Roll of gas-barrier film, and process for producing gas-barrier film
AssigneeKonica Minolta, Inc.
InventorTakahiro MORI
Life of this patent
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Abstract
A roll of a gas barrier film may be obtained by winding a gas barrier film including a base and a gas barrier layer in a direction orthogonal to a width of the film. The gas barrier layer may contain silicon, oxygen, and carbon atoms. A surface of the base, opposite to a side of the gas barrier layer, may have protrusions A having a height of 10 nm or more and less than 100 nm from a roughness center plane at a density of 500 to 10,000/mm2, and protrusions B having a height of 100 nm or more from a roughness center plane at a density of 0 to 500/mm2. The base may have a haze of 1% or less measured in accordance with JIS K-7136. A flatness index defined as the number of sites raised 1 mm or more is within a range of from 0 to 5.
Claims19
A roll of a gas barrier film obtained by winding a gas barrier film comprising a base and a gas barrier layer in a direction orthogonal to a width the film,
- wherein:
- the gas barrier layer contains silicon atoms, oxygen atoms and carbon atoms;
- a carbon distribution curve with a distance from a surface of the gas barrier layer in a film thickness direction as X value and a content ratio of the carbon atoms relative to a total amount of the silicon atoms, the oxygen atoms and the carbon atoms as Y value has a maximum value and a minimum value;
- a surface of the base, opposite to a side on which the gas barrier layer is disposed, has protrusions A having a height of 10 nm or more and less than 100 nm from a roughness center plane at a density of 500 to 10,000/mm2, and protrusions B having a height of 100 nm or more from a roughness center plane at a density of 0 to 500/mm2;
- the base has a haze of 1% or less measured in accordance with JIS K-7136;
- and
- when a strip with a width of 20 mm including both ends in a widthwise direction of the gas barrier film and being obtained by cutting in a direction parallel to the widthwise direction of the gas barrier film is kept for 10 minutes at 25° C. and at 50% RH on a stage, and then the number of sites raised 1 mm or more from a surface of the stage is counted in a lengthwise direction of the strip, a flatness index defined as the number of sites raised 1 mm or more from the surface of the stage per total length of the strip is within a range of from 0 to 5.
A process for producing a gas barrier film using a plasma CVD film-forming apparatus including a vacuum chamber, a pair of film-forming rolls disposed inside the vacuum chamber and having rotation axes being approximately parallel to each other, with a magnetic field-generating member being contained therein, and a power source that provides a potential difference between the pair of film-forming rolls,
- wherein:
- a film formation surface of an elongated base wound around one of the film-forming rolls and a film formation surface of the elongated base wound around the other of the film-forming rolls face each other across film-forming space, as the elongated base is conveyed while being wound around the pair of film-forming rolls, with a wrap angle of the base wound around the film-forming rolls being 150° or more;
- the process comprises:
- supplying a film-forming gas containing an organic silicon compound gas and oxygen gas to the film-forming space;
- providing a potential difference between the pair of film-forming rolls with the power source to generate discharge plasma in the film-forming space;
- and forming a thin film gas barrier layer containing silicon atoms, oxygen atoms and carbon atoms on the film formation surface of the base;
- the base has a haze of 1% or less measured in accordance with JIS K-7136;
- and
- a surface of the base to be in contact with the film-forming roll has protrusions A having a height of 10 nm or more and less than 100 nm from a roughness center plane at a density of 500 to 1,000/mm2, and protrusions B having a height of 100 nm or more from a roughness center plane at a density of 0 to 500/mm2.
Dependencies are inferred from the claim text.