness or rugosity
• CPC Class Codes: B29C 66/82661 by means of vacuum
• CPC Class Codes: B29K 2023/38 Polymers of cycloalkenes, e.g. norbornene or cyclopentene
• CPC Class Codes: B29K 2033/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2105/256 : Sheets, plates, blanks or films
• CPC Class Codes: B29K 2995/0067 : non-permeable
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B32B 2038/0076 : Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2307/202 : Conductive
• CPC Class Codes: B32B 2307/412 : Transparent
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2309/68 : Vacuum
• CPC Class Codes: B32B 2553/00 : Packaging equipment or accessories not otherwise provided for
• CPC Class Codes: B32B 33/00 : Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/003 : to avoid air inclusion
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/249977 : Specified thickness of void-containing component [absolute or relative], numerical cell dimension or density
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31721 : Of polyimide
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

The present invention relates to a gas-barrier film laminate capable of greatly reducing the formation of bubbles and impurities between the gas-barrier film layers and having excellent gas-barrier property interlayer adhesiveness.

The gas-barrier film laminate has at least two gas-barrier film layers laminated via an adhesive layer, wherein the gas-barrier film layer has a substrate film, and at least one constitutive unit layer comprising an anchor coat layer and an inorganic thin film layer formed on at least one surface of the substrate film in that order, and wherein the number of the bubbles having a diameter of at least 0.5 mm and the impurities having a diameter of at least 0.5 mm existing between the gas-barrier film layers is at most 3 in total per 100 cm².

Claims

1. A gas-barrier film laminate having at least two gas-barrier film layers laminated via an adhesive layer, wherein the gas-barrier film layer has a substrate film, and at least one constitutive unit layer comprising an anchor coat layer and an inorganic thin film layer formed on at least one surface of the substrate film in that order, and wherein the number of the bubbles having a diameter of at least 0.5 mm and the impurities having a diameter of at least 0.5 mm existing between the gas-barrier film layers is at most 3 in total per 100 cm².

2. The gas-barrier film laminate as claimed in claim 1 having at least three gas-barrier film layers laminated via an adhesive layer, wherein the number of the bubbles having a diameter of at least 0.5 mm and the impurities having a diameter of at least 0.5 mm existing between the gas-barrier film layers is at most 2 in total per 100 cm².

3. The gas-barrier film laminate of claim 1, having a moisture permeability at 40°

C. and 90% RH of at most 0.02 g/m²/24 hr.

4. The gas-barrier film laminate of claim 1, having a total light transmittance of at least 70%.

5. The gas-barrier film laminate of claim 1, wherein the substrate film is at least one resin selected from polyester-based resin, polycarbonate-based resin, polymethacrylic resin, polyetherimide-based resin, polyether sulfone-based resin and cyclic olefin-based resin.

6. The gas-barrier film laminate of claim 1, wherein the gas-barrier film layer has a moisture permeability at 40°

C. and 90% RH of at most 0.2 g/m²/24 hr.

7. The gas-barrier film laminate of claim 1, wherein the anchor coat layer comprises at least one selected from a group consisting of polyester-based resin, urethane-based resin, acrylic resin, isocyanate group-containing resin, oxazoline group-containing resin, carbodiimide-based resin, and alcoholic hydroxyl group-containing resin.

8. The gas-barrier film laminate of claim 1, wherein the anchor coat layer comprises at least one selected from a group consisting of chromium, silicon oxide, aluminium oxide, titanium oxide, silicon nitride, aluminium nitride, titanium nitride, and hydrocarbon.

9. The gas-barrier film laminate of claim 1, wherein the inorganic thin film layer comprises at least one selected from silicon oxide, aluminium oxide, silicon nitride, aluminium nitride and diamond like carbon.

10. The gas-barrier film laminate of claim 1, wherein the adhesive layer comprises at least one selected from a group consisting of urethane-based resin, polyester-based resin, epoxy-based resin and acrylic resin.

11. The gas-barrier film laminate as claimed in claim 1, wherein the adhesive layer has an oxygen permeability at 25°

C. and 90% RH of at most 1000 ml/m²/24 hr/MPa.

12. The gas-barrier film laminate of claim 1, wherein the adhesive layer contains inorganic particles and/or organic particles having a mean particle size of from 0.005 to 50 μ

m in an amount of from 0.01 to 30% by mass.

13. The gas-barrier film laminate of claim 1, wherein the adhesive layer has a surface roughness (Rms) of from 0.05 to 40 μ

m.

14. The gas-barrier film laminate of claim 1, which is heated or irradiated with energy rays in a vacuum atmosphere at 1000 Pa or less.

15. The gas-barrier film laminate as claimed in claim 14, wherein the energy rays are UV rays or electron rays.

16. A method for producing a gas-barrier film laminate comprising:

(a) a step of forming, on a substrate, at least one constitutive unit layer comprising an anchor coat layer and an inorganic thin film layer in that order, thereby forming a gas-barrier film layer,

(b) a step of laminating at least two formed gas-barrier film layers via an adhesive layer, and

(c) after or simultaneously with the lamination of gas-barrier film layers, a step of heating it or irradiating it with energy rays in a vacuum atmosphere at not more than 1000 Pa.

19. The method for producing a gas-barrier film laminate of claim 16, wherein the water vapor permeability (moisture permeability) at 40°

C. and 90% RH through the gas-barrier layer is at most 0.2 g/m²/24 hr, and the oxygen permeability at 25°

C. and 90% RH through the adhesive layer is at most 1000 ml/m²/24 hr/MPa.

17. A method for producing a gas-barrier film laminate comprising:

(a) a step of forming, on a substrate, at least one constitutive unit layer comprising an anchor coat layer and an inorganic thin film layer in that order, thereby forming a gas-barrier film layer, and

(b) a step of laminating at least two formed gas-barrier film layers via an adhesive layer comprising an epoxy-based resin.

18. The method for producing a gas-barrier film laminate as claimed in claim 17, wherein the adhesive layer in the step (b) comprises at least any one selected from a reaction product of the following (A) and (B), a reaction product of (A) and (C) and a reaction product of (A), (B) and (C):

(A) Metaxylenediamine or paraxylenediamine,

(B) Polyfunctional compound having at least one acyl group capable of forming an amide group moiety through reaction with a polyamine to form an oligomer,

(C) Monovalent carboxylic acid having from 1 to 8 carbon atoms and/or its derivative.