WO2020105312A1 - はく離フィルム、セラミック部品シート、はく離フィルムの製造方法、セラミック部品シートの製造方法、及び積層セラミックコンデンサの製造方法 - Google Patents
はく離フィルム、セラミック部品シート、はく離フィルムの製造方法、セラミック部品シートの製造方法、及び積層セラミックコンデンサの製造方法Info
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- WO2020105312A1 WO2020105312A1 PCT/JP2019/040329 JP2019040329W WO2020105312A1 WO 2020105312 A1 WO2020105312 A1 WO 2020105312A1 JP 2019040329 W JP2019040329 W JP 2019040329W WO 2020105312 A1 WO2020105312 A1 WO 2020105312A1
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- release film
- release
- release layer
- ceramic
- functional group
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/046—Forming abrasion-resistant coatings; Forming surface-hardening coatings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
- C09D133/04—Homopolymers or copolymers of esters
- C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D151/00—Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers
- C09D151/08—Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C09D151/085—Coating compositions based on graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Coating compositions based on derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds on to polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
- C09D183/04—Polysiloxanes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G13/00—Apparatus specially adapted for manufacturing capacitors; Processes specially adapted for manufacturing capacitors not provided for in groups H01G4/00 - H01G11/00
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G4/00—Fixed capacitors; Processes of their manufacture
- H01G4/30—Stacked capacitors
Definitions
- the present disclosure relates to a release film, a ceramic part sheet, a release film manufacturing method, a ceramic part sheet manufacturing method, and a laminated ceramic capacitor manufacturing method.
- a manufacturing method which includes laminating a ceramic green sheet formed on a release film from a release film and laminating a plurality of similarly obtained ceramic green sheets (for example, Patent Document 1).
- Patent Document 1 With the demand for miniaturization of monolithic ceramic capacitors, it is required to reduce the thickness of ceramic green sheets.
- the release film used for forming the ceramic green sheet is required to have a smooth surface with sufficiently reduced irregularities and to have excellent release properties.
- Patent Document 2 discloses a release film including a base film and a polymer layer provided on one surface of the base film, wherein the polymer layer is (meth).
- a layer containing a cured product of an acrylate component, and a film containing a silicone polymer component that covers a part of the surface of the layer opposite to the base film side, and the silicone polymer component comprises:
- One aspect of the present disclosure is a release film having a base material and a release layer provided on the base material, wherein the release layer is a silicone resin having a reactive functional group and other polymerizable components.
- X is the peak intensity of silicon on the surface of the release layer opposite to the substrate side, which is measured by XPS, and is a depth of 4 from the surface of the release layer.
- Y peak intensity of silicon at 1 nm
- Z the peak intensity of silicon measured when a silicone resin layer containing 90% or more of polydimethylsiloxane is formed
- Z A release film having a ratio of X to 40% or more and a ratio of Y to Z of 5 to 50% is provided.
- the release film has a ratio of X to Z of 40% or more with respect to the peak intensity of silicon measured by XPS, and Y (peak intensity of silicon at a depth of 4.1 nm from the surface of the release layer). Is smaller than the above X (peak intensity on the surface of the release layer). Therefore, the resin component derived from the silicone resin having a reactive functional group is more present in the surface layer portion of the release layer, and the release property on the surface of the release layer is excellent.
- the Y is 5 to 50% with respect to the Z (the peak intensity of silicon when the layer made of the silicone resin is formed), other than the release layer at a depth of 4.1 nm, Since the resin component derived from the polymerizable component is appropriately present, aggregation of the resin component derived from the silicone resin is sufficiently reduced, and the release layer has few defects and the like and is sufficiently excellent in smoothness.
- the ratio of Y to X may be 70% or less.
- the release layer may be a cured product of a composition containing a silicone resin having a reactive functional group, a (meth) acrylate having a reactive functional group, and an acrylic silicone graft polymer having a reactive functional group.
- the acrylic silicone graft polymer having a reactive functional group is a silicone resin and a (meth) acrylate (or a polymer thereof). Since it acts to suppress the phase separation of the silicone resin and the aggregation of the silicone resin, it is possible to contain more silicone resin than the conventional release layer, and the release layer and smoothness of the resulting release layer can be increased. And can be compatible at a higher level.
- the content of the acrylic silicone graft polymer may be 10 to 600% by mass based on the total amount of the (meth) acrylate.
- the content of the acrylic silicone graft polymer is within the above range, the phase separation between the silicone resin and the (meth) acrylate (or the polymer thereof) and the aggregation of the silicone resin are more sufficiently suppressed, and the release layer is separated. Compatibility and smoothness can be achieved at a higher level.
- the content of the above silicone resin may be 0.5% by mass or more. By setting the content of the silicone resin within the above range, the content of the silicone resin on the surface of the release layer can be increased, so that the release property of the release layer can be further improved.
- One aspect of the present disclosure includes a release film described above, and at least one green sheet selected from the group consisting of a ceramic green sheet and an electrode green sheet, which is provided on the surface of the release layer, and a ceramic. Provide parts sheet.
- the above-mentioned ceramic component sheet is excellent in peelability, and since it has a release film having sufficient smoothness, occurrence of pinholes in the green sheet provided on the release film, and variation in thickness are sufficiently suppressed. ing. Further, since the above-mentioned ceramic component sheet has a release film having excellent release properties, it is also useful for producing a thin green sheet.
- One aspect of the present disclosure is a method for producing a release film having a base material and a release layer provided on the base material, which has a silicone resin having a reactive functional group and a reactive functional group ( (Meth) acrylate, and a step of applying a slurry containing a composition containing an acrylic silicone graft polymer having a reactive functional group and a solvent onto the substrate, and reducing the content of the solvent in the slurry. And a step of forming a release layer composed of a cured product of the composition by exposing the photosensitive layer to light, thereby providing a method for producing a release film.
- the method for producing the release film uses a composition containing a silicone resin having a reactive functional group, a (meth) acrylate having a reactive functional group, and an acrylic silicone graft polymer having a reactive functional group.
- the above-mentioned acrylic silicone graft polymer acts to suppress phase separation between the silicone resin and the (meth) acrylate (or (meth) acrylate polymer formed during the curing reaction) and aggregation of the silicone resin, so that more silicone resin is contained. Can be included.
- the (meth) acrylate moves to the base material side due to the specific gravity of each component, the surface energy, etc., and the silicone resin moves to the opposite side of the base material. Moving.
- the functional groups in each component react to fix the distribution state of the component in the photosensitive layer.
- the surface of the release layer on the side opposite to the base material side has excellent release properties, and the occurrence of defects due to aggregation of the silicone resin is suppressed.
- a release film having excellent properties can be produced.
- the method may further include a step of preparing the composition so that the content of the acrylic silicone graft polymer is 10 to 600% by mass based on the total amount of the (meth) acrylate.
- a step of preparing the composition so that the content of the acrylic silicone graft polymer is 10 to 600% by mass based on the total amount of the (meth) acrylate.
- the method may further include a step of preparing the composition so that the content of the silicone resin is 0.5% by mass or more.
- preparing the composition so that the content of the silicone resin is within the above range it is possible to produce a release film in which the release property of the release layer is further improved.
- the reactive functional group is at least one functional group selected from the group consisting of (meth) acryloyl group and vinyl group, and the composition may further contain a photopolymerization initiator.
- One aspect of the present disclosure also includes a base material, a release layer provided on the base material, and a ceramic green sheet and an electrode green sheet provided on the surface of the release layer opposite to the base material side.
- a method for producing a ceramic component sheet comprising at least one green sheet selected from the group consisting of: a silicone resin having a reactive functional group, a (meth) acrylate having a reactive functional group, and a reactive resin.
- the ceramic component sheet manufacturing method since a release layer having excellent peelability and sufficient smoothness is prepared and used, occurrence of pinholes in the green sheet and variation in thickness can be sufficiently suppressed.
- the ceramic component sheet obtained by the above-described method for manufacturing a ceramic component sheet the yield of ceramic products such as laminated ceramic capacitors can be improved.
- One aspect of the present disclosure is a method for manufacturing a multilayer ceramic capacitor, including a step of preparing a plurality of the above-mentioned ceramic component sheets, peeling the release sheet from the ceramic component sheets, and stacking the green sheets to form a plurality of layers.
- a method for manufacturing a laminated ceramic capacitor which comprises a step of obtaining a laminated body having the green sheet and a step of sintering the laminated body to obtain a sintered body.
- the present disclosure it is possible to provide a release film having excellent release properties and having sufficient smoothness, and a method for producing the release film. According to the present disclosure, it is also possible to provide a ceramic component sheet having the above-described release film and capable of producing a thin green sheet, and a method for producing the same. The present disclosure can further provide a method for manufacturing a laminated ceramic capacitor using the release film as described above.
- FIG. 1 is a schematic cross-sectional view showing an example of a release film.
- FIG. 2 is a schematic cross-sectional view showing an example of the ceramic component sheet.
- FIG. 3 is a schematic sectional view showing an example of a ceramic component.
- FIG. 4 is a graph showing the results of the depth direction analysis of the release layer by XPS measurement in the examples.
- FIG. 5 is a photograph of the appearance of the release films prepared in Example 3 and Comparative Example 6.
- FIG. 1 is a schematic sectional view showing an example of a release film.
- the release film 10 has a base film 12 and a release layer 14 provided on the base film 12.
- the release film 10 can be used, for example, for producing a green sheet used for producing a laminated ceramic capacitor.
- a synthetic resin film or the like is used as the base film 12.
- the synthetic resin include polyester; polyolefin such as polyethylene and polypropylene; polylactic acid; acrylic resin such as polymethacrylate and polymethylmethacrylate; polyamide such as nylon 6,6; polyvinyl chloride; polyurethane; polystyrene; polycarbonate; polyphenylene sulfide.
- a fluorine-based resin such as polytetrafluoroethylene.
- the synthetic resin preferably contains polyester, more preferably polyethylene terephthalate.
- the polyethylene terephthalate film is relatively inexpensive and has excellent mechanical properties and transparency.
- the base film 12 may contain a filler. Since the base film 12 contains the filler, the mechanical strength of the release film 10 can be sufficiently increased.
- the content of the filler in the base film 12 is not particularly limited, but is preferably such that the transparency is not deteriorated.
- Examples of the filler include calcium carbonate, calcium phosphate, titanium oxide, silica, fumed silica, kaolin, talc, alumina and organic particles.
- the thickness s of the base film 12 is preferably 10 to 100 ⁇ m, more preferably 20 to 50 ⁇ m. By setting the thickness s of the base film 12 to 10 ⁇ m or more, physical properties such as dimensional stability of the release film 10 are more excellent. By setting the thickness s of the base film 12 to 100 ⁇ m or less, the manufacturing cost per unit area of the release film 10 can be further reduced.
- the release layer 14 is composed of a cured product of a composition containing a silicone resin having a reactive functional group and other polymerizable components.
- the silicone resin has a specific distribution along the depth direction of the release layer 14.
- the distribution can be measured by XPS.
- the distribution can be controlled by adjusting the composition and the compounding ratio of the above composition, adjusting the manufacturing conditions of the manufacturing method described later, and the like.
- Distribution measurement of the silicone resin along the depth direction of the release layer 14 by XPS is performed by composition analysis of the release layer surface by XPS measurement and etching of the release layer surface by sputtering using argon ions. Can be used in combination.
- the release layer is shaved from the surface by sputtering, and the composition of the exposed surface is analyzed by XPS while gradually exposing the inside.
- the etching rate is set to 0.05 nm / sec.
- the release layer 14 has a peak intensity of silicon on the surface of the release layer 14 on the side opposite to the base material (base film 12) side measured by XPS as X, and the depth from the surface of the release layer 14 is defined as X.
- X is larger than Y, where Y is the peak intensity of silicon at 4.1 nm and Z is the peak intensity of silicon measured when a silicone resin layer containing 90% or more of polydimethylsiloxane is formed.
- the ratio of X to Z is 40% or more, and the ratio of Y to Z is 5 to 50%.
- the peak intensity X with respect to the peak intensity Z may be, for example, 43% or more, 45% or more, or 50% or more, and may be 90% or less.
- the peak intensity X is within the above range, the release property of the release layer 14 can be further enhanced, and the load required to release the green sheet after forming the green sheet on the release layer 14 can be reduced.
- the peak intensity Y with respect to the peak intensity Z may be, for example, 5 to 40%, 5 to 30%, 10 to 30%, or 10 to 25%.
- the resin component derived from the other polymerizable component coexists appropriately with the resin component derived from the silicone resin, the aggregation of the silicone resin is sufficiently suppressed, and the release layer 14 The smoothness of can be further improved.
- the ratio of the peak intensity Y to the peak intensity X is preferably 70% or less, more preferably 60% or less, still more preferably 50% or less.
- the silicone component on the base film 12 side can be sufficiently reduced, the coating film formability can be improved, and the curing can be performed. It is possible to more sufficiently suppress the breakage at the interface between the release layer and the substrate obtained later.
- the thickness t of the release layer 14 is preferably 0.5 to 3 ⁇ m, more preferably 1 to 2 ⁇ m, and further preferably 1 to 1.5 ⁇ m.
- the smoothness on the (peeling surface 14a) can be made more sufficient.
- the fine roughness Sp of the surface of the release layer 14 on the side opposite to the base film 12 side (release surface 14a) may be 100 nm or less, and may be 50 nm or less, 40 nm or less, 35 nm or less, or 30 nm or less. ..
- the micro-roughness Sp can be measured using a Micromap System (optical interference type three-dimensional non-contact surface profile measuring system) of Ryoka Systems Inc. according to the method described in JIS B 0601: 2013.
- the release film 10 described above can be manufactured, for example, by the following manufacturing method.
- One embodiment of a method for producing a release film is a step of applying a slurry containing a composition containing a silicone resin having a reactive functional group and a solvent onto a substrate (coating step), and A step of reducing the content of the solvent to provide a photosensitive layer (solvent reducing step), and a step of exposing the photosensitive layer to form a release layer composed of a cured product of the composition (exposure step) , With.
- the coating step in the method for producing a release film is a step of coating a slurry on a substrate to form a coating film containing the above composition.
- a coating method for forming the coating film for example, a bar coating method, a Meyer bar coating method, a reverse coating method, a gravure coating method, a rod coating method, a die coating method, a spray coating method, or the like can be used.
- a solvent capable of dissolving the silicone resin having a reactive functional group and other components is used.
- the solvent include toluene, xylene, methyl ethyl ketone (MEK), isopropyl alcohol (IPA), propylene glycol monomethyl ether (PGME), and propylene glycol monomethyl ether acetate (PEGMA). These solvents may be used alone or in combination of two or more.
- the composition containing a silicone resin having a reactive functional group contains a silicone resin having a reactive functional group, a (meth) acrylate having a reactive functional group, and an acrylic silicone graft polymer having a reactive functional group.
- the reactive functional group includes at least one functional group selected from the group consisting of a vinyl group and a (meth) acryloyl group.
- a plurality of reactive functional groups may be the same or different from each other.
- “(meth) acrylate” means acrylate and methacrylate
- “(meth) acryloyl group” means acryloyl group and methacryloyl group.
- the silicone resin having a reactive functional group may be, for example, a modified silicone oil modified with a reactive functional group.
- the modified silicone oil include one-terminal (meth) acrylate-modified silicone oil, both-terminal (meth) acrylate-modified silicone oil, side-chain (meth) acrylate-modified silicone oil, both-end side-chain (meth) acrylate-modified silicone oil, Examples thereof include one-terminal vinyl-modified silicone oil, both-terminal vinyl-modified silicone oil, side-chain vinyl-modified silicone oil, and both-end side-chain vinyl-modified silicone oil. These modified silicone oils may be used alone or in combination of two or more.
- modified silicone oil for example, one represented by the following general formula (1) or the following general formula (2) may be used.
- R 1 and R 2 each independently represent a single bond or a divalent hydrocarbon group.
- m represents an integer of 1 or more.
- R 1 and R 2 are preferably polymethylene groups having 1 to 10 carbon atoms or alkylene groups having 1 to 10 carbon atoms. m is preferably about 10 to 1000.
- R 3 and R 4 each independently represent a single bond or a divalent hydrocarbon group.
- n represents an integer of 1 or more.
- R 3 and R 4 are preferably polymethylene groups having about 1 to 10 carbon atoms or alkylene groups having 1 to 10 carbon atoms. Further, n is preferably about 10 to 1000.
- the (meth) acrylate having a reactive functional group (hereinafter, also referred to as the component (B)) preferably has two or more reactive functional groups and may have three or more reactive functional groups. Good.
- the (meth) acrylate having a reactive functional group has, for example, an alkylenediol di (meth) acrylate, a (meth) acrylate having a trimethylolpropane skeleton, a (meth) acrylate having a pentaerythritol skeleton, and a dipentaerythritol skeleton.
- (Meth) acrylate etc. are mentioned. These (meth) acrylates may be used alone or in combination of two or more.
- alkylenediol di (meth) acrylate examples include nonanediol di (meth) acrylate, decanediol di (meth) acrylate, and butylpropanediol diacrylate.
- Examples of the (meth) acrylate having a trimethylolpropane skeleton include trimethylolpropane di (meth) acrylate and trimethylolpropane tri (meth) acrylate.
- Examples of the (meth) acrylate having a pentaerythritol skeleton examples include pentaerythritol tetra (meth) acrylate.
- Examples of the (meth) acrylate having a dipentaerythritol skeleton examples include dipentaerythritol hexa (meth) acrylate.
- An acrylic silicone graft polymer having a reactive functional group (hereinafter, also referred to as a component (C)) is an acrylic polymer that is a polymer of a monomer containing (meth) acrylic acid and / or a (meth) acrylic acid ester. It is a polymer in which a silicone macromonomer is introduced.
- the acrylic silicone graft polymer having a reactive functional group may be used alone or in combination of two or more.
- the acrylic silicone graft polymer having a reactive functional group preferably has one reactive functional group.
- the silicone that is the graft portion has a polysiloxane structure, preferably a polydimethylsiloxane structure.
- a plurality of polysiloxane structures in the acrylic silicone graft polymer having a reactive functional group are preferably introduced.
- the content ratio of the polysiloxane structure may be, for example, 3% by mass or more based on the total amount of the acrylic silicone graft polymer.
- the “acrylic silicone graft polymer having a reactive functional group” includes an oligomer having a relatively small molecular weight. That is, the “acrylic silicone graft polymer having a reactive functional group” includes an acrylic silicone graft oligomer having a reactive functional group.
- the weight average molecular weight of the acrylic polymer portion constituting the main chain of the acrylic silicone graft polymer having a reactive functional group may be, for example, 5,000 to 2,000,000, 30,000 to 1,000,000, or 100,000 to 400,000. You may.
- the “weight average molecular weight” means a value measured by gel permeation chromatography and is represented by a polystyrene conversion value.
- acrylic silicone graft polymer having a reactive functional group a commercially available one may be used, or a separately synthesized one may be used.
- examples of the acrylic silicone graft polymer having a reactive functional group include KP-500 series manufactured by Shin-Etsu Chemical Co., Ltd., Cymac series manufactured by Toagosei Co., Ltd. (Cymac is a registered trademark), and Taisei Fine Chemical Co., Ltd. 8SS (UV curable silicone acrylic polymer) series and the like can be used.
- the acrylic silicone graft polymer having a reactive functional group can be prepared, for example, by the following preparation method.
- a polymer of a monomer such as (meth) acrylic acid and (meth) acrylate (a linear acrylic polymer) is introduced with a silicone macromonomer by a polymer reaction, and then, A method of preparing an acrylic silicone graft polymer having a reactive functional group by reacting a (meth) acrylate having a glycidyl group with a carboxyl group derived from acrylic acid to introduce a reactive functional group is described. Can be mentioned.
- the preparation method of the acrylic silicone graft polymer having a reactive functional group includes a monomer such as (meth) acrylic acid and (meth) acrylate, and a monomer having a glycidyl group such as glycidyl (meth) acrylate.
- a silicone macromonomer is introduced by a polymer reaction, and then, for the glycidyl group introduced into the acrylic polymer, (meth) acrylic acid,
- a reactive functional group (here, (meth)) is obtained by reacting (meth) acrylic acid chloride, (meth) acrylamide, and a (meth) acrylate having a hydroxyl group (for example, 2-hydroxyethyl (meth) acrylate). It may be a method of preparing an acrylic silicone graft polymer having a reactive functional group by introducing an acryloyl group).
- the method of copolymerizing a monomer having a glycidyl group described above is a method of copolymerizing a monomer having a hydroxyl group and then reacting an isocyanate compound having a (meth) acryloyl group with the hydroxyl group, and a monomer having a phenolic hydroxyl group.
- a method of reacting a (meth) acrylate having a glycidyl group with the phenolic hydroxyl group or the thiol group after copolymerizing a monomer having a thiol group may be used.
- the acrylic silicone graft polymer having a reactive functional group includes a polysiloxane having one vinyl group or a (meth) acryloyl group, a monomer such as (meth) acrylic acid and (meth) acrylate, and glycidyl ( It can also be prepared by a method in which a reactive functional group is introduced into an acrylic polymer having a silicone graft by copolymerizing with a monomer having a glycidyl group such as (meth) acrylate.
- the method may further include a step of preparing the composition so that the content of the component (C) is 10 to 600% by mass based on the total amount of the component (B).
- the content of the component (C) may be, for example, 5 to 400% by mass, 12 to 300% by mass, and 15 to 100% by mass based on the total amount of the component (B).
- the content of the component (C) is within the above range, the content of the component (A) in the slurry can be increased, and the peelability and the smoothness of the release layer 14 are compatible at a higher level. can do.
- the method may further include a step of preparing the composition so that the content of the component (A) is 0.5% by mass or more.
- the content of the component (A) may be, for example, 0.8% by mass or more, 1.0% by mass or more, or 1.2% by mass or more, based on the total amount of the composition.
- the content of the component (A) is within the above range, it is possible to produce a release film in which the release properties of the release layer are further improved.
- the components (A) and (B) have small compatibility with each other.
- the solvent content in the coating film is reduced in the solvent removal step, which will be described later, so that the components inside the coating film are appropriately mixed. Separation can occur. Therefore, in the obtained photosensitive layer, the concentration gradient of the (A) component and the (B) component can be more easily provided in the depth direction.
- the concentration gradient can be adjusted by blending the component (C).
- "not compatible with each other” and "hardly compatible with each other” means that when the respective components are mixed, phase separation occurs, or white turbidity does not result in a uniform solution. ..
- composition containing the silicone resin having a reactive functional group may contain other components in addition to the components (A), (B) and (C).
- other components include a photopolymerization initiator and a filler.
- the photopolymerization initiator a compound that generates a radical upon irradiation with actinic rays can be used.
- the photopolymerization initiator include 1-hydroxy-cyclohexyl-phenyl-ketone, 2-hydroxy-2-methyl-1-phenyl-propan-1-one, and 2-hydroxy-1- ⁇ 4- [4- ⁇ -Hydroxyalkylphenones such as (2-hydroxy-2-methyl-propionyl) -benzyl] phenyl ⁇ -2-methyl-propan-1-one, and 2-methyl-1- (4-methylthiophenyl) -2- Examples include ⁇ -aminoalkylphenones such as morpholinopropan-1-one.
- photopolymerization initiator for example, IRGACURE 184, IRGACURE 127, IRGACURE 907, IRGACURE 379, and DAROCURE 1173 (above, trade name of Ciba Specialty Chemicals Co., Ltd.) can be used.
- the solvent reduction step in the method for producing a release film is a step of reducing the content of the solvent and providing a photosensitive layer containing the composition.
- the solvent reducing step is preferably a step of removing the solvent to provide a photosensitive layer made of the composition.
- the solvent may be removed by heating and drying at a temperature of 50 to 150 ° C. for 10 seconds to 10 minutes, for example.
- the specific gravity of the component (B) contained in the slurry is usually about 0.95 to 1.5, and the specific gravity of the component (A) is usually about 0.95 to 1.5. That is, the specific gravities of the component (B) and the component (A) are almost the same, or the component (A) tends to be slightly lighter. Further, the component (A) has a lower surface energy than the component (B).
- each component moves so that the energy state becomes low.
- the solvent is reduced from the coating film provided on the base material film 12 in the solvent removal step. In the process, the component (A) is more likely to move to the surface opposite to the base film 12 side (the surface that becomes the release surface 14a).
- the photosensitive functional layer formed by reducing the content of the solvent is irradiated with an actinic ray so that the reactive functional groups of the component (A), the component (B) and the component (C) are reacted.
- the group is reacted to cure the composition to form a release layer.
- the irradiation amount of actinic rays can be adjusted according to the thickness of the photosensitive layer and the like.
- the exposure step may be performed under a nitrogen atmosphere. By performing the exposure step in a nitrogen atmosphere, it is possible to suppress deactivation of radical active species due to oxygen, and it is possible to further prevent insufficient curing of the photosensitive layer.
- the actinic radiation is preferably ultraviolet light.
- the light source of ultraviolet rays for example, a mercury lamp, a metal halide lamp, or the like can be used.
- the ceramic component sheet is a base material, a release layer provided on the base material, and a ceramic green sheet and an electrode green provided on the surface of the release layer opposite to the base material side. And at least one green sheet selected from the group consisting of sheets.
- the ceramic component sheet may use the above-mentioned release film 10 as a release film having a base material and a release layer provided on the base material.
- FIG. 2 is a schematic sectional view showing an example of a ceramic component sheet.
- the ceramic component sheet 20 includes a release film 10, a ceramic green sheet 22 on the release surface 14 a of the release layer 14, and an electrode green sheet 24 formed on the ceramic green sheet 22.
- the ceramic green sheet 22 is, for example, a dielectric green sheet for forming a laminated ceramic capacitor.
- the thickness of the ceramic green sheet 22 may be, for example, 0.03 to 5 ⁇ m, or 0.1 to 1 ⁇ m.
- the ceramic green sheet 22 is peeled from the release film 10 and then fired to become a dielectric containing at least one selected from the group consisting of calcium titanate, strontium titanate and barium titanate.
- the electrode green sheet 24 is peeled from the release film 10 and then fired to form an electrode containing at least one selected from the group consisting of copper, nickel and alloys thereof.
- the above-mentioned ceramic component sheet can be manufactured, for example, by the following manufacturing method.
- One embodiment of a method for manufacturing a ceramic component sheet is a composition containing a silicone resin having a reactive functional group, a (meth) acrylate having a reactive functional group, and an acrylic silicone graft polymer having a reactive functional group, and a solvent.
- a step of applying a slurry containing a slurry on a substrate coating step
- a step of reducing the content of the solvent in the slurry to provide a photosensitive layer (solvent reducing step)
- exposing the photosensitive layer exposing the photosensitive layer.
- a step of forming a release layer composed of a cured product of the composition (exposure step), and on the surface of the release layer opposite to the base material side, from the group consisting of ceramic powder and electrode material.
- a step of forming at least one green sheet selected from the group consisting of ceramic green sheets and electrode green sheets by applying a paste containing at least one selected and removing the solvent (sheet forming step); , With.
- the coating process, the solvent reduction process, and the exposure process are common to the method for manufacturing the release film 10 described above, and the above description can be applied.
- the coating film, the solvent reduction process, and the exposure process may be omitted by using the release film 10 described above.
- a paste containing a ceramic powder (ceramic paste) and a paste containing an electrode material (electrode paste) are applied onto the surface 14a of the release film 10 opposite to the base film 12 side.
- the ceramic paste contains, for example, a dielectric material (ceramic powder) and an organic vehicle.
- a dielectric material ceramic powder
- an organic vehicle organic vehicle
- the dielectric material it is possible to appropriately select and use various compounds such as carbonates, nitrates, hydroxides, and organometallic compounds that become complex oxides or oxides by firing.
- the average particle size of the dielectric material is preferably 0.4 ⁇ m or less, more preferably 0.1 to 3.0 ⁇ m.
- the ceramic paste may further contain a dispersant, a plasticizer, an antistatic agent, a dielectric material, a glass frit, an insulator and the like, if necessary.
- the electrode paste is at least selected from the group consisting of conductor materials such as various conductive metals and alloys, and materials that become conductor materials after firing with various oxides, organometallic compounds, resinates and the like.
- conductor materials such as various conductive metals and alloys, and materials that become conductor materials after firing with various oxides, organometallic compounds, resinates and the like.
- One and an organic vehicle examples include nickel metal, nickel alloys, and mixtures thereof.
- the electrode paste may further contain a plasticizer. By containing the plasticizer in the electrode paste, the wettability of the electrode paste with respect to the release layer can be further improved.
- plasticizers include phthalic acid esters such as benzylbutyl phthalate (BBP), adipic acid, phosphoric acid esters, and glycols.
- a binder resin dissolved in an organic solvent can be used as the organic vehicle contained in the ceramic paste and the electrode paste.
- the binder resin include ethyl cellulose, acrylic resin, butyral resin, polyvinyl acetal, polyvinyl alcohol, polyolefin, polyurethane, polystyrene, and copolymers thereof.
- the binder resin preferably contains a butyral resin, specifically a polyvinyl butyral resin. By using a butyral resin as the binder resin, the mechanical strength of the ceramic green sheet 22 and the electrode green sheet 24 can be increased.
- the polymerization degree of the polyvinyl butyral resin is preferably 1000 to 1700, more preferably 1400 to 1700.
- the release property of the ceramic green sheet 22 and the electrode green sheet 24 is further improved by using an alkylenediol di (meth) acrylate monomer as the raw material of the release layer 14. be able to.
- organic solvent used for the organic vehicle examples include terpineol, alcohol, butyl carbitol, acetone, toluene, xylene, and benzyl acetate. These organic solvents may be used alone or in combination of two or more.
- organic solvents include methanol, ethanol, propanol, and butanol.
- the above-mentioned ceramic paste is applied to the surface 14a of the release film 10 using, for example, a doctor blade device. Then, the applied ceramic paste is heated and dried in a commercially available drying device at a temperature of 50 to 100 ° C. for 1 to 20 minutes to form the ceramic green sheet 22.
- the ceramic green sheet 22 shrinks by 5 to 25% compared to before drying.
- an electrode paste is printed on the surface 22a of the formed ceramic green sheet 22 by using, for example, a screen printing device so as to have a predetermined pattern. Then, the applied electrode paste is heated and dried in a commercially available drying device at a temperature of 50 to 100 ° C. for 1 to 20 minutes to form the electrode green sheet 24. This makes it possible to obtain the ceramic component sheet 20 in which the release film 10, the ceramic green sheet 22 and the electrode green sheet 24 are sequentially laminated.
- the ceramic component sheet 20 is manufactured using the release film 10 having the release layer 14
- the green sheet 26 including the ceramic green sheet 22 and the electrode green sheet 24 is sufficiently excellent in the release property, and the green sheet 26. It is possible to sufficiently reduce the peeling residue. Therefore, the variation in the thickness of the green sheet 26 is sufficiently reduced, and the occurrence of pinholes can be sufficiently suppressed.
- the electrode paste or the ceramic paste is applied to the surface 14a of the release layer 14, the occurrence of repellency is sufficiently suppressed. Therefore, it is possible to easily form the green sheet 26 with less pinholes and less variation in thickness. You can This makes it easier to manufacture the monolithic ceramic capacitor.
- a method for manufacturing a monolithic ceramic capacitor which is an embodiment of a method for manufacturing a ceramic component, will be described below.
- One embodiment of a method for manufacturing a laminated ceramic capacitor includes a step of preparing a plurality of ceramic component sheets (preparing step), a laminating step of laminating a plurality of green sheets of ceramic component sheets to obtain a laminated body, and firing the laminated body. And a sintering step for obtaining a sintered body, and an electrode forming step for forming a terminal electrode on the sintered body to obtain a laminated ceramic capacitor.
- a plurality of ceramic component sheets 20 manufactured by the above-described ceramic component sheet manufacturing method are prepared.
- the green sheets 26 of the plurality of ceramic component sheets 20 are laminated to obtain a laminated body in which the plurality of green sheets 26 are laminated.
- the release film 10 of the ceramic component sheet 20 is released to obtain the green sheet 26.
- the green sheet 26 and the ceramic component sheet 20 are laminated so that the surface 22b of the green sheet 26 and the electrode green sheet 24 of another ceramic component sheet 20 face each other.
- the release film 10 is released from the laminated ceramic component sheets 20.
- a laminate can be obtained. That is, in this laminating step, after laminating the ceramic component sheet 20 on the green sheet 26, the procedure of peeling the release film 10 is repeated a plurality of times to form a laminated body.
- the green sheets 26 are laminated so that the front surface 22a of the green sheet 26 and the surface 22b of another green sheet 26 from which the release film 10 has been peeled face each other.
- a stacked body can be obtained. That is, in this laminating step, the laminated body is formed by repeating the procedure of laminating the green sheet 26 from which the peeling film 10 is peeled off a plurality of times.
- the number of green sheets to be laminated in the laminate is not particularly limited, and may be, for example, tens to hundreds of layers. You may provide a thick exterior green sheet in which an electrode layer is not formed on both end surfaces orthogonal to the stacking direction of the stacked body. After forming the laminated body, the laminated body may be cut into green chips.
- the laminated body (green chip) obtained in the laminating step is fired to obtain a sintered body.
- the firing conditions are preferably 1100 to 1300 ° C. and an atmosphere such as a mixed gas of moistened nitrogen and hydrogen.
- the oxygen partial pressure in the atmosphere during firing is preferably 10 ⁇ 2 Pa or less, more preferably 10 ⁇ 2 to 10 ⁇ 8 Pa.
- binder removal processing can be performed under normal conditions.
- a base metal such as nickel and nickel alloy is used as the conductor material of the internal electrode layer (electrode green sheet 24)
- it is preferably performed at 200 to 600 ° C.
- heat treatment may be performed in order to reoxidize the dielectric layer forming the sintered body.
- the holding temperature or maximum temperature in the heat treatment is preferably 1000 to 1100 ° C.
- the oxygen partial pressure during the heat treatment is preferably higher than that in the reducing atmosphere during firing, and more preferably 10 ⁇ 2 Pa to 1 Pa.
- the thus obtained sintered body is preferably subjected to end face polishing by, for example, barrel polishing and sandblasting.
- a laminated ceramic capacitor can be obtained by baking the terminal electrode paste on the side surface of the sintered body to form the terminal electrode.
- the above-described ceramic component sheet is used in the ceramic component manufacturing method of the present embodiment, it is possible to sufficiently suppress the generation of pinholes in the obtained ceramic component, that is, the laminated ceramic capacitor. Therefore, a monolithic ceramic capacitor can be formed with a high yield.
- FIG. 3 is a schematic sectional view showing an example of a ceramic component.
- the monolithic ceramic capacitor 100 shown in FIG. 3 includes an inner portion 40 and a pair of outer portions 50 that sandwich the inner portion 40 in the stacking direction.
- the monolithic ceramic capacitor 100 of this embodiment has a terminal electrode 60 on its side surface.
- the interior portion 40 has a plurality (13 layers in this embodiment) of ceramic layers 42 and a plurality (12 layers in this embodiment) of internal electrode layers 44.
- the ceramic layers 42 and the internal electrode layers 44 are alternately laminated.
- the internal electrode layer 44 is electrically connected to the terminal electrode 60.
- the exterior part 50 is formed of a ceramic layer.
- This ceramic layer is formed from an exterior green sheet and contains, for example, the same components as the ceramic layer 42.
- Example 1 In the reaction vessel, as the component (A), in the following general formula (1), m is 10 to 100, R 1 and R 2 are propyl groups, 0.5 part by mass of a silicone resin, and the component (B) is 85 parts by mass of trimethylolpropane triacrylate, 15 parts by mass of an acrylic silicone graft polymer having an acryloyl group as the component (C), 20 parts by mass of propylene glycol monomethyl ether as the solvent, and methyl ethyl ketone (MEK) and isopropyl alcohol (IPA). 400 parts by mass of the mixed solution of () (a solution in which MEK and IPA were mixed at a volume ratio of 1: 1) was weighed and mixed by stirring to obtain a colorless transparent solution.
- MEK methyl ethyl ketone
- a coating solution slurry
- a bar coater Apply the prepared coating solution to a biaxially stretched polyethylene terephthalate (PET) film (base film, thickness: 38 ⁇ m) and evaporate the solvent by drying with hot air at a heating temperature of 80 ° C. for 30 seconds.
- a photosensitive layer was formed on the PET film.
- the formed photosensitive layer was irradiated with ultraviolet rays in a nitrogen atmosphere having an oxygen concentration of 100 ppm to obtain a release film having a release layer having a thickness of 1016 nm.
- the irradiation amount of ultraviolet rays was set to 250 mJ / cm 2 in terms of integrated light amount. Further, the thickness of the release layer was measured using a spectrophotometer (manufactured by JASCO Corporation, trade name: V-670).
- ⁇ XPS measurement (element distribution measurement of the delamination layer by X-ray photoelectron spectroscopy, analysis in the depth direction)> XPS measurement (depth direction analysis) was performed on the release layer of the obtained release film. More specifically, the composition analysis of the surface of the release layer by XPS measurement and the etching of the surface of the release layer by sputtering using argon ions are used in combination to gradually expose the inside of the release layer and remove the Compositional analysis was performed.
- a solution of polydimethylsiloxane dissolved in a mixed solvent of toluene, MEK and IPA was used to form a release layer on the PET film in the same manner as in Example 1, and XPS measurement (depth Direction analysis) was performed.
- the peak intensity of silicon was 30,000 (average value) regardless of the depth direction.
- FIG. 4 is a graph showing the results of the depth direction analysis of the delamination layer by XPS measurement.
- the vertical axis represents the peak intensity of silicon atoms (value converted to the value based on the measured value in the release layer made of polydimethylsiloxane), and the horizontal axis represents the depth from the release layer surface (etching time The value converted to the depth from the surface of the release layer) is shown. That is, the graph shows the distribution of silicon atoms along the depth direction of the release layer.
- the result of the example is shown by a solid line
- the result of the comparative example is shown by a broken line.
- the fine roughness Sp of the release layer in the obtained release film is based on the method described in JIS B 0601: 2013 with respect to the surface of the release layer on the side opposite to the base film (the surface to be the release surface). Then, the measurement was performed using a Micromap System (optical interference type three-dimensional non-contact surface shape measuring system) of Ryoka System Co., Ltd.
- A No defect was observed in the area of 20 cm ⁇ 20 cm, and the surface was mirror-like.
- B The number of defects observed is 5 or less in a region of 20 cm ⁇ 20 cm, and interference fringes are generated around the defects (with a change in thickness).
- C The number of defects observed is 5 or more in a region of 20 cm ⁇ 20 cm, or it is difficult to count the number of defects and there is no gloss.
- D The number of defects observed is 10 or more and the diameter of at least one of the defects observed is 1 mm or more in a region of 20 cm ⁇ 20 cm.
- FIG. 5 (a) shows the appearance of the release film prepared in Example 3
- FIG. 5 (b) shows the appearance of the release film prepared in Comparative Example 6.
- the release film prepared in Example 3 the reflection of the fluorescent lamp on the release film was observed, and no defects were observed on the surface of the release layer, resulting in a mirror-like surface. It was confirmed that
- the release film prepared in Comparative Example 6 as shown in (b) of FIG. 5, the image of the fluorescent lamp reflected in the release film was not clear, and numerous defects were observed on the surface of the release layer. It was confirmed that the appearance was inferior.
- the peeling property of the release layer in the obtained release film was measured according to "Adhesion test method for peeling release liner from tape adhesive surface" described in ISO 29862: 2007 (JIS Z 0237: 2009) 180 ° peeling. The following measurements were performed.
- a peeling tester manufactured by Shimadzu Corporation, product name: Autograph AG-X (load cell SBL-10N, load: 10N)) was used for the measurement.
- the obtained release film was placed on the washed plate glass so that the base film was in contact with it.
- a 1-inch wide adhesive tape (manufactured by Nitto Denko KK, trade name: 31B) was adhered to the release layer of the release film so that the adhesive surface was in contact with the release layer, and air was not allowed to enter. ..
- the base film side of the release film was attached to the test plate of the release tester. As a grip allowance, the adhesive tape was bent 180 ° and connected upward to the grip jig connected to the load cell.
- the average value of the load detected by the load cell was obtained when the adhesive tape was pulled up at a load speed of 300 mm / min.
- the peelability of the release film was determined by converting the obtained average value when using an adhesive tape having a width of 10 mm.
- Examples 2 to 12, Comparative Examples 1 to 7 A release film was obtained in the same manner as in Example 1 except that the raw materials and the charging ratio (mass ratio) were changed as shown in Table 1. With respect to the obtained release film, the thickness of the release layer, the XPS measurement for the release layer, the appearance, and the release property were evaluated. The results are shown in Table 1 below.
- Component acrylic silicone graft polymer having reactive functional group Acrylic silicone having acryloyl group Graft polymer
- the present disclosure it is possible to provide a release film having excellent release properties and having sufficient smoothness, and a method for producing the release film. According to the present disclosure, it is also possible to provide a ceramic component sheet having the above-described release film and capable of producing a thin green sheet, and a method for producing the same. The present disclosure can further provide a method for manufacturing a laminated ceramic capacitor using the release film as described above.
Abstract
Description
反応容器に、(A)成分として下記一般式(1)において、mが10~100であり、R1及びR2がプロピル基である、シリコーン樹脂を0.5質量部、(B)成分としてトリメチロールプロパントリアクリレートを85質量部、(C)成分としてアクリロイル基を有するアクリルシリコーングラフトポリマーを15質量部、並びに溶剤としてプロピレングリコールモノメチルエーテルを20質量部、及びメチルエチルケトン(MEK)とイソプロピルアルコール(IPA)の混合溶液(MEKとIPAを体積比で、1対1で混合した溶液)を400質量部測り取り、撹拌混合することによって無色透明の溶液を得た。
得られたはく離フィルムのはく離層に対して、XPS測定(深さ方向分析)を行った。より具体的には、XPS測定によるはく離層の表面の組成分析と、アルゴンイオンを用いたスパッタによるはく離層の表面のエッチングとを併用して、はく離層の内部を徐々に露出させながら各表面における組成分析を行った。
得られたはく離フィルムにおけるはく離層の微小粗さSpは、はく離層の基材フィルムとは反対側の表面(はく離面となる面)に対して、JIS B 0601:2013に記載の方法に準拠して、株式会社菱化システムのMicromap System(光学干渉式三次元非接触表面形状測定システム)を用いて測定を行い決定した。
得られたはく離フィルムにおけるはく離層の外観を目視観察し、下記のA~Dの基準で評価した。
A:20cm×20cmの領域中に、欠陥が観測されず、鏡面状となっている。
B:20cm×20cmの領域中に、観測される欠陥の数が5つ以下であり、該欠陥の周囲に干渉縞が生じている(厚さの変動を伴っている)。
C:20cm×20cmの領域中に、観測される欠陥の数が5つ以上ある、又は欠陥の数を数えるのが困難であり且つ光沢が無い。
D:20cm×20cmの領域中に、観測される欠陥の数が10以上であり、且つ観測される欠陥の少なくとも一つの径が1mm以上である。
得られたはく離フィルムにおけるはく離層のはく離性を、ISO29862:2007(JIS Z 0237:2009)に記載された「はく離ライナーをテープ粘着面に対して引きはがす粘着力試験方法」180°はく離に準拠して下記のとおり測定を行った。測定に際しては、はく離試験機(株式会社島津製作所製、製品名:オートグラフ AG-X(ロードセル SBL-10N、荷重:10N))を用いた。
表1に示すとおりに原料及び仕込み比(質量比)を変更したこと以外は、実施例1と同様にして、はく離フィルムを得た。得られたはく離フィルムについて、はく離層の厚さ、はく離層に対するXPS測定、外観、及びはく離性の評価を行った。結果を下記の表1に示す。
(A)成分:反応性官能基を有するシリコーン樹脂
a1:両末端にアクリロイル基を有するジメチルポリシロキサン(式(X)で示す化合物)
a2:側鎖にアクリロイル基を有するポリジメチルシロキサン(ビックケミー・株式会社製、商品名:BYK-3500)
(B)成分:反応性官能基を有する(メタ)アクリレート
b1:トリメチロールプロパントリアクリレート
b2:ジペンタエリスリトールヘキサアクリレート
(C)成分:反応性官能基を有するアクリルシリコーングラフトポリマー
アクリロイル基を有するアクリルシリコーングラフトポリマー
Claims (12)
- 基材と、前記基材上に設けられたはく離層と、を有するはく離フィルムであって、
前記はく離層は、反応性官能基を有するシリコーン樹脂とその他の重合性成分とを含有する組成物の硬化物であり、XPSによって測定される前記はく離層の前記基材側とは反対側の表面におけるケイ素のピーク強度をXとし、前記はく離層の前記表面から深さ4.1nmにおけるケイ素のピーク強度をYとし、ポリジメチルシロキサンを90%以上含有するシリコーン樹脂層を形成した場合に測定されるケイ素のピーク強度をZとしたときに、XがYよりも大きく、Zに対するXの比率が40%以上であり、且つZに対するYの比率が5~50%である、はく離フィルム。 - 前記Xに対する前記Yの比率が70%以下である、請求項1に記載のはく離フィルム。
- 前記はく離層が、反応性官能基を有するシリコーン樹脂、反応性官能基を有する(メタ)アクリレート、及び反応性官能基を有するアクリルシリコーングラフトポリマーを含有する組成物の硬化物である、請求項1又は2に記載のはく離フィルム。
- 前記組成物における前記アクリルシリコーングラフトポリマーの含有量が、前記(メタ)アクリレートの全量を基準として、10~600質量%である、請求項3に記載のはく離フィルム。
- 前記シリコーン樹脂の含有量が、前記組成物の全量を基準として、0.5質量%以上である、請求項3又は4に記載のはく離フィルム。
- 請求項1~5のいずれか一項に記載のはく離フィルムと、
前記はく離層の前記表面上に設けられた、セラミックグリーンシート及び電極グリーンシートからなる群より選択される少なくとも一つのグリーンシートと、を有する、セラミック部品シート。 - 基材と、前記基材上に設けられたはく離層と、を有するはく離フィルムの製造方法であって、
反応性官能基を有するシリコーン樹脂、反応性官能基を有する(メタ)アクリレート、及び反応性官能基を有するアクリルシリコーングラフトポリマーを含有する組成物と溶剤とを含むスラリーを前記基材上に塗工する工程と、
前記スラリー中の前記溶剤の含有量を低減して感光層を設ける工程と、
前記感光層を露光させることによって前記組成物の硬化物で構成されるはく離層を形成する工程と、を有する、はく離フィルムの製造方法。 - 前記アクリルシリコーングラフトポリマーの含有量が、前記(メタ)アクリレートの全量を基準として、10~600質量%となるように前記組成物を調製する工程を更に有する、請求項7に記載のはく離フィルムの製造方法。
- 前記シリコーン樹脂の含有量が0.5質量%以上となるように前記組成物を調製する工程を更に有する、請求項7又は8に記載のはく離フィルムの製造方法。
- 前記反応性官能基が、(メタ)アクリロイル基及びビニル基からなる群より選択される少なくとも一つの官能基であり、
前記組成物が、光重合開始剤を更に含有する、請求項7~9のいずれか一項に記載のはく離フィルムの製造方法。 - 基材と、前記基材上に設けられたはく離層と、前記はく離層の前記基材側とは反対側の表面上に設けられた、セラミックグリーンシート及び電極グリーンシートからなる群より選択される少なくとも一つのグリーンシートと、を有する、セラミック部品シートの製造方法であって、
反応性官能基を有するシリコーン樹脂、反応性官能基を有する(メタ)アクリレート、及び反応性官能基を有するアクリルシリコーングラフトポリマーを含有する組成物と溶剤とを含むスラリーを前記基材上に塗工する工程と、
前記スラリー中の前記溶剤の含有量を低減して感光層を設ける工程と、
前記感光層を露光させることによって前記組成物の硬化物で構成されるはく離層を形成する工程と、
前記はく離層の前記基材側とは反対側の表面に、セラミック粉末及び電極材料からなる群より選択される少なくとも一つを含有するペーストを塗工し、溶剤を除去することによってセラミックグリーンシート及び電極グリーンシートからなる群より選択される少なくとも一つのグリーンシートを形成する工程と、
を有する、セラミック部品シートの製造方法。 - 積層セラミックコンデンサの製造方法であって、
請求項6に記載のセラミック部品シートを複数準備する工程と、
前記セラミック部品シートから前記はく離フィルムをはく離し、前記グリーンシートを積層して、複数の前記グリーンシートを有する積層体を得る工程と、
前記積層体を焼結して焼結体を得る工程と、
を有する、積層セラミックコンデンサの製造方法。
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