High pressure resistant bubble composite structure with uv-filling layer
By using a UV leveling layer to create a three-dimensional wrapping design for the printed layer, edge air gaps during the optical film lamination process are eliminated, achieving seamless lamination, solving the root cause of bubble formation, and improving product quality and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHEJIANG ZHAOYI OPTOELECTRONICS CO LTD
- Filing Date
- 2025-07-11
- Publication Date
- 2026-06-16
Smart Images
Figure CN224360822U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of optical film composite structure technology, specifically to a high-pressure bubble resistant composite structure with a UV filling layer. Background Technology
[0002] In the lamination process of decorative optical films in consumer electronics, the interlayer bonding between local printed layers and optical functional films often results in residual air gaps due to edge height differences. When the product undergoes vacuum lamination or high-pressure curing processes, the residual air expands due to heat, forming visible bubbles, which seriously affects product yield and appearance quality. Existing technologies generally address this problem by optimizing lamination process parameters or increasing interfacial adhesives. However, these methods do not solve the fundamental contradictions at the geometric level. For example, the vertical height difference at the edge of the printed layer forms physical air cavities, and the volume change of these air cavities is uncontrollable under high pressure. Therefore, there is an urgent need for a solution that eliminates the physical space of edge air gaps through structural innovation.
[0003] A search revealed a Chinese patent document disclosing a UV curing device for colored photovoltaic panels [Application No.: 202421299773.X, Publication No.: CN222830062U]. This device includes a base plate, a vacuum chamber mounted on the left side of the upper surface of the base plate, a sealed door hinged to the right rear end of the vacuum chamber, and a locking mechanism mounted on the left rear end of the vacuum chamber. This patent proposes to set up an ultraviolet curing module inside the vacuum chamber to suppress bubble generation through vacuuming and synchronous curing. However, this solution relies on an external sealed cavity and is only suitable for planar photovoltaic panel structures, with poor adaptability to curved surfaces or irregularly shaped electronic devices. Utility Model Content
[0004] In view of the problems existing in the prior art, the purpose of this utility model is to provide a high-pressure bubble resistant composite structure with a UV filling layer.
[0005] A high-pressure bubble resistant composite structure with a UV-cured filling layer is characterized by comprising a substrate layer, a partial printing layer, a UV-cured filling layer, and an optical functional film layer stacked sequentially; the UV-cured filling layer completely covers the upper surface and sidewalls of the partial printing layer, and extends to cover the exposed surface of the substrate layer adjacent to the partial printing layer, forming a continuous and smooth coating structure; the lower surface of the optical functional film layer is completely attached to the upper surface of the UV-cured filling layer.
[0006] Preferably, the partial printing layer is a closed-pattern printing layer, and the UV-cured filler layer completely covers the outer contour of the closed pattern along its boundary.
[0007] Through the above technical solution, the three-dimensional filling structure that simultaneously covers the inner and outer walls of the ring frame structure eliminates the residual conditions of edge air during the coating process in terms of physical space, thereby blocking the root cause of bubble appearance under subsequent high pressure.
[0008] Specifically, in the optical functional film lamination process, traditional methods often create sealed air cavities at the steps due to vertical drops at the edges of the printed layers. This solution addresses this by using a UV leveling layer to completely encapsulate the inner and outer walls of the annular frame, combined with a continuous, smooth curved surface extending over the exposed substrate area. This transforms the originally easily trapped right-angled edges into a gently sloping transition structure without any dead angles. This construction allows the optical film to fully adhere to the leveling layer's curved surface during lamination, eliminating any remaining sealed air gaps. When the product enters the high-pressure process, the lack of expandable air carriers completely avoids the risk of air bubble formation.
[0009] Preferably, the UV-cured filler layer forms a raised arc-shaped transition section at the edge region of the locally printed layer, and the arc-shaped transition section smoothly connects with the exposed surface of the substrate layer.
[0010] The above technical solution constructs a raised arc-shaped transition section in the edge area of the printed layer, eliminating the physical conditions for residual air in the lamination process, thereby avoiding the risk of bubble formation in the subsequent high-pressure process.
[0011] Specifically, during the coating process of optical functional films, traditional right-angled edge structures can create sealed air cavities, while this solution creates a continuous slope interface through an arc-shaped transition section. This curved structure has a dual suppression effect: firstly, the arc slope eliminates mechanical obstruction blind spots during coating, allowing residual gas to be naturally guided away along the curved surface under coating pressure; secondly, the smooth connection between the arc apex and the substrate forms a stepless transition surface, enabling the optical film to achieve full-area adhesion in a gradual manner, avoiding the formation of new air cavities due to localized suspension. When the product enters a high-pressure environment, the lack of an expansion medium for sealed air cavities completely blocks the bubble formation mechanism.
[0012] Preferably, there is a gapless interface between the lower surface of the optical functional film layer and the upper surface of the UV-cured filler layer.
[0013] The above technical solutions enhance the integrity of the bonding between film layers, reduce the possibility of air retention during the coating process, and thus suppress the conditions for bubble formation under subsequent high pressure.
[0014] Specifically, in the process of bonding optical functional films, traditional processes may create localized gaps at the interface due to microscopic unevenness or height differences on the surface of the filler layer. This solution utilizes the continuous, smooth curved surface of the UV filler layer in conjunction with the flexible properties of the optical film to form a tightly bonded interface structure. This structure has a dual optimization effect: firstly, it significantly compresses the physical space of residual gas, enabling more uniform and progressive contact between the films; secondly, the stable interface formed after curing better maintains the structural state under high pressure. When the product undergoes high-pressure processes, the potential for gas expansion is effectively reduced.
[0015] Preferably, the closed graphic printing layer is a ring-shaped border structure, and the UV-cured filler layer covers the inner and outer walls of the ring-shaped border structure.
[0016] By using the above technical solutions, the physical coverage integrity of the edge area is optimized, reducing the risk of air retention during the coating process and thus reducing the possibility of bubble formation under subsequent high pressure.
[0017] Specifically, during the lamination of optical functional films, traditional ring structures, due to operational blind spots on the inner walls, are prone to forming unfilled air gaps at corners. This solution utilizes a UV-filling layer to continuously cover both the inner and outer walls, combined with extended coverage of the exposed substrate area, to create a smooth, surrounding transition interface. This structure produces a dual optimization effect: firstly, simultaneous filling inside and outside eliminates uneven coverage during lamination, allowing for more complete compression of residual gas spaces; secondly, the closed, ring-shaped curved structure provides a uniform support base for the optical films, promoting smoother, progressive lamination of the film material. When the product undergoes high-pressure processes, the conditions for gas expansion are effectively suppressed.
[0018] Preferably, the vertical distance between the highest point of the arc-shaped transition section and the exposed surface of the substrate layer is equal to the thickness of the local printed layer.
[0019] By using the above technical solutions, the spatial distribution of the filling material is optimized, reducing the potential risk of residual air gaps at the edges during the coating process, thereby reducing the possibility of air bubbles appearing during the high-pressure process.
[0020] Specifically, in the process of bonding optical functional films, traditional processes may result in uncovered micro-gaps or raised barriers in the sidewall areas of the printed layer due to insufficient filler layer thickness or excessive buildup. This solution achieves triple technical coordination by controlling the height of the arc apex to match the thickness of the printed layer: firstly, ensuring that the filler material fully covers the vertical sidewalls of the printed layer, eliminating hidden spaces for lateral air gaps; secondly, better matching the arc curvature with the lamination tension, guiding the optical film to transition more naturally to the substrate area; and thirdly, maintaining the minimum necessary thickness of the filler layer to avoid localized stress concentration caused by material buildup. When the product experiences high-pressure environments, the uniformity of the interlayer bonding helps disperse external stress and weakens the conditions that induce gas expansion.
[0021] Preferably, the UV-cured filler layer forms a downwardly sloping guide slope at the edge of the exposed area of the substrate layer.
[0022] The above technical solution, which forms a flow-guiding slope at the edge of the exposed area of the substrate, improves the path control of the adhesive flow, reduces the risk of uneven coverage in the filling process, and thus weakens the potential conditions for bubble formation after lamination.
[0023] Specifically, in the UV filler coating process, traditional processes are prone to material accumulation or coverage defects in the boundary areas due to the surface tension of the adhesive. This solution achieves a triple control effect through a downward-sloping surface structure: First, the slope angle guides the adhesive to naturally extend towards the center of the substrate, reducing thickness anomalies caused by material accumulation at the edges; second, the sloped interface weakens the contact resistance between the adhesive and the substrate, promoting more uniform coverage of the target area by the filler material; third, the clear geometric boundary provides a physical positioning reference for the coating equipment, reducing the complexity of process adjustments. When entering the optical film coating stage, the more uniform filler surface creates favorable conditions for gapless bonding.
[0024] Compared with the prior art, the present invention has the following advantages:
[0025] 1. This utility model employs a three-dimensional encapsulation design of a UV-filling layer around the printed layer. By covering the upper surface, sidewalls, and continuous smooth curved surface extending to the exposed substrate area of the printed layer, the risk of residual edge air gaps is significantly reduced. This structure transforms the right-angled steps in traditional processes into a naturally transitioning arc-shaped interface, enabling a tighter adhesion of the optical functional film layer. This change in geometry effectively weakens the physical basis for air expansion and bubble formation under high pressure. Compared to conventional planar filling solutions, the suppression of bubble problems is more stable and durable, improving the quality consistency of the product under complex working conditions.
[0026] 2. The design of the guide slope and arc-shaped transition section in this utility model fully utilizes the self-leveling properties of UV adhesive, enabling autonomous morphology control during the filling process. Production does not require high-precision positioning equipment; the adhesive naturally spreads on the substrate surface to form a preset coverage path, significantly reducing sensitivity to process fluctuations. Simultaneously, this structure avoids the complex modifications required to traditional dispensing processes; it can be implemented on conventional printing production lines with simple adjustments, controlling equipment investment costs and reducing the impact of human error on yield, providing a feasible technical path for large-scale production. Attached Figure Description
[0027] Figure 1 This is a schematic diagram of the structure of this utility model;
[0028] Figure 2 This is an exploded view of the utility model. Figure 1 ;
[0029] Figure 3 This is an exploded view of the utility model. Figure 2 .
[0030] In the diagram: 1. Substrate layer; 2. Partially printed layer; 3. UV-cured leveling layer; 4. Optical functional film layer. Detailed Implementation
[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0032] Please see Figures 1 to 3 This utility model provides a technical solution:
[0033] A high-pressure bubble resistant composite structure with a UV-cured filling layer is characterized by comprising a substrate layer 1, a partial printing layer 2, a UV-cured filling layer 3, and an optical functional film layer 4, which are stacked sequentially. The UV-cured filling layer 3 completely covers the upper surface and sidewalls of the partial printing layer 2 and extends to cover the exposed surface of the substrate layer 1 adjacent to the partial printing layer 2, forming a continuous and smooth coating structure. The lower surface of the optical functional film layer 4 is completely attached to the upper surface of the UV-cured filling layer 3.
[0034] Specifically, the partial printing layer 2 is a closed graphic printing layer, and the UV-cured filling layer 3 completely covers the outer contour of the closed graphic along its boundary.
[0035] Through the above technical solution, the three-dimensional filling structure that simultaneously covers the inner and outer walls of the ring frame structure eliminates the residual conditions of edge air during the coating process in terms of physical space, thereby blocking the root cause of bubble appearance under subsequent high pressure.
[0036] Specifically, in the bonding process of the optical functional film layer 4, traditional processes often result in sealed air cavities at the steps due to vertical drops at the edges of the printed layer 2. This solution addresses this by using a UV-cured leveling layer 3 to completely encapsulate the inner and outer walls of the annular frame, combined with a continuous, smooth curved surface extending over the exposed area of the substrate layer 1. This transforms the originally easily trapped right-angled edges into a gently sloping transition structure without any dead angles. This construction allows the optical functional film layer 4 to completely conform to the curved surface of the UV-cured leveling layer 3 during bonding, eliminating any remaining sealed air gaps. When the product enters the high-pressure process, the lack of expandable air carriers completely avoids the risk of air bubble formation.
[0037] In actual production, this structure is particularly suitable for decorative components of electronic devices with annular light-transmitting areas. The manufacturing process of these components involves stringent procedures such as vacuum lamination and high-pressure curing, resulting in a high defect rate of air bubbles at the edges of traditional structures. This solution, through the physical intervention of a three-dimensional filling structure, suppresses air bubble problems at the source of the process, significantly improving product yield and batch stability.
[0038] Specifically, the UV-cured filler layer 3 forms a raised arc-shaped transition section in the edge area of the partial printed layer 2, and the arc-shaped transition section is smoothly connected to the exposed surface of the substrate layer 1.
[0039] By constructing a raised arc-shaped transition section in the edge area of the local printing layer 2 through the above technical solution, the physical conditions for air residue in the lamination process are eliminated, thereby avoiding the risk of bubble formation in the subsequent high-pressure process.
[0040] Specifically, during the application of the optical functional film layer 4, traditional right-angled edge structures can create sealed air cavities, while this solution creates a continuous slope interface through an arc-shaped transition section. This curved structure has a dual suppression effect: firstly, the arc slope eliminates the mechanical obstruction blind spot during film application, allowing residual gas to be naturally guided away along the curved surface under film application pressure; secondly, the smooth connection between the arc apex and the substrate layer 1 forms a stepless transition surface, enabling the optical functional film layer 4 to achieve full-area adhesion in a gradual manner, avoiding the formation of new air cavities due to localized suspension. When the product enters a high-pressure environment, the lack of an expansion medium for sealed air cavities completely blocks the bubble formation mechanism.
[0041] In practical applications, this arc-shaped structure is particularly suitable for high-precision gradient printing patterns. When vacuum hot-pressing lamination is performed on such components, the defect rate of bubbles at traditional right-angle edges is significantly higher than that in planar areas. This solution, through geometric optimization, enables curved areas to achieve the same lamination adhesion as planar areas, greatly improving the process stability of irregularly shaped components and providing key technical assurance for the visual quality of precision electronic devices.
[0042] Specifically, there is a gapless interface between the lower surface of the optical functional film layer 4 and the upper surface of the UV-cured leveling layer 3.
[0043] The above technical solutions enhance the integrity of the bonding between film layers, reduce the possibility of air retention during the coating process, and thus suppress the conditions for bubble formation under subsequent high pressure.
[0044] Specifically, during the bonding process of the optical functional film layer 4, traditional processes may create localized interface gaps due to microscopic unevenness or height differences on the surface of the UV-cured leveling layer 3. This solution utilizes the continuous, smooth curved surface of the UV-cured leveling layer 3 in conjunction with the flexible characteristics of the optical functional film layer 4 to form a tightly bonded interface structure. This structure offers dual optimization: firstly, it significantly compresses the physical space of residual gas, enabling more uniform and progressive contact between the film layers; secondly, the stable interface formed after curing better maintains the structural state under high-pressure conditions. When the product undergoes high-pressure processes, the potential for gas expansion is effectively mitigated.
[0045] In practical manufacturing, this interface structure has practical value for curved and irregularly shaped devices. In vacuum high-pressure bonding of such components, the interface bubble problem inherent in traditional processes is more easily manifested. This solution, by establishing a gapless interface bonding mechanism, enables complex curved surfaces to achieve a more reliable interlayer bonding state, providing technical support for the quality control of precision electronic devices.
[0046] Specifically, the closed graphic printing layer has an annular border structure, and the UV-cured filling layer 3 covers the inner and outer walls of the annular border structure.
[0047] By using the above technical solutions, the physical coverage integrity of the edge area is optimized, reducing the risk of air retention during the coating process and thus reducing the possibility of bubble formation under subsequent high pressure.
[0048] Specifically, during the lamination process of the optical functional film layer 4, traditional annular structures, due to the operational blind spots on the inner sidewalls, are prone to forming unfilled air gaps at corners. This solution utilizes a UV-cured leveling layer 3 to continuously cover the inner and outer sidewalls, combined with extended coverage of the exposed area of the substrate layer 1, forming a smooth, surrounding transition interface. This structure produces a dual optimization effect: firstly, simultaneous internal and external leveling eliminates uneven coverage during lamination, allowing for more complete compression of residual gas spaces; secondly, the annular closed curved structure provides a uniform support base for the optical functional film layer 4, promoting smoother, progressive lamination of the film material. When the product undergoes high-pressure processes, the conditions for gas expansion are effectively suppressed.
[0049] In actual production, this structure has practical value for precision ring-shaped devices. In vacuum hot pressing processes, the corner bubble problem is more likely to occur in such components using traditional methods. This solution, through a three-dimensional surrounding filling mechanism, enables complex ring-shaped structures to achieve coating stability similar to that of planar areas, providing technical support for improving the yield of high-precision electronic components.
[0050] Specifically, the vertical distance between the highest point of the arc-shaped transition section and the exposed surface of the substrate layer 1 is equal to the thickness of the local printed layer 2.
[0051] By using the above technical solutions, the spatial distribution of the filling material is optimized, reducing the potential risk of residual air gaps at the edges during the coating process, thereby reducing the possibility of air bubbles appearing during the high-pressure process.
[0052] Specifically, during the lamination of the optical functional film layer 4, traditional processes may result in uncovered micro-gaps or raised barriers in the sidewall areas of the locally printed layer 2 due to insufficient thickness or excessive accumulation of the UV-cured filler layer 3. This solution achieves triple technical coordination by controlling the height of the arc apex to match the thickness of the locally printed layer 2: First, it ensures that the filler material fully covers the vertical sidewalls of the locally printed layer 2, eliminating the hiding space for lateral air gaps; second, it allows for better matching of the arc curvature and lamination tension, guiding the optical functional film layer 4 to transition more naturally to the substrate layer 1 area; third, it maintains the minimum necessary thickness of the UV-cured filler layer 3, avoiding localized stress concentration caused by material accumulation. When the product experiences high-pressure environments, the uniformity of the interlayer bonding helps disperse external stress and weakens the conditions that induce gas expansion.
[0053] In practical applications, this design has practical value for micro-printed patterns. When vacuum-coating such components, sidewall bubbles are more likely to occur using traditional processes. This solution, through precise matching of geometric parameters, improves the leveling effect of micron-level structures, providing technical support for the reliable manufacturing of miniaturized electronic components.
[0054] Specifically, the UV-cured filler layer 3 forms a downwardly sloping guide slope at the edge of the exposed area of the substrate layer 1.
[0055] The above technical solution, which forms a flow-guiding slope at the edge of the exposed area of the substrate layer 1, improves the path control of the adhesive flow, reduces the risk of uneven coverage in the filling process, and thus weakens the potential conditions for bubble formation after lamination.
[0056] Specifically, during the UV-cured filler layer 3 coating process, traditional processes are prone to material accumulation or coverage defects in the boundary areas due to the surface tension of the adhesive. This solution achieves a triple control effect through a downward-sloping structure: firstly, the slope angle guides the adhesive to naturally extend towards the center of the substrate layer 1, reducing thickness anomalies caused by material accumulation at the edges; secondly, the inclined interface weakens the contact resistance between the adhesive and the substrate layer 1, promoting more uniform coverage of the target area by the filler material; and thirdly, the clear geometric boundary provides a physical positioning reference for the coating equipment, reducing the complexity of process adjustments. When entering the optical functional film layer 4 coating stage, the more uniform surface of the UV-cured filler layer 3 creates favorable conditions for gapless bonding.
[0057] In actual production, this design has practical value for large-area substrates. In high-speed coating processes, edge-filling defects are more likely to occur in such components using traditional methods. This solution, through the physical guiding mechanism of the flow-guiding slope, enables the leveling material to achieve more controllable leveling characteristics, providing technical support for process stability in large-scale production.
[0058] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0059] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.
[0060] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.
Claims
1. A high-pressure bubble-resistant composite structure with a UV-filling layer, characterized in that: It includes a substrate layer (1), a partial printing layer (2), a UV-cured filler layer (3), and an optical functional film layer (4) stacked in sequence; the UV-cured filler layer (3) completely covers the upper surface and sidewalls of the partial printing layer (2), and extends to cover the exposed surface of the substrate layer (1) adjacent to the partial printing layer (2), forming a continuous and smooth coating structure; the lower surface of the optical functional film layer (4) is completely attached to the upper surface of the UV-cured filler layer (3).
2. The composite structure according to claim 1, characterized in that: The partial printing layer (2) is a closed graphic printing layer, and the UV-cured filling layer (3) completely wraps the outer contour of the closed graphic along its boundary.
3. The composite structure according to claim 1, characterized in that: The UV-cured filler layer (3) forms a raised arc-shaped transition section in the edge region of the partial printed layer (2), which smoothly connects with the exposed surface of the substrate layer (1).
4. The composite structure according to claim 1, characterized in that: The lower surface of the optical functional film layer (4) and the upper surface of the UV-cured filler layer (3) form a gapless interface.
5. The composite structure according to claim 2, characterized in that: The closed graphic printing layer is a ring-shaped frame structure, and the UV-cured filling layer (3) covers the inner and outer walls of the ring-shaped frame structure.
6. The composite structure according to claim 3, characterized in that: The vertical distance between the highest point of the arc-shaped transition section and the exposed surface of the substrate layer (1) is equal to the thickness of the local printed layer (2).
7. The composite structure according to claim 1, characterized in that: The UV-cured filler layer (3) forms a downward-sloping guide slope at the edge of the exposed area of the substrate layer (1).