In one general aspect, a nylon film according to the present invention includes inorganic particles (A) and organic particles (B) each having an average particle size of 1 to 5㎛, and inorganic particles (C) having an average particle size of 0.05 to 2㎛, wherein the nylon film has total content of inorganic particles in the range of 1600 to 13000ppm, a frictional coefficient according to ASTM D1894 of 0.05 to 0.3, a modulus according to ASTM D882 of 250 to 350kg/㎠, and a film haze according to ASTM D1003 of 10 to 50.
According to the nylon film of the present invention, nylon having a relative viscosity of 2.6 to 3.5 is used as a base resin, and a particle master batch is prepared by compounding the inorganic particles (A) and the organic particles (B) each having an average particle size of 1 to 5㎛ and a shape close to a sphere, and the inorganic particles (C) having an average particle size of 0.05 to 2㎛ and an irregular lump shape. The particle master batch is extruded by using a circular die and biaxially stretched in a tubular manner, thereby manufacturing the nylon film.
The present inventors found that the above three particles are mixed and used, to obtain unexpected effects, such as improvement in post-processability due to a very lowered frictional coefficient and heightened adhesive strength for coating and printing, which led to the completion of the present invention.
Herein, the particle master batch may be prepared by inputting the inorganic particles (A), the organic particles (B), and the inorganic particles (C), separately or altogether. The inorganic particle (A) and the inorganic particle (C) are selected from zeolite, alumina, silica, and kaolin, and as the organic particle (B), an acrylic-based, styrene-based, or silicon-based polymer particle may be used. More specifically, natural or synthetic zeolite composed of silicate of aluminum, alumina, silica, or the like may be used as the inorganic particle (A). The organic particle (B) is in a synthetic bead type, and may employ polymethyl(meth)acrylate or polystyrene, silicone, or the like. The inorganic particle (C) may employ kaolin, silica, or the like.
The prepared particle master batch is added in a process for manufacturing a nylon film to produce a film containing 100 to 1000ppm of the inorganic particles (A), 1000 to 10,000ppm of the organic particles (B), and 500 to 2000ppm of the inorganic particles (C). The process for manufacturing a film may be performed in a tubular type which is a simultaneous biaxial stretching type. The formed film has a machine direction (MD) modulus of 250~400kg/㎟.
The present invention will be described in detail as follows.
The present invention is directed to a nylon film obtained by adding a particle master batch containing inorganic particles in order to improve the slipping property thereof. Here, three kinds of inorganic particles having different shapes and different sizes as the inorganic particles.
First, the inorganic particles (A) and the organic particles (B) each have an average particle size of 1 to 5㎛ and a spherical shape. In addition, since they have a superior performance of forming unevenness on a film surface, they have an excellent effect in improvement of the slipping property. However, if the adding amount thereof is increased, the formed film has an increased haze. As for the inorganic particle (A) and the organic particle (B) having a shape close to sphere, affinity between particles becomes relatively weak since they have a small surface area. This causes voids to be generated in an interface between the particles and the polymer in a case where a sheet having a form close to amorphousness is stretched, and these voids increase the haze. As for the inorganic particle (A) and the organic particle (B) having these characteristics, they are very expensive if sizes thereof are small, while they increase the haze of the film if sizes thereof are large. Therefore, in order to use the inorganic particles (A) and the organic particles (B) commercially, the amount of particles needs to be minimized within a range of haze required for the film. However, this leads to excellent slipping property, but since the number of protrusions formed on the surface of the film is small, the surface of the film is very smooth. As a result, a surface area of the film becomes small, and thus, a contact area of the film is decreased during the post processes, thereby bringing about reduction in adhesive strength.
According to the present invention, the inorganic particle (C) having different shape and size from the inorganic particle (A) and the organic particle (B) is also added together with the particles (A) and (B). The inorganic particle (C) has an irregular lump shape and an average size of 0.5 to 2㎛. As such, when the inorganic particles (C) are also added, a large number of protrusions can be formed as well as the contact area can be increased, thereby improving adhesive strength. Furthermore, this case has a more stable winding property of the film as compared with a case where only the inorganic particle (A) and the organic particle (B) are used. In addition, this case can improve the slipping property under high humidity. When large-sized inorganic particles are used, a large number of particles can not be used due to haze of the film, and thus, the number of particles is absolutely insufficient. As a result, excellent frictional characteristics are exhibited under low humidity, but an increase in frictional coefficient is very sharp. However, when the inorganic particles (C) are added, a large number of small protrusions are formed even under high humidity, thereby reducing the increase in the frictional coefficient.
The inorganic particles (A) and the organic particles (B) have an average particle size of 1 to 5㎛. If the average particle size thereof is smaller than 1㎛, an effect of forming unevenness is small after manufacturing the film, and thus the frictional coefficient can not be effectively decreased. Whereas, if the average particle size thereof is larger than 5㎛, fracture of the film may be increased due to particles at the time of manufacturing the film and haze of the film may be sharply increased.
The inorganic particles (C) has an average particle size of 0.05 to 2㎛ and an irregular lump shape. If the average particle size thereof is smaller than 0.05㎛, an effect of forming unevenness is small after manufacturing the film, thereby having difficulty in improving adhesive strength, and agglomeration occurs a lot in a compounding process at the time of preparing a master batch, thereby decreasing dispersibility. Whereas, if the average particle size thereof is larger than 2㎛, haze of the film may be sharply increased due to a large number of particles. The inorganic particle (C) preferably has a particle size of 1/100 to 1/25 that of the inorganic particle (A). If the particle size of the inorganic particle (C) is larger than 1/25 that of the inorganic particle (A), haze of the film is sharply increased and agglomeration easily occurs at the time of preparing a master batch or manufacturing a film due to the lump shape of the inorganic particle (C). These act as defects of the film, and thus, cause defects to be generated at the time of producing a cell pouch, later. Whereas, if the particle size of the inorganic particle (C) is smaller than 1/100 that of the inorganic particle (A), particle agglomeration occurs a lot at the time of preparing a master batch, thereby having difficulty in preparing the master batch. In addition, the nylon film used in compounding for the master batch preferably has a relative viscosity of 2.6 to 3.5 (measured by 95% sulfuric acid method). If the relative viscosity is lower than 2.6, particle dispersibility is excellent, but viscosity difference is large at the time of mixing with a base resin of the nylon film. As a result, network points, which are partially not printed or adhesive-coated, are generated at the time of printing or adhesive coating after manufacturing the film, resulting in deterioration in quality of the final products. Whereas, if the relative viscosity is larger than 3.5, particle dispersibility is decreased, thereby having difficulty in meeting the required physical properties of the film.
In addition, zeolite, alumina, silica, kaolin, Na2O, CaO, or the like may be used as the inorganic particle (A) and the inorganic particle (C) in the present invention, and an acrylic-based, styrene-based, or silicone-based polymer particle may be used as the organic particle (B). These may be compounded alone or mixedly at the time of preparing a master batch.
The master batch prepared by using the inorganic particles (A), organic particles (B), and inorganic particles (C) preferably has a particle content of 0.5 to 30wt%. If the particle content is smaller than 0.5wt%, the amount of master batches to be prepared is increased, thereby having difficulty in maintaining the quality of master batches as well as increasing the costs for processing the master batches, and thus the preparing costs are increased. Whereas, if the particle content is larger than 30wt%, particle dispersibility is deteriorated and uniform quality of master batches are difficult to produce due to high content of particles. Moreover, particle dispersibility in the film is deteriorated and the amount of particles in the film is difficult to control. In addition, the inorganic particles as above are preferably contained in the range of 1600 to 13000ppm, based on total content of the film.
Furthermore, 100 to 1000ppm of the inorganic particles (A), 1000 to 10000ppm of the organic particles (B), and 500 to 2000ppm of the inorganic particles (C) may be contained.
If the content of the inorganic particles (A) is lower than 100ppm, winding property is largely deteriorated even though the content of the organic particles (B) having a large size is raised. Whereas, if the content of the inorganic particles is higher than 1000ppm, haze of the film is sharply increased without improvement of winding property or low-friction characteristics and the manufacturing costs.
If the content of the organic particles (B) is lower than 1000ppm, low-friction characteristics are difficult to realize even though the inorganic particle (A) having a large size is inputted in a large amount considering the haze. Whereas, if the content of the organic particles (B) is higher than 10000ppm, the slipping property is so high that winding is difficult, and haze of the film is sharply increased and the manufacturing costs are increased.
If the content of the inorganic particles (C) is lower than 500ppm, printing and adhering characteristics are largely deteriorated. Whereas, if the content of the inorganic particles (C) is higher than 2000ppm, the manufacturing costs are increased without improvement in the printing and adhering characteristics.
The nylon film of the present invention is not limited to Nylon 6, and may include nylon-based biaxially stretched film. Generally, the nylon film used in the present invention may have an appropriate thickness within a range of 5 to 50㎛, and the base resin employed in the nylon film has preferably a relative viscosity of 3.0 to 3.6. If the relative viscosity of the base film is lower than 3, physical properties of the nylon film after manufacturing are deteriorated. Whereas, if the relative viscosity of the base film is higher than 3.6, flow property of the base resin is not good at the time of melt extrusion, and stretch property is insufficient, which fails to meet required physical properties.