Monolayered Acrylic Adhesive Resin Layer for Level Difference Substrates
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Solution Overview
Problem
Existing adhesive resin technologies fail to prevent air bubble generation when applied to substrates with level differences, leading to reduced adhering strength and optical properties, and are often costly with complex layer configurations.
Innovation Solution
A monolayered adhesive resin layer composed of an acrylic-based polymer, a hydroxyl-group containing acrylic monomer, and a thermopolymerization initiator, which is thermally cured at 100-250°C, providing pressure-sensitive adhesiveness and excellent followability to substrates with level differences without generating air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pressure sensitive adhesive agent is laminated on a substrate having a level difference, then adhesion is achieved, but air bubbles are generated and adhering strength is reduced
Solution Approach 1:
The adhesive resin composition changes its viscosity parameter in response to temperature changes. At application temperature, the adhesive has low viscosity to flow into level differences and prevent air bubbles. Upon heating, the viscosity increases to maintain the filled shape and provide strong adhesion.
Solution Approach 2:
The adhesive resin transitions from a dynamic, flowable state during application to a static, rigid state after heating. This dynamic behavior allows the adhesive to adapt to substrate irregularities and then maintain structural integrity.
2Adaptability or versatility
If a pressure sensitive adhesive sheet with multiple layers is used to improve followability to level differences, then adhesion is improved, but device complexity and cost increase
Solution Approach 1:
The invention merges multiple functions into a single adhesive resin layer. The adhesive layer simultaneously provides followability to level differences, prevents air bubble generation, and delivers strong adhesion after heating, eliminating the need for separate hard coat layers, multiple adhesive layers, and release sheets.
Solution Approach 2:
The single adhesive resin layer performs multiple functions: it acts as the adhesive layer, the hard coat layer, and the release sheet equivalent. This multi-functional design simplifies the overall structure while maintaining all necessary performance characteristics.
3Productivity
If a photopolymerization-based adhesive is used to achieve fast curing, then productivity is improved, but air bubbles are generated when applied to substrates with level differences
Solution Approach 1:
The invention replaces photopolymerization with thermal polymerization. The thermal curing process allows the adhesive to remain flowable during application to fill level differences, then cures upon heating to prevent air bubbles and provide strong adhesion, unlike photopolymerization which cures too quickly.
4Stability of the object's composition
If an adhesive resin with high viscosity is used to maintain shape, then structural stability is improved, but followability to level differences deteriorates
Solution Approach 1:
The adhesive resin's viscosity parameter is dynamically changed through temperature control. During application at ambient temperature, the adhesive has low viscosity to flow and follow level differences. After heating, the viscosity increases to maintain shape stability and prevent air bubbles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents air bubble formation and maintains transparency, ensuring strong adhesion and durability even on substrates with high level differences, while simplifying the layer configuration and reducing costs.
Implementation Method 1
the adhesive resin layer has pressure sensitive adhesiveness on both surfaces at an ambient temperature, and can be thermally cured by heating at a temperature of 100 to 250°C and a time of 30 seconds to 10 minutes
Implementation Method 2
the adhesive resin layer has pressure sensitive adhesiveness on both surfaces at an ambient temperature
Implementation Method 3
can be thermally cured by heating at a temperature of 100 to 250°C and a time of 30 seconds to 10 minutes
Data Source
Figure 1~3
Figure 4~5
AI summary
The present invention provides an adhesive resin layer, which can prevent generation of air bubbles even when adhered to a substrate having a high level difference, and can maintain transparency, an adhesive resin film, a laminate, and a method of producing a laminate. More specifically, the present invention is a monolayered adhesive resin layer comprising an acrylic-based adhesive resin composition having transparency, wherein the adhesive resin composition contains (A) an acrylic-based polymer, (B) an acrylic-based monomer, and (C) a thermopolymerization initiator, and an adhesive resin layer 11 has pressure sensitive adhesiveness on both surfaces 11a, 11b at an ambient temperature, and can be thermally cured by heating at a temperature of 100 to 250°C and a time of 30 seconds to 10 minutes.