METHOD FOR MANUFACTURING A MASKING FILM AND MASKING FILM MANUFACTURED THEREBY

Abstract

A method for manufacturing a masking film includes forming a molten polymer web that includes at least one polymer, spraying a fluid on one side of the molten polymer web to rapidly cool a random pattern of locations on the one side of the molten polymer web, and cooling the molten polymer web to form the masking film. The masking film includes a plurality of protrusions on one side thereof that correspond to the random pattern of locations on the one side of the molten polymer web contacted by the fluid.

Claims

1. A method for manufacturing a masking film, the method comprising: forming a molten polymer web comprising at least one polymer; spraying a fluid on one side of the molten polymer web to rapidly cool a random pattern of locations on the one side of the molten polymer web; and cooling the molten polymer web to form the masking film, wherein the masking film comprises a plurality of protrusions on one side thereof corresponding to the random pattern of locations on the one side of the molten polymer web contacted by the fluid.

2. The method according to claim 1, wherein the fluid is selected from the group consisting of: water, liquid nitrogen, and dry ice.

3. The method according to claim 2, wherein the fluid is water.

4. The method according to claim 3, wherein the water is deionized water.

5. The method according to claim 1, wherein the fluid is sprayed at a pressure of between 1.5 bars and 2.5 bars.

6. The method according to claim 1, wherein the at least one polymer is a polyolefin.

7. The method according to claim 6, wherein the polyolefin is selected from the group consisting of low density polyethylene, high density polyethylene, and polypropylene.

8. The method according to claim 7, wherein the polyolefin is low density polyethylene.

9. The method according to claim 1, wherein during the cooling of the molten polymer web to form the masking film, a second side of the molten polymer web, opposite the one side of the molten polymer web contacted by the fluid, contacts a cooling roller.

10. The method according to claim 1, further comprising drying the masking film.

11. A masking film manufactured according to claim 1, wherein the masking film has a nominal film thickness of between 20 microns and 50 microns.

12. The masking film according to claim 11, wherein the protrusions have a mean height of between 100 microns and 200 microns.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The components of the following figures are illustrated to emphasize the general principles of the present disclosure and are not drawn to scale. Reference characters designating corresponding components are repeated as necessary throughout the figures for the sake of consistency and clarity.

[0020] FIG. 1 schematically illustrates an embodiment of an apparatus for manufacturing a masking film according to embodiments of the invention;

[0021] FIG. 2 is a photograph of one side of the masking film manufactured on an embodiment the apparatus schematically illustrated in FIG. 1;

[0022] FIG. 2A is a photograph of a zoomed in portion of the masking film illustrated in FIG. 2;

[0023] FIG. 3 is a schematic cross-sectional view of the masking film illustrated in FIG. 2;

[0024] FIG. 4 is a schematic illustration of a protected substrate that has the masking film illustrated in FIGS. 2 and 3 adhered to one side of the substrate and a masking film of the prior art adhered to the opposite side of the substrate;

[0025] FIG. 5 is a schematic illustration of two of the protected substrates illustrated in FIG. 4 in a stacked configuration; and

[0026] FIG. 6 is a graph illustrating mean release time as a function of mean protrusion height of masking films according to embodiments of the invention.

DETAILED DESCRIPTION OF EMBODIMENT(S) OF THE INVENTION

[0027] FIG. 1 illustrates an apparatus 100 for manufacturing a masking film according to embodiments of the invention. As illustrated, the apparatus 100 includes an extrusion die 110 that is located at the end of at least one extruder (not shown) and configured to form a polymer web 120, also known as an extrudate or melt curtain.

[0028] The material used to form the polymer web 120 may include a polyolefin, such as polyethylene (PE), such as high density polyethylene (HDPE), low density polyethylene (LDPE), or linear low density polyethylene (LLDPE), or polypropylene (PP), and/or blends thereof. One or more additives, such as an antioxidant, may be included with the material used to form the polymer web 120.

[0029] In the embodiment illustrated in FIG. 1, the polymer web 120 exits the extrusion die 110 and begins to cool and crystalize before entering a nip 130 formed between a cooling roller 140 that rotates around a first axis, and a process roller 142 that rotates around a second axis that is parallel to the first axis. A nip pressure created in the nip 130 may be adjusted by known means. The cooling roller 140 may have a smooth surface or an embossed surface configured to provide texture to one side of the polymer web 120, and the process roller 142 may have a smooth surface or an embossed surface configured to provide a texture to an opposite side of the polymer web 120. The cooling roller 140 continues to cool the polymer web 120 as it is transformed into a solid masking film 200 so that the film 200 may be pulled off of the cooling roller 140 by another roller 144 and ultimately conveyed in a machine direction MD to a winder 150 and wound into a roll 250. Additional rollers, such as rollers 146, 148 depicted in FIG. 1, may be used to convey the film 200 from the cooling roller 140 to the winder 150. The illustrated embodiment is not intended to be limiting in any way and more or less rollers may be used to convey the film 200 to the winder 150.

[0030] As illustrated in FIG. 1, a nozzle 160 is positioned relative to the polymer web 120 so that the nozzle 160 may apply a fluid 162 in the form of a spray (i.e., spray media) to one side of the polymer web 120. The fluid 162 may be in the form of water, such as deionized water, which may be at any temperature, dry ice (i.e., solid carbon dioxide), liquid nitrogen, or any other suitable fluid that may cool the polymer web 120 in random locations as the polymer web 120 travels between the die 110 and the nip 130.

[0031] In an embodiment, a dryer 170 may optionally be positioned downstream from the cooling roller 140 in the machine direction MD and configured to dry the film 200 and allow any excess or residual moisture to evaporate, if needed, prior to being wound on the winder 150 into the roll 250.

[0032] FIGS. 2 and 2A are photographs of a first side 210 of the film 200, and FIG. 3 is a schematic illustration of a cross-section of the film 200. It has been found that applying the fluid 162 to one side of the polymer web 120 causes rapid cooling and crystallization of the random spots that the fluid 162 contacts, and as a result protrusions 230 are formed at such random spots, thereby providing a matte surface on the first side 210 of the film 200. As illustrated, the film 200 includes a base portion 220 that has a nominal thickness (t), and a plurality of protrusions 230 that extend from the base portion 220 on the first side 210 of the film 200. A second side 240 of the film 200 is opposite the first side 210 and has a relatively smooth surface 242. The relatively smooth surface 242 of the second side 240 is configured to adhere to a smooth surface of a substrate in the manner described above with respect to adhesion via van der Waals forces. The plurality of protrusions 230 are randomly located on the first side 210 of the film 200 and have varying sizes, shapes and heights. The height (h) of a single protrusion 230 is defined as the distance between the smooth surface 242 of the second side 240 of the film 200 and a peak 232 of the protrusion 230, as illustrated in FIG. 3.

[0033] FIG. 4 schematically illustrates a protected substrate 400 that includes a substrate 410, which may, for example, be a thin piece of glass, and the masking film 200 of the present invention attached to one side of the substrate 410. As illustrated, the smooth surface 242 of the masking film 200 is attached to the substrate 410. Another masking film 420, which may be a masking film known in the prior art that has two relatively smooth surfaces, is attached to the opposite side of the substrate 410. FIG. 5 schematically illustrates two protected substrates 400 in a stack 500. As illustrated, the first side 210 of the masking film 200 of the present invention is in contact with the masking film 420, which has a relatively smooth outer surface.

EXAMPLES

[0034] The apparatus 100 schematically illustrated in FIG. 1, equipped with three extruders upstream of the die 110, was used to manufacture a series of films, described below, having a target nominal thickness of 25 m, with a core layer having a target thickness of 21 m and outside layers each having a target thickness of 2 m.

[0035] Example 1: Low density polyethylene (LDPE) was used in each of the three layers. The nozzle 160 was positioned 300 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 2.5 bars.

[0036] Example 2: Low density polyethylene (LDPE) was used in each of the outer layers, and high density polyethylene (HDPE) was used in the core layer. The nozzle 160 was positioned 250 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 2.5 bars.

[0037] Example 3: Low density polyethylene (LDPE) was used in each of the three layers. The nozzle 160 was positioned 250 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 2 bars.

[0038] Example 4: Low density polyethylene (LDPE) was used in each of the outer layers, and high density polyethylene (HDPE) was used in the core layer. The nozzle 160 was positioned 200 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 2 bars.

[0039] Example 5: Low density polyethylene (LDPE) was used in each of the three layers. The nozzle 160 was positioned 200 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 1.5 bars.

[0040] Example 6: Low density polyethylene (LDPE) was used in each of the three layers. The nozzle 160 was positioned 150 mm from the polymer web 120, and the fluid 162 was deionized water that was sprayed onto the polymer web at a spray pressure of 1.5 bars.

[0041] Comparative Example A: Low density polyethylene (LDPE) was used in each of the three layers. No fluid was sprayed onto the polymer web 120 so that no protrusions were formed and the resulting film had relatively smooth outer surfaces on both sides.

[0042] The mean height of the protrusions for each of Examples 1-6 was measured and the results are listed in Table I below.

[0043] In addition, each of the samples was laminated to a piece of 55 glass, with the side 210 having the protrusions 230 facing outward, and a prior art masking film having relatively smooth surfaces was laminated to another piece of 55 glass. The piece of glass having the prior art masking film was placed on the piece of glass having a sample such that the prior art masking film was in contact with the sample. A suction cup was attached to the piece of glass having the prior art masking film and lifted upward to see how long it would take to separate the two pieces of protected glass. The results are listed in Table I as the mean release time.

TABLE-US-00001 TABLE I Characteristics of Masking Films Mean Protrusion Mean Height Release Time Sample microns (sec.) Example 1 100 0.5 Example 2 110 0.45 Example 3 139 0.3 Example 4 138 0.32 Example 5 122 0.4 Example 6 124 0.38 Comparative NA 3 Example A

[0044] FIG. 6 illustrates a graph 600 of the mean release time of Examples 1-6 as a function of mean protrusion height. As illustrated, as the protrusion height increases, the release time decreases in a substantially linear manner over the range tested.

[0045] Because the protrusions 230 are formed from the polymer web and are integral parts of the masking film 200, the protrusions should not separate from the masking film 200 during use, which significantly reduces the chance of potential contamination of the substrates 410 that the masking film 200 protects.

[0046] The embodiments described herein represent a number of possible implementations and examples and are not intended to necessarily limit the present disclosure to any specific embodiments. Instead, various modifications can be made to these embodiments as would be understood by one of ordinary skill in the art. Any such modifications are intended to be included within the spirit and scope of the present disclosure and protected by the following claims.