Window laminate and method of manufacturing the same

Abstract

A window laminate includes: a base layer; and a functional layer formed on the base layer, wherein at least one side end of the functional layer forms a concentric line with a corresponding side end of the base layer. The concentric line between the side end of the base layer and the side end of the functional layer forms a cutting vertical plane.

Description

TECHNICAL FIELD

[0001] The present invention relates to a window laminate. In particular, the present invention relates to a window laminate having uniform flatness and reduced assembly tolerance, and a method for manufacturing the same. BACKGROUND

[0002] In recent years, image display devices have rapidly become flexible in addition to being thin. The flexibility of these display devices requires that the flexible display can be bent, folded, or rolled without loss of performance.

[0003] Flexible window laminates are required for flexible displays. Flexible window laminates are made of ultra-thin glass, flexible plastic, etc. Glass materials have limitations in flexibility and impact resistance, and thus flexible plastic is being actively researched. On the other hand, flexible plastic is advantageous in flexibility, but repeated folding and bending can cause stress accumulation, resulting in breakage and damage of the window laminate. In addition, flexible plastic can be weak in surface strength such as scratch resistance compared to glass materials. To address these problems, conventional window laminates increase a number of functional layers on a base layer.

[0004] Figure 1 is a cross-sectional view showing an example of a window laminate according to the related art.

[0005] As shown in Figure 1 , a conventional window laminate can include a base layer 110, a decorative layer 120, a hard coat layer 130, a planarization layer 140, etc.

[0006] The base layer 110 is a substrate of the window laminate and is made of glass, plastic, etc.

[0007] The decorative layer 120 and the hard coat layer 130 are functional layers. The decorative layer 120 performs a function of blocking light. The hard coat layer 130 is made of a transparent material and performs functions such as preventing scratches, blocking external moisture, shock absorption, and preventing fingerprints. The planarization layer 140 is coupled to the decorative layer 120 to perform functions such as planarization and protection.

[0008] However, in the related art, the decorative layer 120, the hard coat layer 130, etc. are formed by a printing process, a photolithography process, etc. In this case, an inclined portion S is formed at the edge of the decorative layer 120, the hard coat layer 130, etc., and the flatness of the decorative layer 120, the hard coat layer 130, etc. is reduced. In addition, when coupled transversely to other components, a side end step caused by the inclined portion S causes a tolerance at a side joint, which leads to a decrease in product quality. SUMMARY

[0009]

Technical Problem

[0010] The purpose of this invention is to achieve uniform flatness of functional layers, such as decorative layers and hard coatings laminated to the base layer in window laminates.

[0011] Another objective of this invention is to prevent or minimize tolerances in the window laminate when assembling it with other components.

[0012] [Technical Solution]

[0013] To achieve these objectives, the window laminate of the present invention may include a base layer and a functional layer.

[0014] The functional layer is formed on the base layer, and at least one side of the functional layer can form the same line with the corresponding side of the base layer.

[0015] In the window laminate of the present invention, the same line between the side end of the base layer and the side end of the functional layer can be a cutting vertical plane.

[0016] In the window laminate of the present invention, the base layer may be a window film, and the functional layer may be a decorative layer or a hard coating layer.

[0017] In the window laminate of the present invention, the base layer is a window film. The functional layer may include a first functional layer bonded to one surface of the base layer and a second functional layer bonded to the other surface of the base layer. Here, the first functional layer may be a decorative layer, and the second functional layer may be a hard coating layer.

[0018] The window laminate of the present invention may further include a third functional layer connected to the first functional layer. At least one side of the third functional layer may be a cutting vertical plane that forms the same line as the corresponding side of the base layer and the first and second functional layers.

[0019] In the window laminate of the present invention, the third functional layer may be an outer cover layer.

[0020] The window laminate manufacturing method according to the present invention may include: forming a functional layer larger than the target size on a base layer larger than the target size, and vertically cutting at least one edge of the base layer and the functional layer to form the target size.

[0021] In the window laminate manufacturing method of the present invention, the functional layer can be formed by a printing process or a photolithography process to form an inclined portion on at least one edge. In this case, the cutting can be performed from the inclined portion inward.

[0022] In the window laminate manufacturing method of the present invention, the printing process can use inkjet printing with photocurable ink.

[0023] In the window laminate manufacturing method of the present invention, the cutting can be performed using a laser or a pointed tip.

[0024] The window laminate manufacturing method of the present invention may further include determining whether to perform cutting.

[0025] In the window laminate manufacturing method of the present invention, the determination may include determining whether the laminate of the base layer and the functional layer needs to be laterally connected.

[0026] [Beneficial Effects]

[0027] When a functional layer is formed on a window laminate using a printing or photolithography process, the present invention can eliminate any tilted portions that may appear at the edges of the functional layer, thereby making the functional layer uniform overall.

[0028] By cutting the side ends of the window laminate to form a vertical plane, the present invention can facilitate connection when laterally joined with other components and eliminate steps, thereby eliminating or minimizing the occurrence of tolerances. Attached Figure Description

[0029] Figure 1 This is a cross-sectional view showing an example of a window laminate according to the prior art.

[0030] Figures 2a to 2c These are cross-sectional views of the window laminate according to the first to third embodiments of the present invention.

[0031] Figures 3a to 3c These are process diagrams illustrating methods for manufacturing window laminates according to the first to third embodiments of the present invention.

[0032] Figure 4 This is a plan view illustrating various applications of the window laminate according to the present invention. Detailed Implementation

[0033] The invention will be described in more detail below with reference to the accompanying drawings.

[0034] Figures 2a to 2c These are cross-sectional views of the window laminate according to the first to third embodiments of the present invention.

[0035] like Figure 2a As shown, the window laminate of the first embodiment may include a base layer 210, a first functional layer 220, etc.

[0036] The base layer 210 is the substrate of the window laminate, which may be, for example, a window film made of a transparent material.

[0037] As window films, transparent polymers such as the following can be used alone or in mixtures of two or more of them for flexible displays: triacetyl cellulose, acetyl cellulose butyrate, ethylene-vinyl acetate copolymer, propionyl cellulose, butyryl cellulose, acetylpropionyl cellulose, polyester, polystyrene, polyamide, polyetherimide, polyacrylate, polyimide, polyethersulfone, polysulfone, polyethylene, polypropylene, polymethylpentene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetal, polyetherketone, polyetheretherketone, polyethersulfone, polymethyl methacrylate, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polycarbonate.

[0038] The first functional layer 220 is attached to a surface of the base layer 210 to perform a specific function, and may be, for example, a decorative layer.

[0039] The decorative layer can be patterned on one surface of the base layer 210 to act as a light-shielding layer to block light. The decorative layer can be located on a non-display area of ​​the display device, such as the border area surrounding the display area.

[0040] The decorative layer may consist of a black resin composition. As the black resin composition, compositions comprising resins having dispersed black pigment particles, adhesive resins, polymerizable compounds, polymerization initiators, and additives may be used, or photocurable (or thermosetting) resin compositions comprising black pigments that exhibit black color may be used. The decorative layer may use selectively patternable compositions with an optical density of 38 or greater per μm.

[0041] Black pigments can be carbon black, graphite, metal oxides, etc. Black pigments can also include organic black pigments. Organic black pigments can be aniline black, lactam black, or perylene black series pigments.

[0042] Additives may include tackifiers, photocrosslinking sensitizers, curing accelerators, surfactants, dispersants, antioxidants, ultraviolet absorbers, thermal polymerization inhibitors, homogenizers, etc., and may include one or more of these.

[0043] The first functional layer 220 may have at least one side end that forms a line with the corresponding side end of the base layer 210. Here, the same line may be a vertical cutting plane T formed by cutting together with the base layer 210. This eliminates any inclined portions of the first functional layer 220 that might form at the edges when it is formed on the base layer 210. Therefore, the thickness of the first functional layer 220 can be made uniform across the entire surface, and furthermore, in the case of lateral connection with other components, assembly tolerances can be eliminated or minimized by preventing joint steps or the like that might occur due to inclined portions.

[0044] like Figure 2b As shown, the window laminate of the second embodiment may include a base layer 210, a first functional layer 220, a second functional layer 230, etc.

[0045] Since the base layer 210 and the first functional layer 220 of the second embodiment have the same configuration as those of the first embodiment, their detailed description will be replaced with the relevant description in the first embodiment described above.

[0046] The second functional layer 230 can be connected to another surface of the base layer 210, namely the opposite surface of the first functional layer 220.

[0047] The second functional layer 230 may be, for example, a hard coating layer that protects the base layer 210 from scratches, external moisture, etc.

[0048] Hard coatings can include photopolymer compounds, photoinitiators, solvents, etc.

[0049] Photopolymerizable compounds can be components that are photocured to provide a hard coating matrix. For example, photopolymerizable compounds can be oligomers or monomers based on (meth)acrylates. Oligomers based on (meth)acrylates can be, for example, epoxy (meth)acrylates, compounds based on urethane (meth)acrylates, etc., and compounds based on urethane (meth)acrylates are preferred from the perspective of the elasticity and flexural properties of the hard coating. For monomers based on (meth)acrylates, for example, (meth)acryloyl groups can be used as photocurable groups.

[0050] Photoinitiators are included to induce photocuring of the hard coating, and photoradical initiators capable of forming free radicals by light irradiation can be used, for example.

[0051] Solvents can be used without particular restrictions. For example, alcohols (methanol, ethanol, isopropanol, butanol, methyl cellosolve, ethyl cellosolve, etc.) and ketones (methyl ethyl ketone, methyl butyl ketone, methyl isobutyl ketone, diethyl ketone, dipropyl ketone, cyclohexanone, etc.) can be used.

[0052] The second functional layer 230 may have at least one side end that forms a line with the corresponding side ends of the base layer 210 and the first functional layer 220. Here, the same line may be a vertical cutting plane T formed by cutting together with the base layer 210 and the first functional layer 220. This eliminates any inclined portions of the first and second functional layers 220 that might form at the edges when they are formed on the base layer 210. Therefore, the thickness of the first and second functional layers 220 can become uniform across the entire surface, and furthermore, even when laterally joined with other components, assembly tolerances such as joint steps that might be caused by inclined portions can be eliminated or minimized.

[0053] exist Figure 2b In a second embodiment, the window laminate may include only the second functional layer 230 and exclude the first functional layer 220. That is, the window laminate may consist of a base layer 210 and a second functional layer 230, and may be configured to cut at least one side end of the base layer 210 and the second functional layer 230 together, such that these side ends have a cutting vertical plane T forming the same line.

[0054] like Figure 2c As shown, the window laminate of the third embodiment may include a base layer 210, a first functional layer 220, a second functional layer 230, a third functional layer 240, etc.

[0055] The base layer 210, the first functional layer 220, and the second functional layer 230 of the third embodiment are configured the same as those of the first and second embodiments, and therefore their detailed descriptions will be replaced with the relevant descriptions in the first and second embodiments described above.

[0056] The third functional layer 240 is connected to the first functional layer 220 and can be an outer layer that performs functions such as planarization and vibration reduction.

[0057] The outer coating can perform functions such as surface step correction, planarization, refractive index control, and protection.

[0058] The outer coating can be formed from an organic membrane, an inorganic membrane, or an organic-inorganic hybrid membrane. As an organic membrane, polyacrylate, polyimide, polyester, etc., can be used. As an inorganic membrane, silazane, silica, or an inorganic or metal membrane that ensures light transmittance can be used. The inorganic membrane may contain inorganic fillers. The inorganic fillers can be spherical nanoparticles capable of improving light extraction efficiency. The organic-inorganic hybrid membrane can use dispersed organic-inorganic hybrid complexes, such as siloxanes or silsesquioxanes.

[0059] The outer coating can be replaced by an adhesive layer or a sticky layer, and for example, a pressure-sensitive adhesive (PSA) composition or an optically clear adhesive (OCA) composition can be used.

[0060] The third functional layer 240 may have at least one side end that forms a line with the corresponding side ends of the base layer 210, the first functional layer 220, and the second functional layer 230. Here, the same line may be a vertical cutting plane T formed by cutting together with the base layer 210, the first functional layer 220, and the second functional layer 230. This eliminates any inclined portions of the first functional layer 220, the second functional layer 230, and the third functional layer 240 that might form at the edges when they are formed on the base layer 210. Therefore, the thickness of the first functional layer 220, the second functional layer 230, and the third functional layer 240 can become uniform across the entire surface, and even when laterally joined with other components, assembly tolerances such as joint steps that might occur due to inclined portions can be eliminated or minimized.

[0061] Figures 3a to 3c These are process diagrams illustrating methods for manufacturing window laminates according to the first to third embodiments of the present invention.

[0062] Figure 3a A method for manufacturing the window laminate of the first embodiment is shown.

[0063] In the first step, a base layer 210 larger than the target size can be prepared. The base layer 210 is the substrate of the window laminate and can be, for example, a polymer film of a transparent material.

[0064] In the second step, a first functional layer 220 larger than the target size can be formed on the base layer 210. The first functional layer 220 can be a decorative layer. The decorative layer can be formed on the non-display area of ​​the display device, that is, on the border area surrounding the display area. The decorative layer can be composed of a black resin composition.

[0065] In the second step, the black resin composition can be applied by a printing process such as inkjet printing, or by methods such as blade coating, extrusion coating, spraying, spin coating, gravure coating, or roll coating, or it can be formed using a photolithography process with a photosensitive black resin composition. In this case, the first functional layer 220 may have an inclined portion S in the edge region where the thickness decreases towards the end.

[0066] In the third step, the base layer 210 and the first functional layer 220 are simultaneously cut along the cutting line C, wherein the inclined portion S serves as the outer region, allowing the base layer 210 and the first functional layer 220 to be formed to the target dimensions. Cutting can be performed using methods such as pointed cutting or laser cutting.

[0067] In the fourth step, a window laminate of the first embodiment can be produced, which has an edge cut-out portion, i.e., a cut vertical plane T formed at the side end.

[0068] Figure 3b A method for manufacturing the window laminate of the second embodiment is shown, wherein, as Figure 3a As shown, in the first step, a base layer 210 larger than the target size can be prepared, and in the second step, a first functional layer 220 larger than the target size can be formed on one surface of the base layer 210.

[0069] In the third step, a second functional layer 230 may be formed on another surface of the base layer 210. The second functional layer 230 may be a hard coating. The hard coating may be formed using roll-to-roll gravure coating, doctor blade coating, extrusion coating, inkjet printing, die coating, reverse roller coating, spraying, etc. When inkjet printing is used, the ink may preferably be a photocurable ink that is easy to apply to film formation.

[0070] In the edge regions of the first functional layer 220 and the second functional layer 230 formed in the second and third steps, inclined portions S with a thickness decreasing toward the ends may be formed.

[0071] In the fourth step, the base layer 210, the first functional layer 220, and the second functional layer 230 can be cut simultaneously along the cutting line C, wherein the inclined portion S serves as the outer region, allowing the base layer 210, the first functional layer 220, and the second functional layer 230 to be formed to the target dimensions. Cutting can be performed using methods such as pointed cutting or laser cutting.

[0072] In the fifth step, a portion of the edge may be cut to create the window laminate of the second embodiment, which has a cut vertical plane T at the side end.

[0073] Figure 3c A method for manufacturing the window laminate of the third embodiment is shown, wherein, as Figure 3b As shown, in the first step, a base layer 210 larger than the target size is prepared. In the second step, a first functional layer 220 larger than the target size is formed on one surface of the base layer 210, and in the third step, a second functional layer 230 is formed on the other surface of the base layer 210.

[0074] In the fourth step, a third functional layer 240 is formed on the first functional layer 220. The third functional layer 240 may be an outer coating. The outer coating may be formed using a die coater, reverse roller, sprayer, doctor blade, gravure, or other adhesive composition containing an acrylic copolymer and a crosslinking agent, or an adhesive composition containing urethane (meth)acrylate resin, (meth)acrylate monomer, and a photoinitiator. The outer coating may also be a pressure-sensitive adhesive (PSA) composition or an optically clear adhesive (OCA) composition.

[0075] The first functional layer 220, the second functional layer 230 and the third functional layer 240 formed in the second to fourth steps respectively may have inclined portions S with thickness decreasing towards the ends in the edge regions.

[0076] In the fifth step, the base layer 210, the first functional layer 220, the second functional layer 230, and the third functional layer 240 can be cut simultaneously along the cutting line C. The inclined portion S serves as the outer region, allowing the base layer 210, the first functional layer 220, the second functional layer 230, and the third functional layer 240 to be formed to the target dimensions. Cutting can be performed using methods such as pointed cutting or laser cutting.

[0077] In the sixth step, a portion of the edge may be cut to create the window laminate of the third embodiment, which has a cut vertical plane T at the side end.

[0078] Figures 3a to 3c The manufacturing method may also include the following steps: determining whether to cut the base layer 210 and the functional layers connected thereto. The step of determining whether to cut may be a step of determining whether the laminate of the base layer 210 and the functional layers 220 to 240 needs to be laterally connected to other components.

[0079] Figure 4 This is a plan view illustrating various applications of the window laminate according to the present invention.

[0080] First, such as Figure 4 As shown in (a) to (d), the cutting vertical plane T of the base layer 210 and the functional layer 220 can be selectively formed on one, two, three or all four sides of the multiple sides as needed.

[0081] In addition, such as Figure 4 As shown in (e) and (f), the cutting vertical plane T of the base layer 210 and the functional layer 220 may include recessed (notched) areas, protruding areas, etc.

[0082] The window laminate described above can be applied to various display panels. Display panels can include plasma display panels (PDP), light-emitting diode (LED) panels, organic light-emitting diode (OLED) panels, liquid crystal display (LCD) panels, thin-film transistor liquid crystal display (LCD-TFT) panels, etc.

[0083] Although specific embodiments of the invention have been shown and described, those skilled in the art will understand that the invention is not intended to be limited to the preferred embodiments, and it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, the scope of the invention will be defined by the appended claims and their equivalents.

[0084] [Explanation of reference numerals in the attached figures]

[0085] 110, 210: Basic layer; 120, 220: First functional layer

[0086] 130, 230: Second functional layer; 140, 240: Third functional layer

[0087] C: Cutting line; S: Inclined portion

[0088] T: Cutting a vertical plane

Claims

1. A method for manufacturing a window laminate, comprising: A functional layer, also larger than the target size and having a sloping portion at its edge, is formed on a base layer that is larger than the target size and has a flat upper surface, wherein the sloping portion of the functional layer is located on the flat upper surface of the base layer; and At least one edge of the laminate is cut perpendicularly inward from the inclined portion of the functional layer along the thickness direction of the laminate to form the target size, the laminate consisting of the base layer and the functional layer.

2. The method for manufacturing a window laminate according to claim 1, wherein: The functional layer is formed by a printing process or a photolithography process.

3. The method for manufacturing a window laminate according to claim 2, wherein, The printing process uses inkjet printing with photocurable inks.

4. The method for manufacturing a window laminate according to claim 1, wherein, The cutting is performed using a laser or a sharp point.

5. The method for manufacturing a window laminate according to any one of claims 1 to 4, further comprising: Determine whether to perform the cut.

6. The method for manufacturing a window laminate according to claim 5, wherein, The determination process determines whether the laminates of the base layer and the functional layer need to be horizontally connected.

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