A novel composite membrane

Abstract

This utility model provides a novel composite film for use in the production of display screens. It consists of a release film, a POL layer, an HC hardening layer, an OCA layer, and a PET layer, sequentially laminated together. The composite film is flattened and laminated using a dual-roller lamination device composed of a rubber roller and a steel roller. During the lamination process, the temperature is controlled at 50-70℃, and the pressure is controlled at 0.8-1.2MPa. After lamination, the film is cut and shaped using a mold equipped with a visual alignment system, achieving one-time lamination and molding of the automotive display module. This application adopts a one-time lamination and molding process, which, compared to traditional multi-lamination processes, reduces production steps, shortens the production cycle, improves production efficiency, effectively reduces production costs, enhances the company's market competitiveness, and meets the needs of large-scale production of automotive display screens.

Description

Technical Field

[0001] This application relates to the field of display screen manufacturing, and in particular to a novel composite film. Background Technology

[0002] With the continuous improvement of automotive intelligence and informatization, in-vehicle displays have become the core window for human-machine interaction, and their performance directly affects the driving experience and driving safety. Currently, the materials used for in-vehicle displays face many challenges:

[0003] Current display screen material manufacturing mostly adopts a step-by-step bonding process, which requires multiple operations to complete the combination of different functional layers. Typically, POL material and OCA material are produced first, and then bonded together a second time. This method is not only time-consuming and inefficient, but also easily introduces impurities such as air bubbles and dust during each bonding process, resulting in a yield rate of only 75%-85%, increasing production costs and making it difficult to meet the needs of large-scale production.

[0004] Therefore, a novel composite membrane is proposed. Utility Model Content

[0005] The purpose of this application is to address the technical problems of long production cycles and low efficiency in the existing automotive display manufacturing process of bonding POL and OCA materials. Compared with the existing technology, a novel composite film is provided, which consists of a heavy release film, a POL layer, an HC hardening layer, an OCA layer and a PET layer bonded together in sequence.

[0006] The surface of the HC hardened layer facing the POL layer is provided with a micron-level anti-reflective groove array. The grooves are rectangular in shape, 3-5 μm deep, and 10-15 μm apart. The OCA layer adopts a gradient viscosity structure, with a viscosity of 15-20 N / 25 mm near the HC hardened layer and a viscosity of 8-12 N / 25 mm near the PET layer. The composite film is flattened and laminated using a double-roller lamination device consisting of a rubber roller and a steel roller. During the lamination process, the temperature is controlled at 50-70℃ and the pressure is controlled at 0.8-1.2 MPa.

[0007] The side of the release film away from the POL layer is also bonded with a PET protective film. After the composite film and the PET protective film are bonded together, they are cut and shaped by a mold with a vision alignment system to achieve one-time bonding and shaping of the vehicle display module. The PET protective film is not cut and is used to support or pull the cut composite film.

[0008] Furthermore, the POL layer is prepared using a directional stretching process, with a polarization degree ≥99.5% and haze ≤0.5% in the 45° direction.

[0009] Furthermore, the PET layer is made of biaxially oriented polyethylene terephthalate with a thickness of 50-80 μm, and its surface is treated with corona discharge to form a micro-nano structure with a roughness Ra≤0.3 μm.

[0010] Furthermore, the dual-roller composite device is equipped with a pressure feedback regulation system, which monitors the composite pressure in real time through a pressure sensor and feeds the data back to the PLC control system to control the pressure fluctuation range within ±0.1MPa.

[0011] Furthermore, the die cutting head is manufactured using laser cladding technology, with a cutting edge hardness of HRC60-65 and a cutting accuracy controlled within ±0.03mm.

[0012] Furthermore, the composite film has an overall light transmittance of ≥92%, a haze of ≤1.0%, and an interlayer peel strength reduction rate of ≤10% after aging for 1000 hours at 85℃ / 85%RH.

[0013] Compared to existing technologies, the advantages of this application are:

[0014] This application utilizes the high polarization degree design of the POL layer, the anti-reflection groove array of the HC hardened layer, and the synergistic effect of optical optimization of each layer material to achieve high overall light transmittance and reduced reflectivity in the composite film, providing drivers with a clear and comfortable visual experience and ensuring driving safety.

[0015] Meanwhile, this application adopts a one-time bonding molding process, which reduces production steps, shortens the production cycle, and improves production efficiency compared to the traditional multiple bonding process. This effectively reduces production costs, enhances the company's market competitiveness, and meets the needs of large-scale production of vehicle-mounted displays. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this application.

[0017] Explanation of the labels in the diagram:

[0018] 1. Release film; 2. POL layer; 3. HC hardening layer; 4. OCA layer; 5. PET layer; 6. PET protective film. Detailed Implementation

[0019] The embodiments will be described clearly and completely with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments in this application without creative effort are within the scope of protection of this application. Example

[0020] This utility model provides a novel composite membrane. Please refer to [link / reference]. Figure 1It consists of a heavy release film 1, a POL layer 2, an HC hardening layer 3, an OCA layer 4, and a PET layer 5, which are bonded together in sequence. The heavy release film 1, as the outermost protective structure of the composite film, is made of polyester material with a thickness of 50μm and a release force set at 8-12g / 25mm. Its main function is to provide physical protection for the internal structure during the material production, transportation, and storage stages, preventing the surface of the POL layer 2 from being contaminated or scratched. Due to its moderate release force, it can be firmly attached to the POL layer 2 and easily peeled off during subsequent use without leaving any adhesive residue, thus avoiding adverse effects on the optical performance of the POL layer 2.

[0021] POL layer 2 is prepared using a directional stretching process. The core material is polyvinyl alcohol (PVA) film, which undergoes dyeing, stretching, and drying to achieve a polarization degree of ≥99.5% at 45°, haze control of ≤0.5%, and a thickness of 25μm. POL layer 2 is crucial for realizing the optical functions of the display screen. It can precisely control the polarization direction of light, significantly reduce reflected light, and significantly improve the contrast and viewing angle of the display screen. This ensures clear and accurate display under various lighting conditions, providing drivers with a good visual experience.

[0022] The HC hardening layer 3 is constructed on a 75μm thick acrylic resin substrate using nanoimprint technology to create a rectangular micron-scale anti-reflective groove array. The groove depth is 3-5μm and the spacing is 10-15μm. After hardening treatment, the hardness reaches 4H. Based on the principles of light scattering and refraction and thin film optics theory, this groove array can effectively change the light propagation path, reduce surface reflection, and significantly improve the light transmittance of the composite film. At the same time, the high hardness gives the material excellent wear resistance and impact resistance, which can effectively resist external physical damage and protect the internal optical structure.

[0023] The PET layer 5 is made of biaxially oriented polyethylene terephthalate with a thickness of 75 μm. Its surface is corona treated to form a micro-nano structure with a roughness Ra≤0.3 μm. With its good flexibility, mechanical strength and chemical stability, the PET layer 5 provides reliable structural support for the composite film. The surface micro-nano structure increases the contact area with the OCA layer 4, enhances the adhesion, and reduces the reflection loss of light between layers.

[0024] OCA layer 4 uses an acrylate copolymer system and forms a gradient viscosity structure through a special coating process. The viscosity is 15-20 N / 25 mm near the HC hardened layer 3 and 8-12 N / 25 mm near the PET layer 5, with a thickness of 25 μm. This unique viscosity design ensures strong adhesion between layers while effectively dispersing the stress generated during the composite process, avoiding problems such as interlayer separation and warping caused by stress concentration, and ensuring the stability of the composite film structure.

[0025] PET protective film 6 serves as the bottom layer of protection for the composite film. It is made of polyethylene terephthalate with a thickness of 50μm and a release force of 1-3g / 25mm. It is used for support or traction during the lamination or cutting of the composite film to prevent scratches or deformation during transportation. It can also be easily peeled off after cutting without affecting the overall output of the composite film.

[0026] It should be noted that this composite film is flattened and laminated using a double-roller lamination device consisting of a rubber roller and a steel roller. The double-roller lamination device is equipped with a pressure feedback adjustment system, including a pressure sensor and a PLC control system. The pressure sensor monitors the lamination pressure in real time and transmits the data to the PLC control system. When the pressure fluctuation exceeds ±0.1MPa, the system automatically adjusts the pressure of the rubber roller and the steel roller to ensure that the pressure during the lamination process is stable at 0.8-1.2MPa. At the same time, the lamination temperature is controlled at 50-70℃ to ensure that the materials of each layer are tightly bonded at a suitable temperature, avoiding the generation of bubbles and wrinkles. The laminated roll is cut into shape by a mold with a vision alignment system. The cutting head of the mold is made using laser cladding technology, with a cutting edge hardness of HRC60-65 and a cutting accuracy controlled within ±0.03mm. This allows for precise cutting of products that meet the size requirements of automotive display modules, achieving one-time lamination and forming, simplifying the production process, and improving production efficiency and yield.

[0027] This application achieves a composite film with an overall light transmittance of ≥92%, haze ≤1.0%, and reflectivity reduced to below 3% through the synergistic effect of the high polarization degree design of the POL layer 2, the anti-reflection groove array of the HC hardened layer 3, and optical optimization of the materials in each layer. Even in strong light environments, the display screen remains clearly visible with accurate color reproduction, effectively improving display quality and providing drivers with a clear and comfortable visual experience, thus ensuring driving safety.

[0028] This application employs a one-step lamination molding process, which reduces production steps by more than 50% and shortens the production cycle by 40% compared to traditional multi-step lamination processes, significantly improving production efficiency. Furthermore, precise control over lamination and cutting processes increases the yield rate to over 95%, effectively reducing production costs, enhancing the company's market competitiveness, and meeting the demands of large-scale automotive display production.

[0029] The above description is only the best implementation method adopted in this application in combination with current practical needs, but the scope of protection of this application is not limited thereto.

Claims

1. A novel composite membrane, characterized in that, It consists of a release film (1), a POL layer (2), an HC hardening layer (3), an OCA layer (4), and a PET layer (5) that are sequentially laminated together; The HC hardened layer (3) has a micron-level anti-reflective groove array on the surface facing the POL layer (2). The grooves are rectangular in shape, 3-5 μm deep, and 10-15 μm apart. The OCA layer (4) adopts a gradient viscosity structure. The viscosity on the side near the HC hardened layer (3) is 15-20 N / 25 mm, and the viscosity on the side near the PET layer (5) is 8-12 N / 25 mm. The composite film is flattened and laminated by a double roller laminating device composed of a rubber shaft and a steel shaft. During the laminating process, the temperature is controlled at 50-70℃ and the pressure is controlled at 0.8-1.2 MPa. The side of the release film (1) away from the POL layer (2) is also covered with a PET protective film (6). After the composite film and the PET protective film (6) are combined, they are cut and shaped by a mold with a visual alignment system to realize the one-time bonding and shaping of the vehicle display module. The PET protective film (6) is not cut and is used to support or pull the cut composite film.

2. A novel composite film as claimed in claim 1, wherein, The POL layer (2) is prepared by directional stretching process, with a polarization degree ≥99.5% and haze ≤0.5% in the 45° direction.

3. The novel composite film according to claim 1, characterized in that, The PET layer (5) is made of biaxially oriented polyethylene terephthalate with a thickness of 50-80 μm. Its surface is treated with corona to form a micro-nano structure with a roughness Ra≤0.3 μm.

4. The novel composite film according to claim 1, characterized in that, The dual-roller composite device is equipped with a pressure feedback regulation system, which monitors the composite pressure in real time through a pressure sensor and feeds the data back to the PLC control system to control the pressure fluctuation range within ±0.1MPa.

5. The novel composite film according to claim 1, characterized in that, The die cutting head is manufactured using laser cladding technology, with a cutting edge hardness of HRC60-65 and a cutting accuracy controlled within ±0.03mm.

6. The novel composite membrane according to claim 1, characterized in that, The composite film has an overall light transmittance of ≥92%, a haze of ≤1.0%, and an interlayer peel strength reduction rate of ≤10% after aging for 1000 hours at 85℃ / 85%RH.

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