High-hardness and high-toughness polarizing composite film as well as preparation method, production system and application thereof

Abstract

The invention discloses a high-hardness and high-toughness polarized light composite film as well as a preparation method, a production system and application thereof, and belongs to the technical field of polarized light composite films. The preparation method comprises the following steps: preparing a mixed coating liquid of organic / inorganic hybrid resin and nano particles, wherein the particle size of the nano particles is 20-50nm, and the content of the nano particles is 3-8%; two surfaces of the substrate layer are synchronously coated to form a symmetrical coating structure, and the thickness difference is controlled within + / -1 [mu] m; a sectional type UV curing process is adopted; dynamically adjusting process parameters according to environmental conditions; and the upper surface is coated with an anti-fingerprint / anti-dazzle functional coating. The prepared high-hardness and high-toughness polarized light composite film has the advantages of high hardness and high toughness. The production system comprises a double-sided synchronous coating device, an intelligent UV curing system, an online quality detection unit and a central control unit. The high-hardness and high-toughness polarized light composite film has a wide application prospect on a touch display screen.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of polarizing composite films, and particularly relates to a high-hardness and high-toughness polarizing composite film, a preparation method thereof, a production system and application. BACKGROUND

[0002] In the manufacturing process of a liquid crystal display screen, two polarizing sheets are tightly attached to the front and back of a liquid crystal glass to form a liquid crystal sheet. In order to improve the surface hardness and wear resistance, a base material is usually coated on the front polarizing sheet, and a layer of paint is cured at the end of the base material away from the polarizing sheet to form a polarizing composite film. However, the existing polarizing composite film has the problem of low hardness (pencil hardness of only about 3H), which cannot meet the demand of modern mobile devices for high-hardness surfaces, so an additional cover glass is needed in actual application, resulting in a thick and heavy product, high cost and fragility.

[0003] Patent application with publication number CN 119331506 A discloses a kind of anti-glare hard film for display screen surface and its preparation method and application, including base material layer and glue layer coated on base material layer, formed by curing process. The deficiency of this technology is that only single UV curing is used, making it difficult to balance surface hardness and internal toughness, and cracks are easily produced in repeated bending tests. Patent application with publication number CN 116410508 A discloses a kind of high-hardness anti-glare film and its preparation method, which proposes a kind of high-hardness anti-glare film, using organic resin and nano particles to prepare a hard coating. The defect of this technology is that the nano particles have a wide particle size distribution, leading to uneven dispersion, affecting the transparency and mechanical property consistency of the coating, and the standard deviation of the pencil hardness of the product reaches 1.5H.

[0004] Various means are used in the prior art, such as: ① Double-sided coating of high-hardness coating: high-hardness coating is coated on both sides of the base material to improve the overall hardness. However, simply increasing the coating thickness will cause warping problems, and the contradiction between hardness and toughness is not solved. ② Adding a toughening agent: adding an elastomeric toughening agent to the high-hardness coating to improve toughness. However, the toughening agent will reduce the surface hardness and may cause a decrease in coating transparency. ③ Multi-layer composite structure: using multi-layer coatings with different hardnesses to try to balance the hardness and toughness. However, the interfacial bonding force is insufficient, which is prone to delamination, and the process is complex and costly. However, the above methods have not effectively solved the contradiction between high hardness and high toughness, and have not achieved precise control of the production process and stable guarantee of product quality. Therefore, there is an urgent need for a polarizing composite film with high hardness and high toughness, a simplified process, and a low cost, as well as a preparation method and a production system. SUMMARY

[0005] One of the purposes of the present application is to provide a preparation method of a high-hardness and high-toughness polarizing composite film, which solves the problems of low hardness and poor toughness of the existing polarizing composite film.

[0006] The second objective of this invention is to provide a high-hardness, high-toughness polarizing composite film, which is prepared by the above-mentioned method for preparing a high-hardness, high-toughness polarizing composite film.

[0007] The third objective of this invention is to provide a production system for a high-hardness, high-toughness polarizing composite film, which is used to realize the above-mentioned preparation method of the high-hardness, high-toughness polarizing composite film.

[0008] The fourth objective of this invention is to provide an application of a high-hardness, high-toughness polarizing composite film in a touch display screen, wherein the high-hardness, high-toughness polarizing composite film used is the aforementioned high-hardness, high-toughness polarizing composite film.

[0009] The objective of this invention can be achieved through the following technical solutions: In a first aspect, a method for preparing a high-hardness, high-toughness polarizing composite film includes the following steps: S1. Prepare a mixed coating solution of organic / inorganic hybrid resin and nanoparticles, wherein the nanoparticles have a particle size of 20-50 nm and a content of 3% to 8% of the resin weight; S2. The mixed coating liquid is simultaneously applied to both sides of the substrate layer to form a symmetrical coating structure, and the thickness difference between the upper and lower coatings is controlled within ±1μm. S3. Employ a segmented UV curing process: First, irradiate with short-wavelength UV light, with a wavelength range of 250-300nm and an energy density of 500-800mJ / cm³. 2 The treatment time is 2-4 seconds; followed by long-wavelength UV irradiation, with a wavelength range of 350-400 nm and an energy density of 800-1200 mJ / cm³. 2 The exposure time is 4–6 seconds; finally, it is irradiated again with short-wavelength UV light with an energy density of 300–500 mJ / cm³. 2 Time: 1-3 seconds; S4. Based on the real-time monitoring of the coating surface condition and environmental conditions, dynamically adjust the UV irradiation parameters, and control the energy density ratio of short-wavelength UV to long-wavelength UV within the range of 1:1.5-1:2. S5. Apply an anti-fingerprint / anti-glare coating with a thickness of 10-20μm to the high-hardness coating on the upper surface to form a multifunctional composite structure.

[0010] Furthermore, the organic / inorganic hybrid resin has an organic component to inorganic component weight ratio of (5-7):(3-5), the organic component is a mixture of polyurethane acrylate and epoxy acrylate, and the inorganic component is silane coupling agent modified silica.

[0011] Furthermore, the anti-fingerprint / anti-glare functional coating contains perfluorooctyltriethoxysilane at a content of 0.5% to 1.5%, and silica microparticles at a particle size of 3-5 μm at a content of 1% to 3%.

[0012] Furthermore, the segmented UV curing process also includes a real-time UV spectrum monitoring step, which monitors the spectral distribution in real time during the UV curing process. When a decrease in short-wavelength UV intensity of more than 10% is detected, the lamp power is automatically increased by 5% to 10% to maintain stable energy density.

[0013] Furthermore, the substrate layer is a PET film with a thickness of 80-120μm, the total thickness of the high-hardness coating is 25-35μm, and the total thickness of the product is controlled within the range of 120-140μm.

[0014] Furthermore, it also includes environmental adaptation adjustment steps: for every 5°C decrease in ambient temperature, the energy density of the first-stage UV spectrum increases by 50 mJ / cm². 2 For every 10% increase in ambient humidity, the energy density of the first-stage UV spectrum increases by 50 mJ / cm³. 2 For every 10μm increase in substrate thickness, the UV energy density of the second stage increases by 100mJ / cm². 2 .

[0015] Secondly, a high-hardness and high-toughness polarizing composite film is prepared by the above-mentioned method for preparing a high-hardness and high-toughness polarizing composite film.

[0016] Thirdly, a production system for a high-hardness, high-toughness polarizing composite film includes: The double-sided synchronous coating device includes coating heads symmetrically arranged at the top and bottom and a precision tension control system. The slit width of the coating head is adjustable from 50 to 100 μm with an adjustment accuracy of 0.1 μm and the tension control accuracy is ±0.5 N. The intelligent UV curing system includes a short-wavelength UV light source, a long-wavelength UV light source, and a control system. The UV light source uses LED-UV technology with a spectral purity >95%. The online quality inspection unit includes an optical inspection module and a mechanical property prediction module. The optical inspection module includes a transmittance meter, a haze meter, and a reflectance meter. The mechanical property prediction module includes a water contact angle meter and a pencil hardness prediction module. The central control unit receives feedback signals from the quality inspection unit, dynamically adjusts process parameters through preset algorithms, establishes a historical data database, and continuously optimizes process parameter settings through machine learning algorithms.

[0017] Furthermore, the intelligent UV curing system also includes a UV spectral analysis module and a real-time energy density adjustment module. The UV spectral analysis module has a spectral resolution of 0.5 nm and a sampling frequency of 10 Hz, while the energy density adjustment module has an adjustment accuracy of ±10 mJ / cm². 2 Response time <50ms.

[0018] Furthermore, the online quality detection unit has a water contact angle measuring accuracy of ±0.5°, a pencil hardness prediction module with a prediction accuracy of >95%, and the detection data is transmitted to the central control unit in real time with a data transmission delay of <100ms.

[0019] Furthermore, it also includes an environmental monitoring and control system that monitors the temperature and humidity of the production environment in real time, with a temperature control accuracy of ±1℃ and a humidity control accuracy of ±3%, and automatically adjusts process parameters according to environmental conditions.

[0020] Fourthly, the application of a high-hardness and high-toughness polarizing composite film in a touch display screen, wherein the high-hardness and high-toughness polarizing composite film used is the aforementioned high-hardness and high-toughness polarizing composite film.

[0021] The beneficial effects of this invention are: (1) By controlling the particle size of nanoparticles within the range of 20-50 nm and controlling their content to 3% to 8% of the resin weight, the present invention achieves the best balance between nano-reinforcement effect and dispersion stability. In addition, under the action of organic and inorganic components, flexible organic segments and rigid inorganic networks coexist in the resin crosslinking network, which can provide high crosslinking density to ensure hardness and absorb energy through the movement of organic segments to improve toughness.

[0022] (2) This invention employs a symmetrical coating structure, achieving precise stress balance on both sides of the substrate by controlling the thickness difference between the upper and lower coatings within ±1μm. The tension control system achieves an accuracy of ±0.5N, ensuring the flatness of the substrate during the coating process and avoiding uneven coating thickness caused by substrate deformation. This solves the warping problem caused by double-sided coating, enabling the product to maintain good flatness and meet the requirements of subsequent bonding processes.

[0023] (3) This invention employs a three-stage UV curing process, controlling the energy density ratio of short-wavelength UV to long-wavelength UV within the range of 1:1.5-1:2 to achieve precise regulation of the energy gradient within the coating. Short-wavelength UV (250-300nm) photons have high energy and are mainly absorbed by the coating surface, promoting rapid cross-linking of the surface resin and forming a high-hardness surface layer; while long-wavelength UV (350-400nm) has strong penetrating power and can penetrate deep into the coating, promoting full cross-linking of the internal resin and improving the overall toughness of the material. In the three-stage process, the first stage of short-wavelength UV ensures full surface curing, the second stage of long-wavelength UV ensures complete internal cross-linking, and the third stage of short-wavelength UV further optimizes the surface properties. This energy gradient distribution enables the coating to form a gradient structure of "high surface hardness and good internal toughness," which can effectively disperse external impact energy and prevent crack propagation, thereby achieving synergistic optimization of high hardness and high toughness.

[0024] (4) This invention dynamically adjusts UV irradiation parameters based on substrate thickness and environmental conditions, establishing a mapping relationship between process parameters and environmental conditions. Ambient temperature affects the mobility of resin molecules, humidity affects the solvent evaporation rate, and substrate thickness affects the UV energy absorption distribution. By establishing a mathematical model of these parameters and UV energy requirements, this invention can adjust process parameters in real time to ensure that ideal curing effects can be obtained under different conditions.

[0025] (5) This invention adds an anti-fingerprint / anti-glare functional material (10-20 μm) to the high-hardness coating on the upper surface. Fluorosilane compounds form a low surface energy layer on the surface, reducing the water contact angle and achieving an anti-fingerprint effect. Meanwhile, silica microparticles form a micron-level rough structure on the surface, achieving an anti-glare effect through light scattering. This invention precisely controls the particle size and content to keep the surface roughness within the optimal range, ensuring both the anti-glare effect and avoiding excessive roughness that could lead to a decrease in light transmittance. This surface microstructure design enables the product to simultaneously possess high hardness, anti-fingerprint properties, and anti-glare functionality, meeting the multiple needs of touch display devices. Detailed Implementation

[0026] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below.

[0027] In some embodiments, a method for preparing a high-hardness, high-toughness polarizing composite film includes the following steps: S1. Prepare a mixed coating solution of organic / inorganic hybrid resin and nanoparticles, wherein the nanoparticles have a particle size of 20-50 nm and a content of 3% to 8% of the resin weight; A precise ratio of organic / inorganic hybrid resin to nanoparticles of a specific size is employed, with the nanoparticle size controlled within the range of 20-50 nm and the content precisely controlled at 3%–8% of the resin weight. By controlling the particle size and content of the nanoparticles, the coating hardness can be improved without significantly reducing toughness. When the particle size is less than 20 nm, the nano-effect is not obvious, and the hardness improvement is limited; when the particle size is greater than 50 nm, stress concentration points are easily formed, reducing toughness. When the content is less than 3%, the hardness improvement is not significant; when the content is greater than 8%, dispersion is difficult, which easily leads to increased coating haze.

[0028] S2. The mixed coating liquid is simultaneously applied to both sides of the substrate layer to form a symmetrical coating structure, and the thickness difference between the upper and lower coatings is controlled within ±1μm. A symmetrical coating head is used to prevent substrate warping due to unilateral stress, thus improving product flatness. Strict tolerance control (thickness difference ±1μm) based on a thin film mechanics model ensures stress balance in both coating sides, reduces internal strain, prevents curling or delamination, and guarantees optical uniformity.

[0029] S3. Employ a segmented UV curing process: First, irradiate with short-wavelength UV light, with a wavelength range of 250-300nm and an energy density of 500-800mJ / cm³. 2 The treatment time is 2-4 seconds; followed by long-wavelength UV irradiation, with a wavelength range of 350-400 nm and an energy density of 800-1200 mJ / cm³. 2 The exposure time is 4–6 seconds; finally, it is irradiated again with short-wavelength UV light with an energy density of 300–500 mJ / cm³. 2 Time: 1-3 seconds; Segmented curing is based on the principles of curing kinetics. The first segment uses short-wavelength UV light, where high-energy photons (250-300nm) are strongly absorbed by the surface resin, rapidly initiating cross-linking and forming a high-hardness surface layer. The second segment uses long-wavelength UV light, where lower-energy photons (350-400nm) penetrate deeper, completing internal curing, reducing unreacted monomers, and preventing cracks (due to internal stress release). The third segment uses short-wavelength UV light to repair surface defects (such as a sticky layer caused by oxygen inhibition), improving surface smoothness and wear resistance. Energy density and time parameters are optimized through experimental design to avoid over-curing or under-curing.

[0030] S4. Based on the real-time monitoring of the coating surface condition and environmental conditions, dynamically adjust the UV irradiation parameters, and control the energy density ratio of short-wavelength UV to long-wavelength UV within the range of 1:1.5-1:2. Increased substrate thickness leads to increased UV energy absorption, necessitating a corresponding increase in the UV energy density of the second stage. Increased ambient humidity slows solvent evaporation, requiring an increase in the UV energy density of the first stage to compensate for insufficient surface curing. This environmentally adaptive adjustment mechanism ensures product quality stability and overcomes the limitations of traditional fixed-parameter processes.

[0031] S5. Apply an anti-fingerprint / anti-glare coating with a thickness of 10-20μm to the high-hardness coating on the upper surface to form a multifunctional composite structure.

[0032] Anti-fingerprint properties are achieved by reducing surface energy with fluorinated compounds (such as perfluorosilanes), resulting in a droplet contact angle >110° and thus achieving hydrophobicity and oleophobicity. Anti-glare is achieved by adding micron-sized silica particles (3-5μm) to create a micro-roughened structure that scatters incident light and reduces specular reflectivity (haze controlled at 4%–10%). A thickness of 10-20μm ensures anti-glare effectiveness without significantly reducing light transmittance.

[0033] In some embodiments, the weight ratio of organic to inorganic components in the organic / inorganic hybrid resin is (5-7):(3-5), the organic component is a mixture of polyurethane acrylate and epoxy acrylate, and the inorganic component is silane coupling agent modified silica.

[0034] The organic / inorganic ratio is (5-7):(3-5), optimized using response surface methodology. The inorganic phase provides hardness, while the organic phase provides toughness. Polyurethane acrylates impart flexibility and impact resistance; epoxy acrylates provide high crosslinking density and adhesion. Silane coupling agents (such as KH-570) introduce vinyl groups onto the silica surface, improving interfacial compatibility with the organic phase and preventing phase separation.

[0035] In some embodiments, the anti-fingerprint / anti-glare functional coating contains perfluorooctyltriethoxysilane at a content of 0.5% to 1.5%, and silica microparticles at a particle size of 3-5 μm at a content of 1% to 3%.

[0036] Perfluorooctyltriethoxysilane (0.5%–1.5%) forms a monolayer covering, achieving low surface energy; however, excessive amounts may cause coating embrittlement. Silica microparticles (3–5 μm, 1%–3%) effectively scatter light; excessive amounts will increase haze, while insufficient amounts will result in inadequate anti-glare effects.

[0037] In some embodiments, the segmented UV curing process further includes a real-time UV spectrum monitoring step, which monitors the spectral distribution in real time during the UV curing process. When a decrease in short-wavelength UV intensity of more than 10% is detected, the lamp power is automatically increased by 5% to 10% to maintain stable energy density.

[0038] Automatic power adjustment compensates for strength loss, ensuring constant curing energy density and avoiding performance differences between batches.

[0039] In some embodiments, the substrate layer is a PET film with a thickness of 80-120 μm, the total thickness of the high-hardness coating is 25-35 μm, and the total thickness of the product is controlled within the range of 120-140 μm.

[0040] The PET substrate thickness is 80-120μm, balancing mechanical strength and flexibility, and suitable for roll-to-roll processes. The total thickness of the high-hardness coating is 25-35μm. If the coating is too thin, the hardness is insufficient; if it is too thick, it is prone to cracking. The total thickness is 120-140μm to meet the requirements of thinner and lighter touch display modules.

[0041] In some embodiments, an environmental adaptation adjustment step is also included: for every 5°C decrease in ambient temperature, the energy density of the first-stage UV spectrum increases by 50 mJ / cm². 2 For every 10% increase in ambient humidity, the energy density of the first-stage UV spectrum increases by 50 mJ / cm³. 2 For every 10μm increase in substrate thickness, the UV energy density of the second stage increases by 100mJ / cm². 2 .

[0042] Low temperatures reduce resin reactivity; the reaction rate halves for every 5°C drop, necessitating increased energy to compensate for the curing rate. High humidity (>60%) can cause water absorption on the coating surface, affecting UV absorption; increasing energy ensures surface curing. Increased thickness requires higher energy penetration; energy demand is directly proportional to thickness.

[0043] In some embodiments, a production system for a high-hardness, high-toughness polarizing composite film includes: The double-sided synchronous coating device includes coating heads symmetrically arranged at the top and bottom and a precision tension control system. The slit width of the coating head is adjustable from 50 to 100 μm with an adjustment accuracy of 0.1 μm and the tension control accuracy is ±0.5 N. A symmetrical coating head ensures simultaneous application of the upper and lower coatings, preventing deformation caused by uneven substrate tension. The slit width is 50-100μm, corresponding to the wet film thickness of the coating, preventing drips or breaks. Tension control is ±0.5N to precisely control substrate tension and prevent tensile deformation.

[0044] The intelligent UV curing system includes a short-wavelength UV light source, a long-wavelength UV light source, and a control system. The UV light source uses LED-UV technology with a spectral purity >95%. Compared to mercury lamps, LED-UV lamps offer narrower spectral output and >95% spectral purity, reducing heat radiation and preventing thermal deformation of the substrate. Integrated PLC and spectral sensors enable precise closed-loop control of energy and wavelength.

[0045] The online quality inspection unit includes an optical inspection module and a mechanical property prediction module. The optical inspection module includes a transmittance meter, a haze meter, and a reflectance meter. The mechanical property prediction module includes a water contact angle meter and a pencil hardness prediction module. The central control unit receives feedback signals from the quality inspection unit, dynamically adjusts process parameters through preset algorithms, establishes a historical data database, and continuously optimizes process parameter settings through machine learning algorithms.

[0046] In some embodiments, the intelligent UV curing system further includes a UV spectral analysis module and a real-time energy density adjustment module. The UV spectral analysis module has a spectral resolution of 0.5 nm and a sampling frequency of 10 Hz. The energy density adjustment module has an adjustment accuracy of ±10 mJ / cm² and a response time of <50 ms.

[0047] 0.5nm precision enables accurate detection of UV wavelength shifts, ensuring wavelength remains within the target range. 10Hz sampling frequency (sampling every 0.1s) promptly captures instantaneous lamp attenuation, preventing defect accumulation. ±10mJ / cm² 2 Accuracy and a response speed of <50ms ensure stable energy density and meet the requirements for consistent curing.

[0048] In some embodiments, the online quality detection unit has a water contact angle measuring accuracy of ±0.5°, a pencil hardness prediction module with a prediction accuracy of >95%, and the detection data is transmitted to the central control unit in real time with a data transmission delay of <100ms.

[0049] Excessive latency can lead to delayed adjustments and a continuous stream of defective products; low latency enables a rapid response in the "detection-adjustment" closed loop, reducing waste.

[0050] In some embodiments, an environmental monitoring and control system is also included, which monitors the temperature and humidity of the production environment in real time, with a temperature control accuracy of ±1℃ and a humidity control accuracy of ±3%, and automatically adjusts process parameters according to environmental conditions.

[0051] Temperature and humidity are controlled within ±1℃ to prevent changes in resin viscosity, and humidity is controlled within ±3% to prevent the coating from absorbing water and affecting curing. An integrated environmental sensor and central control unit enable feedforward control, reducing external interference and achieving automatic adjustment.

[0052] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0053] Example 1

[0054] This embodiment provides a method for preparing a high-hardness, high-toughness polarizing composite film: 1. Material preparation: Substrate layer: PET film, 100μm thick, 1300mm wide, 600mm roll diameter; High-hardness coating solution: Prepared by mixing organic / inorganic hybrid resin (weight ratio 6:4) with nano-silica particles (particle size 30nm, content 5%). The specific formulation is: 40 parts polyurethane acrylate, 20 parts epoxy acrylate, 30 parts silane coupling agent modified silica, 5 parts photoinitiator, 1 part leveling agent, and 4 parts solvent. The upper surface functional coating is a mixed coating liquid with added anti-fingerprint / anti-glare materials. The anti-fingerprint material is perfluorooctyltriethoxysilane (content 1%), and the anti-glare material is silica microparticles (particle size 4μm, content 2%).

[0055] 2. The preparation steps are as follows: S1. Feed the substrate layer into the double-sided synchronous coating device and apply high-hardness coating liquid to both the upper and lower surfaces simultaneously, controlling the coating thickness to be 15μm on each side. Set the slit width of the coating head to 75μm, the coating speed to 10m / min, and the tension to 12±0.5N. S2. After the drying process, it enters the UV curing system. The drying temperature is set to 80℃, the air velocity to 2m / s, and the drying time to 30s to ensure complete solvent evaporation. S3. Employs a segmented UV curing process: First segment: Short-wavelength UV (280nm), energy density 650mJ / cm² 2 Time: 3 seconds; Second segment: Long-wavelength UV (380nm), energy density 1000mJ / cm³ 2 Time: 5 seconds; Third segment: Short-wavelength UV (280nm), energy density 400mJ / cm³ 2 Time: 2 seconds; During the UV curing process, the surface temperature of the coating is monitored in real time to ensure that the temperature fluctuation is within ±3℃. S4. Apply an anti-fingerprint / anti-glare coating (15μm thick) to the high-hardness coating on the upper surface and perform a second UV curing. The second UV curing uses short-wavelength UV (280nm) with an energy density of 500mJ / cm². 2 Time: 3 seconds; S5. Lamination of protective film (45μm thickness). The protective film is made of PE material and has anti-scratch and anti-pollution functions, ultimately resulting in a high-hardness and high-toughness polarizing composite film.

[0056] 3. Performance Testing: Pencil hardness: 9H (no scratches at 5 / 5 points under 500g test conditions), conforming to ISO15184 standard; Light transmittance: 91.2% (average value of 380-780nm), conforming to JIS K7361-1 standard; Haze: 0.65%, conforming to JIS K7136 standard; Water contact angle: 108.5°, conforming to ASTM D7334 standard; Abrasion resistance: 1kg steel wool test showed no scratches after 1000 cycles, meeting JISK5600-5-4 standard; Bending performance: It can be bent to a diameter of 3mm and can be repeatedly bent 180° 1000 times without cracking; UV resistance: UVA340, 0.71W / cm 2 Over 72 hours, the color coordinate changes were Δx < 0.003 and Δy < 0.005. Adhesion: Grade 5B in cross-cut adhesion test, conforming to ASTM D3359 standard.

[0057] Example 2: Preparation experiments with different parameter ranges

[0058] To verify the effective range of the process parameters of this invention, a series of comparative experiments were conducted on the prepared high-hardness and high-toughness polarizing composite film. The results are shown in the table below:

[0059] Experimental results show that: The product performance is best when the nanoparticle size is in the range of 20-50nm; when it is smaller than 20nm or larger than 50nm, the performance decreases significantly; the product performance is stable when the nanoparticle content is in the range of 3% to 8%; when it is lower than 3% or higher than 8%, the performance fluctuates greatly; the organic / inorganic ratio is in the range of (5-7):(3-5) to achieve the best balance between hardness and toughness; when the ratio deviates from this range, the performance decreases; the product has the best overall performance when the energy density ratio of short-wave UV to long-wave UV is in the range of 1:1.5-1:2.

[0060] Example 3: Production System for High-Hardness and High-Toughness Polarizing Composite Film

[0061] 1. System Composition: (1) Double-sided synchronous coating device: including symmetrical coating heads, tension control system and thickness automatic adjustment mechanism; Coating head: Slit design, width adjustable from 50-100μm, accuracy 0.1μm; Tension control system: 8 high-precision tension sensors (accuracy ±0.1N), servo motor response time <10ms; Automatic thickness adjustment mechanism: displacement sensor accuracy ±0.1μm, servo motor adjustment range 0-100μm; (2) Intelligent UV curing system: Equipped with short-wavelength UV lamps (250-300nm) and long-wavelength UV lamps (350-400nm), with an adjustable energy density range of 200-1500mJ / cm². 2 ; UV light source: LED-UV technology, spectral purity >95%, lifespan >10,000 hours; Spectral analysis module: spectral resolution 0.5nm, sampling frequency 10Hz; Energy density adjustment module: adjustment accuracy ±10mJ / cm 2 Response time <50ms; Temperature monitoring system: infrared temperature measurement accuracy ±0.5℃, cooling system response time <5s; (3) Online quality inspection unit: including transmittance meter, haze meter, water contact angle meter and pencil hardness prediction module; Transmittance meter: Measurement range 0%~100%, accuracy ±0.1%; Haze meter: Measurement range 0%~100%, accuracy ±0.05%; Water contact angle measuring instrument: measuring range 0-180°, accuracy ±0.5°; Pencil hardness prediction module: Based on a machine learning prediction model, with an accuracy rate >95%; (4) Central control unit: receives detection data and dynamically adjusts process parameters through a preset algorithm; Data acquisition system: sampling frequency 100Hz, delay <100ms; Control algorithms: PID control, fuzzy control, and adaptive control; Database and AI optimization module.

[0062] 2. Work Process

[0063] (1) After the substrate layer enters the system, it first passes through the raw material detection unit to confirm the substrate characteristics (thickness, width, surface condition, etc.). Laser thickness gauge: Measurement accuracy ±0.5μm; Surface defect detection: resolution 10μm, detection speed 30m / min; (2) The double-sided synchronous coating device automatically adjusts the coating thickness according to the characteristics of the substrate; Thickness setting: Calculate the target coating thickness based on the substrate thickness, ensuring the total thickness is between 120-140μm; Real-time adjustment: Thickness data is collected every 10ms to dynamically adjust the slit width of the coating head; (3) The UV curing system dynamically adjusts the energy ratio of short-wavelength and long-wavelength UV based on online detection data; Spectral monitoring: Real-time monitoring of the UV light source spectrum to ensure the wavelength is within the set range; Energy adjustment: Calculate the optimal energy ratio based on coating thickness and environmental conditions; Temperature control: Real-time monitoring of coating surface temperature and adjustment of cooling system operation status; (4) The quality inspection unit monitors product performance in real time and feeds the data back to the central control unit; Optical performance: Real-time measurement of parameters such as transmittance, haze, and reflectance; Surface properties: Prediction of parameters such as water contact angle and pencil hardness; Mechanical properties: Bending properties are indirectly evaluated using an infrared thermal imager; (5) The central control unit optimizes the process parameters of subsequent products based on historical data and current test results; Anomaly detection: When the detection parameters exceed the set range, the system will automatically adjust or stop. Parameter optimization: Predict optimal process parameters based on historical data; Quality prediction: Predicting the performance of the final product and adjusting process parameters in advance.

[0064] Example 4: Adjustment of process parameters under different environmental conditions

[0065] To verify the adaptability of this invention under different environmental conditions, a series of environmental adaptability tests were conducted: 1. Test conditions: Temperature range: 15℃-35℃; Humidity range: 30%~70%RH; Substrate thickness variation: 80μm-120μm; 2. Process parameter adjustment strategy: (1) Temperature compensation: For every 5°C decrease in temperature, the energy density of the first-stage UV radiation increases by 50 mJ / cm². 2 ; For every 5°C increase in temperature, the drying temperature decreases by 5°C. (2) Humidity compensation: For every 10% increase in humidity, the energy density of the first-stage UV spectrum increases by 50 mJ / cm³. 2 ; For every 10% increase in humidity, the coating speed decreases by 1 m / min; (3) Substrate thickness compensation: For every 10 μm increase in substrate thickness, the UV energy density of the second stage increases by 100 mJ / cm². 2 ; For every 10μm increase in substrate thickness, the coating thickness decreases by 1μm. 3. Test Results:

[0066] Test results show that, through the process parameter adjustment strategy of the present invention, high-hardness and high-toughness polarizing composite films with consistent performance can be stably produced under different environmental conditions, and the product performance fluctuation is controlled within an acceptable range.

[0067] Example 5: Application of Touch Display Module

[0068] The high-hardness and high-toughness polarizing composite film prepared by this invention can be directly applied to touch display modules, replacing the traditional "cover glass + OCA adhesive layer + polarizer" structure. 1. Application steps: (1) The end of the high-hardness and high-toughness polarizing composite film with the polarizer structure is attached to the touch display module structure; Bonding pressure: 0.3-0.5 MPa; Bonding temperature: 40-50℃; Bonding speed: 5-10 m / min; (2) No cover glass is required, which simplifies the production process; Eliminates the need for processes such as cutting, cleaning, and bonding the cover glass; Eliminates the OCA adhesive coating and curing process; (3) The product thickness was reduced from 0.755mm to 0.25mm, and the weight was reduced from about 75g to about 12g; The thickness is reduced by 67%, which is beneficial for the design of thinner and lighter equipment. The weight is reduced by 84%, significantly reducing the overall weight of the equipment; (4) The cost was reduced from approximately RMB 35 per piece to approximately RMB 13.2 per piece, a reduction of 63%; Material costs reduced by 55%; Production costs reduced by 70% (fewer processes); 2. Performance Comparison: Surface hardness: increased from 3H to 9H, wear resistance improved by more than 300%; Weight: Reduced by 84%, from 75g to 12g (14-inch product); Thickness: Reduced by 67%, from 0.755mm to 0.25mm; Cost: Reduced by 63%, from 35 yuan / tablet to 13.2 yuan / tablet; Impact resistance: upgraded from fragile to withstand a 1.5m drop test; Optical performance: Light transmittance increased from 88% to 91%, and haze decreased from 0.5% to 0.65%.

[0069] Comparative Example 1: Single-wavelength UV curing

[0070] 1. Using the same material formulation and coating process as in Example 1, but using only a single wavelength UV curing: Short-wavelength UV (280nm): energy density 1800mJ / cm², duration 8s; Long-wavelength UV (380nm): energy density 1800mJ / cm², duration 8s; 2. Performance Testing: (1) Short-wavelength UV-curable products: Pencil hardness: 9H; Water contact angle: 110.2°; Abrasion resistance: No scratches after 500 steel wool tests, but noticeable scratches appear after 1000 tests; Bending performance: It can be bent to a diameter of 5mm, and cracks will appear after being repeatedly bent at 180° 200 times; Adhesion: 4B grade in cross-cut adhesion test; (2) Long-wavelength UV-curable products: Pencil hardness: 7H; Water contact angle: 102.5°; Abrasion resistance: Obvious scratches appear after 300 steel wool tests; Bending performance: It can be bent to a diameter of 2mm and can be repeatedly bent 180° 1000 times without cracking; Adhesion: 5B grade in cross-cut adhesion test; The results show that single-wavelength UV curing cannot simultaneously meet the requirements of high hardness and high toughness. Short-wavelength UV-cured products have high hardness but poor toughness, while long-wavelength UV-cured products have good toughness but low hardness.

[0071] Comparative Example 2: Traditional Material Formula

[0072] 1. High-hardness coating prepared using traditional material formulations: Pure organic resin system: 100 parts polyurethane acrylate; Pure inorganic resin system: 100 parts silica sol; Organic / inorganic mixed system: 50 parts polyurethane acrylate, 50 parts silica sol; Nanoparticle system: 85 parts polyurethane acrylate, 15 parts nano silica (particle size 100nm). 2. Performance Testing:

[0073] The results show that traditional material formulations cannot achieve both high hardness and high toughness at the same time. Pure inorganic resin systems have high hardness but poor toughness, while other formulations have significant deficiencies in terms of either hardness or toughness.

[0074] Comparative Example 3: Asymmetric Coating Process

[0075] 1. An asymmetric coating process is used, with a high-hardness coating applied only to one side of the substrate: Top surface coating thickness: 30μm; The lower surface has no coating or only a protective layer (5μm); 2. Performance Testing: Pencil hardness: 9H (top surface), 3H (bottom surface); Warpage: 8.5 mm / m (measured at room temperature); Adhesion performance: Warping leads to a bonding failure rate as high as 35%; Performance: When used in touch display modules, warping issues cause a 20% decrease in touch accuracy. The results show that the asymmetric coating process causes severe product warping, affecting subsequent processing and performance, and failing to meet practical application requirements.

[0076] Comparative Example 4: UV Curing with Fixed Parameters

[0077] 1. The same material formulation and coating process as in Example 1 were used, but UV curing parameters were fixed without any environmental adaptation adjustments: Short wavelength UV: 650mJ / cm 2 3s; Long-wavelength UV: 1000mJ / cm 2 5s; Short wavelength UV: 400mJ / cm 2 , 2s; 2. Product performance was tested under different environmental conditions. Test results:

[0078] The results show that when UV curing with fixed parameters is used, the product performance fluctuates greatly when environmental conditions change, and the stability of product quality cannot be guaranteed.

[0079] Comparative Example 5: Traditional Three-Layer Touch Display Module

[0080] Touch display modules using a traditional three-layer structure of "cover glass + OCA adhesive layer + polarizer": 1. Structural parameters: Cover glass: 0.5mm thick, weighs approximately 63g (14 inches); OCA adhesive layer: 0.15mm thick; Polarizing film: 0.1mm thickness, pencil hardness 3H; 2. Performance Testing: Surface hardness: 3H; Total thickness: 0.75mm; Total weight: Approximately 75g (14 inches); Cost: Approximately 35 yuan per piece; Durability: 75% intact after a 1.5m drop test; Optical performance: 88% light transmittance, 0.5% haze; 3. Comparison with the product of this invention: Thickness: Increased by 0.5mm (67%); Weight: Increased by 63g (84%); Cost: Increased by 21.8 yuan (63%); Durability: The success rate was 23 percentage points lower; Optical performance: Light transmittance is 3% low, haze is comparable; The results show that the traditional three-layer structure is significantly inferior to the product of this invention in terms of thickness, weight, cost and durability, and cannot meet the requirements of modern mobile devices for thinness, high rigidity and low cost.

[0081] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A method for preparing a high-hardness, high-toughness polarizing composite film, characterized in that, The method comprises the following steps: S1, preparing a mixed coating solution of organic / inorganic hybrid resin and nanoparticles, wherein the particle size of the nanoparticles is 20-50 nm, and the content is 3%-8% of the weight of the resin; S2, synchronously coating the mixed coating solution on both sides of the substrate layer to form an upper and lower symmetrical coating structure, and the thickness difference of the upper and lower coatings is controlled within ±1 μm; S3, using a segmented UV curing process: first with short wavelength UV irradiation, wavelength range 250-300 nm, energy density 500-800 mJ / cm 2 , time 2-4 s; then with long wavelength UV irradiation, wavelength range 350-400 nm, energy density 800-1200 mJ / cm 2 , time 4-6 s; finally again with short wavelength UV irradiation, energy density 300-500 mJ / cm 2 , time 1-3 s; S4, dynamically adjusting the UV irradiation parameters according to the real-time monitored coating surface state and environmental conditions, and controlling the energy density ratio of short wavelength UV to long wavelength UV within the range of 1:1.5-1:2; S5, coating an anti-fingerprint / anti-glare functional coating on the high-hardness coating on the upper surface, and the thickness is 10-20 μm to form a multifunctional composite structure.

2. The method for preparing a high-hardness, high-toughness polarizing composite film according to claim 1, characterized in that, The weight ratio of the organic component to the inorganic component in the organic / inorganic hybrid resin is (5-7):(3-5), the organic component is a mixture of polyurethane acrylate and epoxy acrylate, and the inorganic component is silica modified by a silane coupling agent.

3. The method for preparing a high-hardness, high-toughness polarizing composite film according to claim 1, characterized in that, In the segmented UV curing process, a real-time UV spectrum monitoring step is further included, the spectrum distribution is monitored in real time during the UV curing process, when the short wavelength UV intensity is detected to decrease by more than 10%, the lamp power is automatically increased by 5%-10% to maintain the stability of the energy density.

4. The method for preparing a high-hardness, high-toughness polarizing composite film according to claim 1, characterized in that, The anti-fingerprint / anti-glare functional coating contains perfluorooctyltriethoxysilane with a content of 0.5%-1.5%, and silica particles with a particle size of 3-5 μm and a content of 1%-3%; The substrate layer is a PET film with a thickness of 80-120 μm, and the total thickness of the high-hardness coating is 25-35 μm, and the total thickness of the product is controlled within the range of 120-140 μm.

5. The method for preparing a high-hardness, high-toughness polarizing composite film according to claim 1, characterized in that, Also included are environmental adaption steps: for every 5°C drop in ambient temperature, the first segment UV energy density is increased by 50 mJ / cm 2 ; for every 10% increase in ambient humidity, the first segment UV energy density is increased by 50 mJ / cm 2 ; for every 10 μm increase in substrate thickness, the second segment UV energy density is increased by 100 mJ / cm 2 .

6. A high-hardness high-toughness polarizing composite film, characterized by comprising: The high-hardness high-toughness polarized composite film is prepared by the method of any one of claims 1-5.

7. A production system of a high-hardness and high-toughness polarizing composite film, characterized by comprising: The method for preparing the high-hardness high-toughness polarized composite film comprises: A double-sided synchronous coating device comprising upper and lower symmetrical coating heads and a precision tension control system, the coating head slit width is adjustable within the range of 50-100 μm, the adjustment accuracy is 0.1 μm, and the tension control accuracy is ±0.5 N; An intelligent UV curing system comprising a short wavelength UV light source, a long wavelength UV light source and a control system, the UV light source adopts LED-UV technology, and the spectral purity is >95%; An online quality detection unit comprising an optical detection module and a mechanical property prediction module, the optical detection module comprises a transmittance detector, a haze meter and a reflectance meter, and the mechanical property prediction module comprises a water contact angle measuring instrument and a pencil hardness prediction module; A central control unit receiving feedback signals from the quality detection unit, dynamically adjusting process parameters through a preset algorithm, establishing a historical data database, and continuously optimizing process parameter settings through machine learning algorithms.

8. The production system of a high-hardness and high-toughness polarizing composite film according to claim 7, characterized in that, The intelligent UV curing system further comprises a UV spectrum analysis module and a real-time energy density adjustment module, the spectral resolution of the UV spectrum analysis module is 0.5nm, the sampling frequency is 10Hz, the adjustment accuracy of the energy density adjustment module is ±10mJ / cm 2 , and the response time is <50ms. The water contact angle measuring instrument of the online quality detection unit has a measurement accuracy of ±0.5°, the prediction accuracy of the pencil hardness prediction module is >95%, and the detection data is transmitted to the central control unit in real time, and the data transmission delay is <100 ms.

9. The production system of a high-hardness and high-toughness polarizing composite film according to claim 7, characterized in that, Further comprising an environmental monitoring and adjusting system for real-time monitoring of the temperature and humidity of the production environment, the temperature control accuracy is ±1℃, the humidity control accuracy is ±3%, and the process parameters are automatically adjusted according to the environmental conditions.

10. The use of a high-hardness and high-toughness polarizing composite film in a touch display screen, characterized in that, The applied high-hardness and high-toughness polarizing composite film is the high-hardness and high-toughness polarizing composite film according to claim 6. The applied high-hardness and high-toughness polarizing composite film is the high-hardness and high-toughness polarizing composite film according to claim

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