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TW202024265A - 單面壓敏膠帶 - Google Patents

單面壓敏膠帶 Download PDF

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Publication number
TW202024265A
TW202024265A TW108145977A TW108145977A TW202024265A TW 202024265 A TW202024265 A TW 202024265A TW 108145977 A TW108145977 A TW 108145977A TW 108145977 A TW108145977 A TW 108145977A TW 202024265 A TW202024265 A TW 202024265A
Authority
TW
Taiwan
Prior art keywords
layer
tape
pressure
adhesive
meth
Prior art date
Application number
TW108145977A
Other languages
English (en)
Other versions
TWI820272B (zh
Inventor
宋珍秀
李東珍
韓棟宇
Original Assignee
美商羅傑斯公司
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Application filed by 美商羅傑斯公司 filed Critical 美商羅傑斯公司
Publication of TW202024265A publication Critical patent/TW202024265A/zh
Application granted granted Critical
Publication of TWI820272B publication Critical patent/TWI820272B/zh

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Abstract

揭露一種單面壓敏膠帶，其包含一基板、設置於基板之一表面上之一反射金屬層、設置於反射金屬層上之一壓敏黏合劑層、一熱塑性聚合物層及設置於熱塑性聚合物層之一表面上之一遮光層；其中遮光層係被乾法層壓至基板之與設置有反射金屬層之表面相對之表面上。揭露包含該膠帶之製品以及製作及使用該膠帶之方法。

Description

單面壓敏膠帶
本發明係關於一種單面壓敏膠帶、製作及使用該單面壓敏膠帶之方法以及包含該單面壓敏膠帶之製品。
液晶顯示器（liquid crystal display；LCD）用於包含例如電腦顯示器、手機及液晶顯示器電視等消費電子裝置之各種裝置。出於功能原因及視覺美學二者，許多消費電子裝置之液晶顯示器（LCD）周圍之邊框之寬度已變得更窄。然而，隨著邊框變窄，自顯示器邊緣洩漏之光變得更成問題。儘管已嘗試了各種方法來使光洩漏量最小化，然而沒有一種方法係為完全成功的。
此外，在過去，液晶顯示器之導光板（light guide panel；LGP）被固定於剛性框架內，然後貼附至液晶顯示器面板。然而，由於低邊框及無邊框顯示器以及對越來越薄之裝置之需求，製造商已自剛性框架轉向對LGP裝框架之替代方式，例如膠帶，此容許達成一整體更薄之裝置設計。
若干性質對於待用於對LGP裝框架之膠帶很重要。膠帶之遮光效能決定了膠帶將漏光最小化之能力。膠帶之反射效能決定了膠帶提高液晶顯示器之亮度之能力。此外，對於電視顯示器而言，將特別有利的是用作一導光框架基板之一膠帶具有高表面能以用於接合至將LGP黏結至LCD面板之一泡棉膠帶，而無需對框架膠帶進行任何預處理，該框架膠帶係為由低表面能聚碳酸酯製成之框架所需要的。
本文揭露一種單面壓敏膠帶以及製作及使用該膠帶之方法。
一種單面壓敏膠帶包含一基板、設置於基板之一表面上之一反射金屬層、設置於反射金屬層上之一壓敏黏合劑層、一熱塑性聚合物層及設置於熱塑性聚合物層之一表面上之一遮光層；其中遮光層係被乾法層壓至基板之與設置有反射金屬層之表面相對之表面上。
揭露一種包含該膠帶之製品。
一種製造用於液晶顯示器之導光板之方法包含將單面壓敏膠帶黏合至導光板周邊之至少一部分以形成框架。
上述及其他特徵係藉由下圖、詳細說明及申請專利範圍來舉例說明。
本發明之本發明人已開發出一種具有優異遮光及反射效能之單面壓敏膠帶。該膠帶更有利地具有高表面能。該等特性使得單面壓敏膠帶特別適合用於低邊框或無邊框液晶顯示器之框架型導光板。
單面壓敏膠帶包含一基板、設置於基板之一表面上之一反射金屬層、設置於反射金屬層上之一壓敏黏合劑層、一熱塑性聚合物層及設置於熱塑性聚合物層之一表面上之一遮光層；其中遮光層係被乾法層壓至基板之與設置有反射金屬層之表面相對之表面上。
在藉由實施例1中闡述之方法於550奈米下確定時，單面壓敏膠帶於一選定表面上具有80%或更高（80%至100%）、較佳地85%或更高以及更佳低90%或更高之反射率。在藉由實施例1中闡述之方法於550奈米下確定時，單面壓敏膠帶亦具有0.1%或更低、更佳地0.05%或更低之透射率。
第1圖係為一例示性單面壓敏膠帶9之剖視圖，其包含熱塑性聚合物層1、遮光層2、乾法層壓層3、基板4、反射金屬層5、壓敏黏合劑層6及可移除剝離層7。應理解，於本文闡述之所有實施態樣中，各層可完全或部分地相互覆蓋。亦應理解，各層可與相鄰層直接物理接觸（直接位於相鄰層上），或者可存在任何中間層，例如黏合劑層。
儘管第1圖之膠帶9繪示每一各別層1至7相對於其自身及相對於另一層具有特定視覺尺寸，然而將領會到，此僅用於例示目的，而不旨在限制本文所揭露之本發明之範圍。膠帶9之每層具有適宜對膠帶9提供所需特性之厚度。
對基板4之組成進行選擇以提供具有良好拉伸強度之膠帶。適合於基板之聚合材料之實例包括聚酯（例如聚對苯二甲酸乙二醇酯、聚萘二甲酸乙二醇酯、聚對苯二甲酸丁二醇酯或聚萘二甲酸丁二醇酯）、聚烯烴（例如聚乙烯、聚丙烯或乙烯-丙烯共聚物）、聚乙烯醇、聚偏二氯乙烯、聚氯乙烯、氯乙烯-醋酸乙烯酯共聚物、聚醋酸乙烯酯、聚醯胺、聚醯亞胺、纖維素、氟化樹脂、聚醚、聚苯乙烯樹脂（例如聚苯乙烯）、聚碳酸酯、聚醚碸、以及前述聚合物之組合。於某些實施態樣中，基板包含聚對苯二甲酸乙二醇酯、聚萘二甲酸乙二醇酯、聚甲基丙烯酸甲酯、或其組合。更佳地，基板可包含聚對苯二甲酸乙二醇酯。
基板之厚度不受特別限制。基板厚度可例如介於1微米至150微米範圍內，較佳地介於2微米至100微米範圍內，且更佳地介於4微米至75微米範圍內。
根據需要，基板材料可更包含添加劑，以獲得期望之性質。添加劑之實例包含填料、阻燃劑、抗老化劑、抗靜電劑、軟化劑、紫外線吸收劑、抗氧化劑、塑化劑、界面活性劑、及其組合。
基板可藉由任何合適之方法形成。例如，可藉由將選定聚合物組成物澆鑄成一膜，或者藉由利用例如擠出成型、注射成型或壓延成型等一模製方法將構成選定聚合物材料之樹脂組成物模製成一片材來形成基板。
設置於基板上之反射金屬層可係為鋁、銀、銅、鉑、鎳、或其組合。反射金屬層可藉由任何合適之方法於基板上沈積至0.5奈米（nm）至200奈米、1奈米至100奈米、2奈米至75奈米、2.5奈米至50奈米、或3奈米至40奈米之厚度。例如，可藉由物理氣相沈積、化學氣相沈積、或其組合來沈積金屬。物理氣相沈積方法包括電子束蒸發、濺射、熱蒸發等。
反射金屬層之反射率能夠於單面壓敏膠帶之一選定表面上提供80%或更高之反射率。因此，反射層本身之反射率係為80%或更高（80%至100%），較佳為85%或更高，且更佳為90%或更高。
對設置於反射金屬層上之壓敏黏合劑（pressure-sensitive adhesive；PSA）之類型及厚度進行選擇，以為膠帶提供合適之黏合性水準及可移除性進而用於膠帶之期望用途。於一個應用中，黏合劑層需要足夠之黏合性，使得膠帶可貼附至導光板之周邊。黏合劑層之厚度可係為例如10微米（µm）至150微米、20微米至100微米或25微米至80微米。
壓敏黏合劑之實例包括丙烯酸壓敏黏合劑、橡膠壓敏黏合劑、胺基甲酸酯壓敏黏合劑、矽氧烷（silicone）壓敏黏合劑、聚酯型壓敏黏合劑、聚醯胺壓敏黏合劑、環氧壓敏黏合劑、乙烯基烷基醚壓敏黏合劑、氟化壓敏黏合劑、及其組合。於某些實施態樣中，壓敏黏合劑包括丙烯酸壓敏黏合劑、橡膠壓敏黏合劑、胺基甲酸酯壓敏黏合劑、矽氧烷壓敏黏合劑、或其組合。
丙烯酸壓敏黏合劑含有丙烯酸聚合物作為主要組分或基礎聚合物。丙烯酸聚合物不受特別限制，但較佳地採用(甲基)丙烯酸烷基酯（丙烯酸烷基酯或甲基丙烯酸烷基酯）作為主要構成單體組分（主要單體組分）。(甲基)丙烯酸烷基酯之具體實例包括(甲基)丙烯酸甲酯、(甲基)丙烯酸乙酯、(甲基)丙烯酸丙酯、(甲基)丙烯酸異丙酯、(甲基)丙烯酸丁酯、(甲基)丙烯酸異丁酯、(甲基)丙烯酸第二丁酯、(甲基)丙烯酸第三丁酯、(甲基)丙烯酸戊酯、(甲基)丙烯酸異戊酯、(甲基)丙烯酸新戊酯、(甲基)丙烯酸己酯、(甲基)丙烯酸庚酯、(甲基)丙烯酸2-乙基己酯、(甲基)丙烯酸辛酯、(甲基)丙烯酸異辛酯、(甲基)丙烯酸壬酯、(甲基)丙烯酸異壬酯、(甲基)丙烯酸癸酯、(甲基)丙烯酸異癸酯、(甲基)丙烯酸十一烷基酯、及(甲基)丙烯酸十二烷基酯。(甲基)丙烯酸烷基酯可單獨採用或以其組合形式採用。
關於構成丙烯酸聚合物之單體組分，只要採用(甲基)丙烯酸烷基酯作為主要單體組分即可，亦可使用能夠與(甲基)丙烯酸烷基酯共聚合之另一單體組分（亦被稱為「可共聚單體組分」）。以構成丙烯酸聚合物之所有單體組分計，(甲基)丙烯酸烷基酯較佳地以50重量%或更高之比例採用。當以構成丙烯酸聚合物之所有單體組分計(甲基)丙烯酸烷基酯之量小於50重量%時，難以表現出丙烯酸聚合物之特性（例如壓敏黏合性質）。
可共聚單體組分可用於將交聯位點引入丙烯酸聚合物中或用於提高丙烯酸聚合物之內聚能力（cohesive power）。可共聚單體組分可單獨採用或者以二或更多種不同之可共聚單體組分之組合形式採用。
例如，為了將交聯位點引入丙烯酸聚合物中，可採用含官能基之單體組分（特別是用於將熱交聯位點引入丙烯酸聚合物中之含熱交聯官能基之單體組分）。此種含官能基之單體組分可係為任何能夠與(甲基)丙烯酸烷基酯共聚合且具有提供交聯位點之官能基之單體組分而不受特別限制，並且其實例包括含羧基之單體，例如(甲基)丙烯酸、衣康酸、巴豆酸、馬來酸、富馬酸及異巴豆酸、及其酸酐（例如馬來酸酐及衣康酸酐）；含羥基之單體，例如(甲基)丙烯酸羥烷基酯，例如(甲基)丙烯酸2-羥乙酯、(甲基)丙烯酸2-羥丙酯及(甲基)丙烯酸2-羥丁酯、乙烯醇及烯丙醇；醯胺型單體，例如(甲基)丙烯醯胺、N,N-二甲基(甲基)丙烯醯胺、正丁基(甲基)丙烯醯胺、N-羥甲基(甲基)丙烯醯胺、N-羥甲基丙烷(甲基)丙烯醯胺、N-甲氧基甲基(甲基)丙烯醯胺及N-丁氧基甲基(甲基)丙烯醯胺；含胺基之單體，例如(甲基)丙烯酸胺基乙酯、(甲基)丙烯酸N,N-二甲基胺基乙酯及(甲基)丙烯酸第三丁基胺基乙酯；含環氧基之單體，例如(甲基)丙烯酸縮水甘油酯及(甲基)丙烯酸甲基縮水甘油酯；含氰基之單體，例如丙烯腈及甲基丙烯腈；以及具有含氮環之單體，例如N-乙烯基-2-吡咯啶酮、N-甲基乙烯基吡咯啶酮、N-乙烯基吡啶、N-乙烯基哌啶酮、N-乙烯基嘧啶、N-乙烯基哌嗪、N-乙烯基吡嗪、N-乙烯基吡咯、N-乙烯基咪唑、N-乙烯基噁唑、N-乙烯基嗎啉、N-乙烯基己內醯胺及N-(甲基)丙烯醯基嗎啉。作為含官能基之單體，可有利地採用含羧基之單體，例如丙烯酸或其酸酐。
此外，可採用另一可共聚單體組分來增加丙烯酸聚合物之內聚能力。此種另一可共聚單體組分之實例包括乙烯基酯型單體，例如醋酸乙烯酯及丙酸乙烯酯；苯乙烯型單體，例如苯乙烯、取代之苯乙烯（例如α-甲基苯乙烯）及乙烯基甲苯；不含芳環之(甲基)丙烯酸酯，例如(甲基)丙烯酸環烷基酯（例如(甲基)丙烯酸環己酯或二(甲基)丙烯酸環戊基酯）、(甲基)丙烯酸冰片酯及(甲基)丙烯酸異冰片酯；含芳環之(甲基)丙烯酸酯，例如(甲基)丙烯酸芳基酯（例如(甲基)丙烯酸苯基酯）、(甲基)丙烯酸芳氧基烷基酯（例如(甲基)丙烯酸苯氧基乙酯）及(甲基)丙烯酸芳基烷基酯（例如(甲基)丙烯酸苄酯）；烯烴單體，例如乙烯、丙烯、異戊二烯、丁二烯及異丁烯；氯乙烯、偏二氯乙烯；含異氰酸酯基之單體，例如2-(甲基)丙烯醯氧基乙基異氰酸酯；含烷氧基之單體，例如(甲基)丙烯酸甲氧基乙酯及(甲基)丙烯酸乙氧基乙酯；乙烯基醚型單體，例如甲基乙烯基醚及乙基乙烯基醚；及多官能單體，例如1,6-己二醇二(甲基)丙烯酸酯、乙二醇二(甲基)丙烯酸酯、二乙二醇二(甲基)丙烯酸酯、三乙二醇二(甲基)丙烯酸酯、四乙二醇二(甲基)丙烯酸酯、(聚)乙二醇二(甲基)丙烯酸酯、丙二醇二(甲基)丙烯酸酯、(聚)丙二醇二(甲基)丙烯酸酯、新戊二醇二(甲基)丙烯酸酯、季戊四醇二(甲基)丙烯酸酯、三羥甲基丙烷三(甲基)丙烯酸酯、季戊四醇三(甲基)丙烯酸酯、二季戊四醇六(甲基)丙烯酸酯、甘油二(甲基)丙烯酸酯、環氧丙烯酸酯、聚酯丙烯酸酯、胺基甲酸酯丙烯酸酯、二乙烯基苯、二(甲基)丙烯酸丁酯及二(甲基)丙烯酸己酯。
橡膠壓敏黏合劑之實例包括含有彈性體組分之黏合劑，例如天然橡膠、苯乙烯-異戊二烯-苯乙烯嵌段共聚物（styrene-isoprene-styrene；SIS嵌段共聚物）、苯乙烯-丁二烯-苯乙烯嵌段共聚物（styrene-butadiene-styrene；SBS嵌段共聚物）、苯乙烯-乙烯╱丁烯-苯乙烯嵌段共聚物（styrene-ethylene/butylene-styrene；SEBS嵌段共聚物）、苯乙烯-丁二烯橡膠、聚丁二烯、聚異戊二烯、聚異丁烯、丁基橡膠、氯丁橡膠、矽氧烷橡膠、丙烯腈-丁二烯橡膠、乙烯-丙烯三元共聚物以及此等橡膠之各種組合。
亦可使用矽氧烷壓敏黏合劑。矽氧烷黏合劑一般係為聚二有機矽氧烷（亦被稱為矽氧烷膠，通常具有約5000道爾頓（Da）至約10,000,000道爾頓，較佳地約50,000道爾頓至約1,000,000道爾頓之數量平均分子量）與包含三有機矽氧烷單元及SiO4/2 單元之共聚矽氧烷樹脂（通常具有約100道爾頓至約1,000,000道爾頓，較佳地約500道爾頓至約50,000道爾頓之數量平均分子量）之摻合物。較佳地，矽氧烷黏合劑包含約20重量份至約60重量份之矽氧烷膠以及對應地約40重量份至約80重量份之共聚矽氧烷樹脂。就改善黏合性質而言，提供使共聚矽氧烷樹脂與聚二有機矽氧烷反應之化學方法係為有益的。
矽氧烷壓敏黏合劑之摻合物亦係為有用的。實例包括二不同之二甲基矽氧烷系壓敏黏合劑之摻合物或二甲基矽氧烷系壓敏黏合劑與二甲基矽氧烷╱二苯基矽氧烷系壓敏黏合劑之摻合物。
矽氧烷壓敏黏合劑亦可購自各種製造商。市售矽氧烷壓敏黏合劑之實例包括可自道康寧公司（Dow Corning）以商品名280A、282、Q2-7406及Q2-7566獲得之該等黏合劑；可自邁圖高新材料公司（Momentive Performance Materials，Inc .）以商品名錫爾格裡普（SILGRIP）PSA 590、PSA 600、PSA 595、PSA 610、PSA 518、PSA 6574及PSA 529獲得之該等黏合劑；以及自俄亥俄州阿克倫市信越公司（Shin-Etsu, Akron, Ohio）以商品名為KR-100P、KR-100及KR-101-10獲得之該等黏合劑。
壓敏黏合劑亦可含有少量添加劑。此類添加劑可包括例如交聯劑（crosslinking agent）、交黏劑（cross bonding agent）、填料、阻燃劑、抗老化劑、抗靜電劑、軟化劑、紫外線吸收劑、抗氧化劑、塑化劑、界面活性劑等。根據所需之最終用途，添加劑之用量可自壓敏黏合劑材料之0.1重量%至49重量%變化。
壓敏黏合劑層可藉由任何合適之方法形成。例如，壓敏黏合劑層可藉由將壓敏黏合劑塗佈至反射金屬層之一表面上、然後可選地進行乾燥或固化來形成，或者壓敏黏合劑層可藉由將壓敏黏合劑塗佈於支撐物（例如，剝離襯層）上、然可選地進行乾燥或固化以於該剝離襯層上獲得壓敏黏合劑層，且然後將壓敏黏合劑層黏合至該反射金屬層之一表面上來形成。為塗佈壓敏黏合劑組成物，可使用任何合適之塗佈設備，例如一凹版輥塗機、一逆轉輥塗機、一濕潤輥塗機、一浸漬輥塗機、一棒塗機、一刮刀塗佈機或一噴塗機。
膠帶9可選地包含至少一個可移除剝離層7。剝離層7之厚度可係為5微米至150微米、10微米至125微米、20微米至100微米、40微米至85微米或50微米至75微米。
「剝離層」意指包含一剝離塗層之任何單層或複合層，其視需要由包含剝離襯層之一或多個額外層支撐。雙面剝離層係為包含二個外部剝離塗層之複合層，該二個外部剝離塗層藉由一或多個額外層而隔開。在一個實施態樣中，膠帶包含雙面剝離層。雙面剝離層容許將整個膠帶或膠帶材料片捲繞成一卷以供使用。
剝離層可係為透明的或彩色的塑膠材料，但並非僅限於此。具體而言，剝離層可包含支撐物或「襯層」，例如基於紙或塑膠之載體或網狀材料。舉例而言，具體襯層係為牛皮紙（Kraft Paper），且具體中間塗層係為高密度聚乙烯（high-density polyethylene；HDPE）。剝離襯層可包含例如選自由聚對苯二甲酸乙二醇酯（polyethylene terephthalate；PET）、聚萘二甲酸乙二醇酯（polyethylene naphthalate；PEN）、聚酯聚醯胺（polyester polyamide）、聚碳酸酯、乙烯醋酸乙烯酯共聚物（ethylene vinyl acetate copolymer）、乙烯-丙烯酸乙酯共聚物（ethylene-ethyl acrylate copolymer）、乙烯-丙烯共聚物、及聚氯乙烯組成之群組之材料。具體而言，矽氧烷樹脂或寡聚物可被塗佈於PET上或塗佈有聚烯烴之紙上。黏合劑無需在剝離襯層上形成一連續或連貫之層。
具體而言，剝離層可包含襯層，該襯層在一側或二側上塗佈有剝離劑，該剝離劑提供針對任何種類之黏性材料（例如黏合劑）之剝離效果。剝離包含使襯層自黏合劑材料分離。
各種剝離層為此項技術中所習知，且在一個實施態樣中可包含襯層、中間塗層、及剝離塗層。例示性剝離層可以商品名雷盛德奎格雷德（Rexam Grade）16043購自貝德福德公園Ill之雷盛德奎瑞斯公司（Rexam Release, Bedford Park, Ill）。
剝離層可視需要於襯層之二個面上皆包含中間塗層及剝離塗層，即於襯層之一側上包含第一中間塗層及第一剝離塗層並於襯層之另一側上包含第二中間塗層及第二剝離塗層。此能夠達成所謂之差異式剝離（differential release），其中自一卷分配之泡棉膠帶優先地在接觸膠帶之一個層的剝離塗層與作為膠帶下伏層之第一黏合劑層之間分離。因此，雙面剝離層於二相對之側上包含剝離塗層。具體而言，剝離塗層可包含矽氧烷聚合物。
在一個實施態樣中，膠帶9僅於膠帶之一側上具有剝離層，其可係為一雙面剝離層。作為另一選擇，膠帶可於二側上皆具有雙面剝離層，抑或可於一側上具有雙面剝離層而於另一側上具有單面剝離層。
包含剝離層7之膠帶9之總厚度可係為20微米至600微米、25微米至500微米、30微米至400微米、35微米至350微米、或38微米至300微米。
對熱塑性聚合物層之組成進行選擇以提供足夠之表面能進而成為接合至另一種材料之良好基板，而無需中間處理來達成該表面能。例如，如第2圖所示，於液晶顯示器之製造中，於使用膠帶20對導光板40裝框架之後，接著使用泡棉膠帶10將裝框架之導光板40貼附至液晶顯示器面板30。於此種應用中，期望膠帶框架之外表面、即熱塑性聚合物層1具有至少40毫牛╱米（mN/m）或至少42毫牛╱米之表面能，以成為與泡棉膠帶10黏結之良好基板。熱塑性聚合物層1亦應足夠可撓，以容許在彎曲或不平坦表面上使用所得膠帶。
如本文所用之用語「熱塑性」係指塑性或可變形之材料，當加熱時熔化成液體，而當充分冷卻時凝固成易碎之玻璃狀態。可使用之熱塑性聚合物之實例包括環狀烯烴聚合物（包括聚降冰片烯及含有降冰片烯基單元之共聚物，例如，例如降冰片烯等環狀聚合物與例如乙烯或丙烯等無環烯烴之共聚物）、氟聚合物（例如，聚氟乙烯（polyvinyl fluoride；PVF）、聚偏二氟乙烯（polyvinylidene fluoride；PVDF）、氟化乙烯-丙烯（fluorinated ethylene-propylene；FEP）、聚四氟乙烯（polytetrafluoroethylene；PTFE）、聚(乙烯-四氟乙烯)（poly(ethylene-tetrafluoroethylene；PETFE）、全氟烷氧（perfluoroalkoxy；PFA））、聚縮醛（例如，聚氧乙烯及聚甲醛）、聚(C1-6 烷基)丙烯酸酯、聚丙烯醯胺（包括未取代之以及單-N-及二-N-(C1-8 烷基)丙烯醯胺）、聚丙烯腈、聚醯胺（例如，脂肪族聚醯胺、聚鄰苯二甲醯胺及聚芳醯胺）、聚醯胺醯亞胺、聚酐、聚伸芳基醚（例如，聚伸苯基醚）、聚伸芳基醚酮（例如，聚醚醚酮（polyether ether ketones；PEEK）及聚醚酮酮（polyether ketone ketones；PEKK））、聚伸芳基酮、聚伸芳基硫醚（例如，聚伸苯基硫醚（polyphenylene sulfides；PPS））、聚伸芳基碸（例如，聚醚碸（polyethersulfones；PES）、聚伸苯基碸（polyphenylene sulfones；PPS）等）、聚苯并噻唑、聚苯并噁唑、聚苯并咪唑、聚碳酸酯（包括均聚碳酸酯及聚碳酸酯共聚物，例如聚碳酸酯-矽氧烷、聚碳酸酯-酯及聚碳酸酯-酯-矽氧烷）、聚酯（例如，聚對苯二甲酸乙二醇酯、聚對苯二甲酸丁二醇酯、聚芳酯及聚酯共聚物，例如聚酯-醚）、聚醚醯亞胺（包括例如聚醚醯亞胺-矽氧烷共聚物等共聚物）、聚醯亞胺（包括例如聚醯亞胺-矽氧烷共聚物等共聚物）、聚(C1-6 烷基)甲基丙烯酸酯、聚烷基丙烯醯胺（包括未取代之及單-N-及二-N-(C1-8 烷基)丙烯醯胺）、聚烯烴（例如，例如高密度聚乙烯（HDPE）、低密度聚乙烯（low density polyethylene；LDPE）及線性低密度聚乙烯（linear low density polyethylene；LLDPE）等聚乙烯、聚丙烯、及其鹵代衍生物（例如聚四氟乙烯）及其共聚物（例如乙烯-α-烯烴共聚物））、聚噁二唑、聚甲醛、多肽、聚矽氮烷、聚矽氧烷（矽氧烷）、聚苯乙烯（包括例如丙烯腈-丁二烯-苯乙烯（acrylonitrile-butadiene-styrene；ABS）及甲基丙烯酸甲酯-丁二烯-苯乙烯（methyl methacrylate-butadiene-styrene；MBS）等共聚物）、聚硫化物、聚磺醯胺、聚磺酸酯、聚碸、聚硫酯、聚三嗪、聚脲、聚胺基甲酸酯、乙烯基聚合物（包括聚乙烯醇、聚乙烯酯、聚乙烯基醚、聚乙烯基鹵化物（例如，聚氯乙烯）、聚乙烯基酮、聚乙烯基腈及聚乙烯基硫醚）等。可使用前述熱塑性聚合物之組合。
於某些實施態樣中，熱塑性聚合物層包含聚胺基甲酸酯、聚乙烯、聚酯或其組合；較佳地，熱塑性聚合物層包含聚胺基甲酸酯。包含聚胺基甲酸酯之熱塑性聚合物層可具有42毫牛╱米之表面能。熱塑性聚合物層可藉由任何合適之方法獲得。例如，熱塑性聚合物層可澆鑄於一可移除支撐物或剝離層上。
熱塑性聚合物層之厚度可例如介於1微米至150微米範圍內、較佳地於2微米至100微米範圍內且更佳地介於4微米至75微米範圍內。
設置於熱塑性聚合物層之一表面上之遮光層可係為表現出遮光性質，即具有低透光率之任何層。遮光層可為黑色層或白色層，且可藉由任何合適之方法形成。
遮光層可包含表現出遮光性質之各種材料，例如壓敏黏合劑組成物、樹脂組成物、油墨組成物或其組合。遮光層較佳為油墨層，更佳為印刷層。
於某些實施態樣中，遮光層係為黑色層。當遮光層係為黑色層時，該層將含有黑色著色劑。
當遮光層係為顯示黑色之油墨層，更具體而言係為顯示黑色之印刷層時，黑色油墨層可由含有黑色著色劑之黑色油墨組成物形成。
此外，遮光層可係為顯示黑色之樹脂層（黑色樹脂層）。當遮光層係為黑色樹脂層時，黑色樹脂層可例如由含有黑色著色劑之黑色樹脂組成物形成。
黑色著色劑可係為任何合適之顏料或染料。黑色著色劑之具體實例包括碳黑（例如爐黑、槽法碳黑、乙炔黑、熱碳黑或燈黑）、石墨、氧化銅、二氧化錳、苯胺黑、苝黑、鈦黑、花青黑、活性碳、鐵氧體、磁鐵礦、氧化鉻、氧化鐵、二氧化鉬、鉻錯合物、複合氧化物型黑色染料、蒽醌型有機黑色染料及其組合。
一黑色印刷層可使用油墨組成物藉由任何合適之印刷方法形成。油墨組成物包含例如著色組分（油墨組分）、黏結劑樹脂及固化劑。
用於黑色印刷層之著色組分之實例包括碳黑、乙炔黑、石墨、氧化鐵、氧化銅、苯胺黑、活性碳及其組合。黏結劑樹脂之實例包括聚胺基甲酸酯樹脂、酚樹脂、環氧樹脂、丙烯酸樹脂、聚酯樹脂、聚烯烴樹脂、天然橡膠、苯乙烯-丁二烯橡膠、丁二烯橡膠、乙烯-丙烯橡膠及其組合。於某些實施態樣中，較佳為聚胺基甲酸酯樹脂。固化劑之實例包括異氰酸酯固化劑、環氧固化劑、三聚氰胺固化劑、氮丙啶硬化劑及其組合。油墨組成物中各組分之比例可根據需要來確定。
黑色印刷層之厚度可係為0.5微米至10微米、0.5微米至6微米、1微米至5微米或2微米至4微米。
與油墨組成物一起使用之印刷方法之實例包括凹版印刷方法、柔版印刷方法、膠版印刷方法、凸版印刷方法、網版印刷方法、模版印刷方法、活版印刷方法等。
層壓可需要將遮光層之與接觸熱塑性聚合物層之表面相對之表面層壓至基板之與反射金屬層相對之表面以形成層狀結構，其中基板與二堆疊層之遮光層之間具有一可選之中間層。遮光層可與基板直接接觸，而不存在中間層。作為另一選擇，可存在一中間層。中間層可係為塗佈於與反射金屬層相對之基板表面上或與熱塑性聚合物層相對之遮光層表面上之合適液體黏合劑之乾燥層。黏合劑層（當存在時）之厚度可係為0.5微米至10微米、1微米至8微米或3微米至7微米。合適之液體黏合劑包括丙烯酸黏合劑。然後，可將層狀結構於一壓力及溫度下置於一壓機（例如，真空壓機）中歷經一段持續時間，該持續時間係適合於對層進行接合並形成層壓板之時間。層壓及可選之固化可藉由一步製程（one-step process）進行（例如，使用真空壓機），或者可藉由多步製程進行。於一步製程中，層狀結構可被置於使用加熱至例如50℃至70℃或55℃至65℃或60℃之軋輥之一軋輥系統中，其中層壓壓力例如為50磅╱平方英吋（pounds per square inch；psi）至150磅╱平方英吋（345千帕（kiloPascals；kPa）至1034千帕）或60磅╱平方英吋至100磅╱平方英吋（414千帕至689千帕）且層壓溫度例如為60攝氏度（℃）至140℃或80℃至120℃。
於乾法層壓以獲得第1圖所示之一包含層1至層5之一多層式堆疊之後，如上所述，可藉由任何合適之方法於反射金屬層之表面上形成具有可選剝離層7之壓敏黏合劑層6，以獲得所揭露之多層式單面膠帶9。
於自第1圖之膠帶9移除可選之剝離層7（若存在）之後，膠帶之壓敏黏合劑層6可如第2圖示意性所示直接與導光板40周邊之至少一部分黏合，以形成用於導光板40之框架。
單面壓敏膠帶可用作光反射╱遮光壓敏膠帶，以用於對液晶顯示器設備（LCD）之導光板裝框架，特別是低邊框緊湊型液晶顯示器設備，例如於優質電視及行動電話中所採用之設備。
亦揭露包含單面壓敏膠帶之製品。例示性製品包含導光板、液晶顯示器、電視、行動電話、電腦監視器或平板電腦。於某些實施態樣中，製品係為一低邊框製品。
亦揭露一種製造用於液晶顯示器之導光板之方法。該方法包含將本文揭露之膠帶之單面壓敏黏合劑層黏合至導光板周邊之至少一部分以形成框架。該方法可更包含自單面壓敏膠帶移除剝離層或將導光板貼附至液晶顯示器。於膠帶貼附至導光板之後，熱塑性聚合物層不與液晶顯示器面板直接接觸。
所揭露之單面壓敏膠帶具有意外之優點，即優異之遮光效能（在550奈米下為0.1%或更低之透射率）以及在550奈米下為80%或更高之優異反射率。該等性質使得膠帶作為低邊框或無邊框液晶顯示器之導光板之框架材料特別有利。此外，於此種應用中，膠帶之被暴露表面具有足夠高之表面能（≥ 40毫牛╱米），使得於經由泡棉膠帶接合至液晶顯示器面板之前不需要對膠帶表面進行預處理，因而會節省生產顯示模組之時間及成本。
提供以下實施例來例示本發明。該等實施例僅係為說明性的，且不旨在將根據本發明製成之裝置限制於其中闡述之材料、條件或製程參數。 實施例
膠帶之透光率及反射率藉由以下測試方法來確定。將多層式膠帶之50毫米方形測試樣品置於分光光度計上，以於360奈米至740奈米之波長範圍內每10奈米確定樣品之透射率及反射率。分光光度計係為CM-5╱柯尼卡美能達公司（KONICA MINOLTA）（日本（Japan）），配備有氙燈作為光源，使用10°之視角。對每一樣品進行了三次不同之測試。
表面能係根據美國測試與材料協會（American Society for Testing and Materials；ASTM）D-2578進行量測。 實施例1：單面壓敏膠帶
製備如第1圖所示之一多層式單面壓敏膠帶。
藉由電子束蒸發將鋁層於12微米厚之聚對苯二甲酸乙二醇酯基板之一個表面上沈積至20奈米之厚度。藉由微凹版塗佈將包含10重量%碳黑及10重量%聚胺基甲酸酯樹脂之黑色塗層於熱塑性聚胺基甲酸酯層之一表面上沈積至3微米之厚度。與鋁層相對之基板表面及熱塑性聚胺基甲酸酯層之黑色塗佈之表面（20微米之厚度）使用5微米丙烯酸黏合劑層乾法層壓於一起。乾法層壓完成後，將於相對之表面上具有50微米剝離層之30微米厚之丙烯酸壓敏黏合劑層之一表面黏合至與聚對苯二甲酸乙二醇酯基板相對之鋁表面。
膠帶於550奈米下之平均透射率及反射率值以及所量測之表面能如表1所示。 表1. 膠帶性質
透光率 0.00%（於550奈米下）
反射率 83.2%（於550奈米下）標準偏差=0.02
表面能 42 毫牛╱米
實施例2：作為導光板框架之單面壓敏膠帶
如第2圖示意性繪示，將大致根據實施例1製成之單面壓敏膠帶黏合至導光板之周邊並貼附至LCD面板。
下文闡述本發明之各種非限制性態樣。
態樣1 一種單面壓敏膠帶包含一基板、設置於該基板之一表面上之一反射金屬層及設置於該反射金屬層上之一壓敏黏合劑層；一熱塑性聚合物層以及設置於該熱塑性聚合物層之一表面上之一遮光層；其中該遮光層係被乾法層壓至該基板之與設置有該反射金屬層之該表面相對之表面上。
態樣2 如態樣1所述之膠帶，其中該基板係為聚對苯二甲酸乙二醇酯、聚萘二甲酸乙二醇酯、聚甲基丙烯酸甲酯、或其組合。
態樣3 如態樣1或2所述之膠帶，其中該壓敏黏合劑係為丙烯酸黏合劑、橡膠黏合劑、矽氧烷黏合劑、胺基甲酸酯黏合劑、或其組合。
態樣4 如態樣1至3中任一項所述之膠帶，其中該反射金屬層係為鋁、銀、銅、鉑、鎳、或其組合。
態樣5 如態樣1至4中任一項所述之膠帶，其中該反射金屬層係藉由物理氣相沈積、濺射、熱蒸發、化學氣相沈積、或其組合來沈積。
態樣6 如態樣1至5中任一項所述之膠帶，其中該反射金屬層具有1奈米至100奈米之厚度。
態樣7 如態樣1至6中任一項所述之膠帶，其中該遮光層包含黑色塗層或白色塗層。
態樣8 如態樣1至7中任一項所述之膠帶，其中該熱塑性聚合物層包含聚胺基甲酸酯、聚乙烯、聚酯、或其組合；較佳地，該熱塑性聚合物層包含聚胺基甲酸酯。
態樣9 如態樣1至8中任一項所述之膠帶，更包含設置於該壓敏黏合劑層上之可移除剝離層。
態樣10 如態樣1至9中任一項所述之膠帶，其中該壓敏黏合劑層與導光板周邊之至少一部分直接接觸。
態樣11 如態樣1至10中任一項所述之膠帶，其中該膠帶具有0.1%或更低之透射率；及╱或80%或更高之至少一個表面之反射率。
態樣12 一種製品，包含如態樣1至11中任一項所述之膠帶。
態樣13 如態樣12所述之製品，其係為導光板、液晶顯示器、電視、行動電話、電腦監視器或平板電腦。
態樣14 如態樣12或13所述之製品，其中該製品係為低邊框製品。
態樣15 一種製造用於液晶顯示器之導光板之方法，包含：將如態樣1至11中任一項所述之膠帶之單面壓敏黏合劑層黏合至導光板周邊之至少一部分以形成框架。
態樣16 如態樣15所述之方法，更包含：將該導光板貼附至一液晶顯示器，或者自該單面壓敏膠帶移除剝離層。
態樣17 如態樣16所述之方法，其中於貼附後，該熱塑性聚合物層不與該液晶顯示器直接接觸。
態樣18 如態樣15至17中任一項所述之方法，其中該熱塑性聚合物層包含聚胺基甲酸酯。
作為另一選擇，該等組成物、方法及製品可包含本文所揭露之任何適當材料、步驟或組分、由本文所揭露之任何適當材料、步驟或組分組成或實質上由本文所揭露之任何適當材料、步驟或組分組成。該等組成物、方法及製品可另外地或另選地被配製成不含或實質上不含達成該等組成物、方法及製品之功能或目標原本所不需要之任何材料（或物質）、步驟或組分。
用語「一（a及an）」並不表示對數量進行限制，更確切而言表示存在所引用項至少其中之一。除非上下文清楚地另外指明，否則用語「或」意指「及╱或」。說明書通篇中之參考「態樣」、「實施態樣」、「另一實施態樣」、「某些實施態樣」等意指結合該實施態樣闡述之一特定要素（例如，特徵、結構、步驟或特性）包含於本文所述之至少一個實施態樣中，且可存在或可不存在於其他實施態樣中。另外，應理解所述要素可於各種實施態樣中以任何合適方式加以組合。
當例如一層、膜、區或基板等一元件被稱為位於另一元件「上」時，該元件可直接位於該另一元件上，或者亦可存在中間元件。相反，當一元件被稱為「直接」位於另一元件「上」時，不存在中間元件。
除非本文中作出相反之規定，否則所有測試標準係為截至本申請案之申請日期之最新有效標準，或者若主張優先權，則係為測試標準出現之最早優先權申請案之申請日期。
指向同一組件或性質之所有範圍之端點包含端點，可獨立地組合，且包含所有中間點以及範圍。例如，「至多25重量%或5重量%至20重量%」之範圍包含端點以及「5重量%至25重量%」範圍之所有中間值，例如10重量%至23重量%等。
用語「組合」包含摻合物、混合物、合金、反應產物等。此外，「至少其中之一」意指列表各別地包含每一要素以及該列表之二或更多個要素之組合及該列表之至少一個要素與未命名之類似要素之組合。在一列表可替代使用的物質中，「其組合」意謂該組合可包含該列表之至少一個要素與未命名之一或多個類似要素之組合。
除非另有定義，否則本文所使用之技術及科學用語具有與熟習本發明所屬技術者所通常理解之含義相同之含義。
所有引用之專利、專利申請案以及其他參考文獻皆以引用方式全文併入本文中。然而，若本申請案中之一用語與所併入參考文獻中之一用語相矛盾或衝突，則來自本申請案之該用語優先於所併入參考文獻中之衝突用語。
儘管已闡述了特定實施態樣，然而本申請人或熟習此項技術者可想到目前無法預料或者目前可能無法預料之替代形式、潤飾、變型、改進以及實質等效形式。因此，所申請且其可修訂之所附申請專利範圍旨在包含所有此等替代形式、潤飾、變型、改進以及實質等效物。
1:熱塑性聚合物層 2:遮光層 3:乾法層壓層 4:基板 5:反射金屬層 6:壓敏黏合劑層 7:剝離層 9:單面壓敏膠帶╱膠帶 10:泡棉膠帶 20:單面壓敏膠帶╱膠帶 30:LCD面板 40:導光板 100:電視顯示器
以下係為對圖式之簡要闡述，呈現該等圖式係用於例示本文揭露之例示性實施態樣，而非用於限制該等實施態樣。於附圖中，相同元件之編號係為相同的。
第1圖係為具有如下七個層之單面壓敏膠帶9之實施態樣之剖視圖：1：熱塑性聚合物層；2：遮光層；3：乾法層壓層；4：基板；5：反射金屬層；6：壓敏黏合劑層；7：可移除剝離層。
第2圖係為電視顯示器（100）之實施態樣之剖視圖，其中使用單面壓敏膠帶（20）對導光板（40）裝框架，且裝框架之導光板經由將LCD面板（30）與框架型單面壓敏膠帶（20）接合之泡棉膠帶（10）貼附至LCD面板（30）。
1:熱塑性聚合物層
2:遮光層
3:乾法層壓層
4:基板
5:反射金屬層
6:壓敏黏合劑層
7:剝離層
9:單面壓敏膠帶/膠帶

Claims (18)

  1. 一種單面壓敏膠帶，包含： 一基板， 一反射金屬層，設置於該基板之一表面上， 一壓敏黏合劑層，設置於該反射金屬層上， 一熱塑性聚合物層，以及 一遮光層，設置於該熱塑性聚合物層之一表面上； 其中該遮光層係被乾法層壓至該基板之與設置有該反射金屬層之該表面相對之表面上。
  2. 如請求項1所述之膠帶，其中該基板係為聚對苯二甲酸乙二醇酯、聚萘二甲酸乙二醇酯、聚甲基丙烯酸甲酯、或其組合。
  3. 如請求項1或2所述之膠帶，其中該壓敏黏合劑係為丙烯酸黏合劑、橡膠黏合劑、矽氧烷（silicone）黏合劑、胺基甲酸酯黏合劑、或其組合。
  4. 如請求項1或2所述之膠帶，其中該反射金屬層係為鋁、銀、銅、鉑、鎳、或其組合。
  5. 如請求項1或2所述之膠帶，其中該反射金屬層係藉由物理氣相沈積、濺射、熱蒸發、化學氣相沈積、或其組合來沈積。
  6. 如請求項1或2所述之膠帶，其中該反射金屬層具有1奈米至100奈米之厚度。
  7. 如請求項1或2所述之膠帶，其中該遮光層包含黑色塗層或白色塗層。
  8. 如請求項1或2所述之膠帶，其中該熱塑性聚合物層包含聚胺基甲酸酯、聚乙烯、聚酯、或其組合。
  9. 如請求項1或2所述之膠帶，更包含設置於該壓敏黏合劑層上之可移除剝離層。
  10. 如請求項1或2所述之膠帶，其中該壓敏黏合劑層與導光板周邊之至少一部分直接接觸。
  11. 如請求項1或2所述之膠帶，其中該膠帶具有0.1%或更低之透射率；及╱或 至少一個表面之反射率為80%或更高。
  12. 一種製品，包含如請求項1至11中任一項所述之膠帶。
  13. 如請求項12所述之製品，其係為導光板、液晶顯示器、電視、行動電話、電腦監視器或平板電腦。
  14. 如請求項12或13所述之製品，其中該製品係為低邊框製品。
  15. 一種製造用於液晶顯示器之導光板之方法，包含： 將如請求項1至11中任一項所述之膠帶之單面壓敏黏合劑層黏合至導光板周邊之至少一部分以形成框架。
  16. 如請求項15所述之方法，更包含： 將該導光板貼附至液晶顯示器，或者 自該單面壓敏膠帶移除剝離層。
  17. 如請求項16所述之方法，其中於貼附後，該熱塑性聚合物層不與該液晶顯示器直接接觸。
  18. 如請求項15至17中任一項所述之方法，其中該熱塑性聚合物層包含聚胺基甲酸酯。
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