Barrier film

Abstract

Provided is a barrier film and a manufacturing method thereof. The barrier film has a structure comprising a polysilazane barrier layer, which can exhibit excellent running properties in a so-called roll-to-roll process or the like, and can maintain or improve the performance of the barrier layer even during an unwinding and/or winding process, and the like.

Claims

1. A barrier film, comprising: a barrier layer; an anti-blocking layer; and a functional layer between the barrier layer and the anti-blocking layer, wherein: the barrier layer is a polysilazane barrier layer, and the anti-blocking layer comprises an acrylate unit and particles having an average particle diameter in a range from 0.3 μm to 50 μm, and the anti-blocking layer has a thickness of 0.2 μtm to 100 μm, and a surface of the anti-blocking layer facing away from the functional layer has arithmetic mean roughness (Ra) in a range of 50 nm to 500 nm and a maximum cross-sectional height (Rt) in a range of 1 μm to 10 μm.

2. The barrier film according to claim 1, wherein the functional layer is at least one of a base layer and a buffer layer.

3. The barrier film according to claim 1, wherein the polysilazane barrier layer comprises a polysilazane compound comprising a unit of Formula 1: ##STR00002## wherein; R.sub.1, R.sub.2 and R.sub.3 are each independently hydrogen, an alkyl group, an alkenyl group, an aryl group, or an alkoxy group; and n is an arbitrary number.

4. The barrier film according to claim 3, wherein the polysilazane compound has been oxidized to convert a portion of the Si-N bonding units to Si-O.

5. The barrier film according to claim 1, wherein the barrier layer has a thickness in a range from 10 nm to 500 nm.

6. The barrier film according to claim 1, wherein the weight ratio of the polyfunctional acrylate unit with tetrafunctionality or less is 60 weight % or more relative to the total weight of the anti-blocking layer excluding the particles.

7. The barrier film according to claim 6, wherein the anti-blocking layer comprises 1 to 50 parts by weight of the polyfunctional acrylate unit with more than tetrafunctionality relative to 100 parts by weight of the polyfunctional acrylate unit with tetrafunctionality or less.

8. The barrier film according to claim 1, wherein the surface of the anti-blocking layer facing away from the functional layer has a static friction coefficient between a stainless steel surface and the anti-blocking layer measured using a sled weighting 200 g at a measuring speed of 18 cm/min for a region with a length of 8 cm that is in a range of 0.15 to 0.5.

9. The barrier film according to claim 1, wherein the surface of the anti-blocking layer facing away from the functional layer has a kinetic friction coefficient between a stainless steel surface and the anti-blocking layer measured using a sled weighing 200 g at a measuring speed of 18 cm/min for a region with a length of 5 cm that is in a range of 0.15 to 0.5.

10. The barrier film according to claim 1, wherein the ratio (AB) of the average particle diameter (A) of the particles to the thickness (B) of the anti-blocking layer is in a range of 1.5 to 50.

11. An illuminating device, comprising: a light source and the barrier film of claim 1.

12. A display device, comprising: the illuminating device of claim 11.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIGS. 1 and 2 show structures of exemplary barrier films.

(2) FIGS. 3 and 4 show structures of exemplary illuminating devices.

EXAMPLES

(3) Hereinafter, the barrier film of the present application or the like will be described by way of examples, but the scope of the barrier film of the present application or the like is not limited to the following examples.

Test Example 1. Measurement of Water Vapor Transmission Rate

(4) The water vapor transmission rates of the barrier films of Examples or Comparative Examples below were measured using an AQUATRAN2 instrument (MOCON) under conditions of a temperature of 30° C. and 100% relative humidity. The measurement results are shown in Table 1 below.

Test Example 2. Measurement of Surface Roughness

(5) The surface roughness of the anti-blocking layers in the barrier films of Examples or Comparative Examples below was measured using a Nano view E1000 instrument (Nanosystem). The surface roughness was measured for any area region of 0.310 mm×0.232 mm on the surface of the anti-blocking layer. The results are shown in Table 1 below.

Test Example 3. Measurement of Friction Coefficient

(6) The friction coefficients of the anti-blocking layers in the barrier films of Examples or Comparative Examples below were measured using an FP-2260 instrument (Thwing-Albert Instrument Company). The friction coefficient between the SUS (stainless steel) surface and the anti-blocking layer was measured using a sled weighing 200 g. The static friction coefficient was measured at a measuring speed of 18 cm/min for a region with a length of 8 cm, and the kinetic friction coefficient was measured at a measuring speed of 18 cm/min in a region of 5 cm.

Example 1

(7) Production of Barrier Layer

(8) A coating solution obtained by dissolving polysilazane in dibutyl ether was applied to a PET (poly(ethylene terephthalate)) film (T600E50, Mitsubishi) having a thickness of 50 m by a bar coating method, and the obtained coating film was maintained at 70° C. for 1 minute and at 130° C. for 2 minutes to form a polysilazane layer having a thickness of about 300 nm.

(9) Production of Anti-Blocking Layer

(10) Pentaerythritol triacrylate (PETA, trifunctionality, molecular weight: about 298.291 g/mol) and dipentaerythritol hexaacrylate (DPHA, hexafunctionality, molecular weight: about 524 g/mol) were dissolved in a solvent (propylene glycol monomethyl ether) in a weight ratio of 8:2 (PETA: DPHA). A coating solution was prepared by adding 4 parts by weight of a polymerization initiator (Irgacure 127, Ciba) and 0.4 parts by weight of particles (average particle diameter (D50 particle diameter): 5 μm, GB05S, Aica Kogyo) relative to 100 parts by weight of the total weight of PETA and DPHA thereto. The coating liquid was applied to the side without any polysilazane layer in the PET film that the polysilazane layer was formed on one side by a bar coating method, and the obtained coating film was maintained at 100° C. for 2 minutes and then cured through ultraviolet irradiation to form an anti-blocking layer having a thickness of about 1 μm or so.

(11) Blocking Test

(12) Two laminates thus prepared (polysilazane layer/PET film/anti-blocking layer) were cut to sizes of 20 cm and 30 cm, respectively. Subsequently, the anti-blocking layer of one laminate and the polysilazane layer of the other laminate were brought into contact with each other, and a load of 20 kg was applied thereto for 24 hours.

(13) Manufacturing of Barrier Film

(14) After the blocking test, the polysilazane layer was cured by a vacuum plasma curing method commonly used for curing polysilazane to produce a barrier film.

Example 2: Production of Barrier Film

(15) A barrier film was produced in the same manner as in Example 1, except that particles (MX-2000, Soken) having an average particle diameter (D50 particle diameter) of 20 μm were applied instead of particles having an average particle diameter (D50 particle diameter) of 5 m at the time of preparing the coating solution for forming the anti-blocking layer.

Comparative Example 1. Production of Barrier Film

(16) A barrier film was produced in the same manner as in Example 1, except that particles having an average particle diameter (D50 particle diameter) of 0.05 μm and particles having an average particle diameter of 0.1 μm were applied instead of particles having an average particle diameter (D50 particle diameter) of 5 μm at the time of preparing the coating solution for forming the anti-blocking layer.

Comparative Example 2. Production of Barrier Film

(17) A barrier film was produced in the same manner as in Example 1, except that particles having an average particle diameter (D50 particle diameter) of 0.1 μm were applied instead of particles having an average particle diameter (D50 particle diameter) of 5 μm at the time of preparing the coating solution for forming the anti-blocking layer.

(18) TABLE-US-00001 TABLE 1 Water vapor transmission rate Static Kinetic (10.sup.−3 g/ Ra Rt friction friction m.sup.2 .Math. day) (μm) (μm) coefficient coefficient Example 1 0.05 or less 0.14 3.14 0.24 0.25 2 0.05 or less 0.34 5.13 0.23 0.23 Comparative 1 1.11 0.009 0.43 0.27 0.25 Example 2 0.57 0.012 0.74 0.28 0.29