# US 8,540,837 B2 · Functional film and method for manufacturing the functional film

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- Number: US 8,540,837 B2
- Document ID: US8540837B2
- Status: Granted
- Kind: B2
- Application number: 12/712,981
- Filed: 2010-02-25
- Published: 2010-08-26
- Granted: 2013-09-24
- Earliest claimed: 2009-02-26
- Assignees: FUJIFILM Corporation
- Applicants: Eijirou Iwase; Jun Fujinawa; Toyoaki Hieda; Toshiyuki Katagiri; Hiroshi Arakatsu
- Inventors: Eijirou Iwase; Jun Fujinawa; Toyoaki Hieda; Toshiyuki Katagiri; Hiroshi Arakatsu
- Web page: https://patentgrep.com/patent/US8540837B2

## CPC

- C23C 14/562: {for coating elongated substrates}
- C23C 14/024: {Deposition of sublayers, e.g. to promote adhesion of the coating (C23C14/027 takes precedence)}
- C23C 14/081: {of aluminium, magnesium or beryllium}
- C23C 16/0272: {Deposition of sub-layers, e.g. to promote the adhesion of the main coating}
- C23C 16/545: {for coating elongated substrates}
- B05D 7/04: to surfaces of films or sheets (producing layered products by applying coatings of pasty or pulverulent plastics B29C41/00)
- B05D 2252/02: of indefinite length
- B32B 37/003: {to avoid air inclusion}
- B32B 37/12: characterised by using adhesives
- B32B 37/203: {One or more of the layers being plastic}
- B32B 38/10: Removing layers, or parts of layers, mechanically or chemically
- B32B 2037/243: {Coating}
- B32B 2305/02: Cellular or porous
- B32B 2309/68: Vacuum
- B32B 2457/00: Electrical equipment
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A method for manufacturing a functional film includes steps of: feeding a support continuously from a first film roll, forming a coating film on the support, providing a laminate film on a surface of the coating film, and taking up the support to a second film roll; and loading the second film roll made by the aforementioned step in a vacuum film-forming apparatus, feeding the support provided with the laminate film continuously from the film roll, peeling off the laminate film, forming an inorganic film on the coating film on the support, and taking up the support to a third film roll.

## Claims

### Claim 1

A method for manufacturing a functional film, comprising steps of:
feeding a support continuously from a first film roll, forming a coating film on the support, providing a laminate film on a surface of the coating film under atmospheric pressure, and taking up the support to a second film roll; and
loading the second film roll made by the aforementioned step in a vacuum film-forming apparatus, feeding the support provided with the laminate film continuously from the second film roll, peeling off the laminate film, forming an inorganic film on the coating film on the support, and taking up the support to a third film roll, wherein
an adhesive material having a peel force of 1 N/m or more and 5 N/m or less against the coating film is applied on the laminate film, wherein
the laminate film has a porous structure, and
the laminate film is provided after curing of the coating film and before a pass roller coming in contact with the coating film side of the support, and the laminate film is peeled off before formation of the inorganic film and after passing through all pass rollers coming in contact with the coating film side of the support.

### Claim 2 (depends on 1)

The method for manufacturing a functional film according to claim 1, wherein thickness of the laminate film is 10 μm or more and 300 μm or less.

### Claim 3 (depends on 1)

The method for manufacturing a functional film according to claim 1, wherein the thickness of the inorganic film is 10 nm or more and 200 nm or less.

### Claim 4 (depends on 1)

The method for manufacturing a functional film according to claim 1, wherein the moisture permeability of the functional film is less than 1.0×10−3 g/m2·day.

### Claim 5 (depends on 1)

The method for manufacturing a functional film according to claim 1, wherein the coating film is formed from a material comprising a radiation-curable monomer or oligomer.

### Claim 6 (depends on 1)

A method for manufacturing a functional film according to claim 1, wherein the laminate film is a sheet-like member having a porous structure.

### Claim 7 (depends on 1)

The method for manufacturing a functional film according to claim 1, wherein the coating film has a hardness of “HB” or higher in terms of pencil hardness (defined by the Japanese Industrial Standards, No. JIS S 6006), and the coating film has an average surface roughness of 10 nm or less per 10 μm square.