Active energy ray curable resin composition, laminate, manufacturing method thereof, and product
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Solution Overview
Problem
Existing laminates with anti-fogging or anti-fouling properties often suffer from visibility issues due to distorted image edges caused by projected portions at the laminate's edge, which degrade the appearance and functionality of products like mirrors and glass surfaces.
Innovation Solution
A laminate design featuring a primer layer and a functional layer with a surfactant-containing active energy ray curable resin composition, where the edge portion has a controlled projected portion with specific height, width, and length dimensions to minimize distortion, and the functional layer exhibits anti-fogging and anti-fouling properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a functional layer with anti-fogging and anti-fouling properties is applied onto a substrate to prevent reduction of visibility and good appearance, then the anti-fogging and anti-fouling performance is improved, but the projected portion at the edge portion causes distortion of images and degrades visibility
Solution Approach 1:
The patent applies different properties to different parts of the laminate. The central region maintains the functional layer with anti-fogging and anti-fouling properties, while the edge portion is specifically controlled to have a projected portion with height of 10 μm or less. This local differentiation ensures that the functional performance is preserved in the main area while minimizing image distortion at the edges where such distortion is most noticeable.
Solution Approach 2:
The patent changes the physical parameters of the projected portion at the edge portion by controlling its height to be 10 μm or less. This parameter control is achieved through specific formulation of the active energy ray curable resin composition containing surfactants and controlled curing conditions, which allows the functional layer to be formed with minimized edge projection that causes less image distortion.
2Strength
If a primer layer is formed between the substrate and the functional layer to improve adhesion, then the adhesion is improved, but the projected portion at the edge portion still causes image distortion
Solution Approach 1:
The primer layer is applied selectively to improve adhesion where needed, while the edge portion geometry is independently controlled. The primer layer ensures strong bonding between the substrate and functional layer in the main area, while the projected portion height control at the edge (10 μm or less) addresses the image distortion issue separately, allowing both adhesion and visual quality to be optimized.
Solution Approach 2:
The laminate structure is segmented into distinct functional components: a primer layer for adhesion, a functional layer for anti-fogging and anti-fouling properties, and a controlled edge portion with specific projected height. This segmentation allows each component to be optimized independently - the primer layer for bonding strength and the edge portion geometry for minimizing image distortion.
3Object-affected harmful factors
If the projected portion at the edge portion is reduced to improve visibility, then image distortion is reduced, but the anti-fogging and anti-fouling performance may be compromised
Solution Approach 1:
The patent ensures that the functional layer maintains its anti-fogging and anti-fouling properties in the central region while allowing controlled edge geometry. The surfactant-containing resin composition provides these functional properties throughout the layer, but the edge portion is specifically controlled to have projected height of 10 μm or less, creating local quality differences that satisfy both functional performance and visual quality requirements.
Solution Approach 2:
The functional layer uses a composite resin composition containing surfactants that provide both the anti-fogging and anti-fouling properties while allowing controlled curing behavior. This composite material formulation enables the layer to maintain its functional performance while being formable into the desired geometry with minimized edge projection through controlled curing processes.
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 laminate provides excellent visibility and effective anti-fogging and anti-fouling performance by reducing the height, width, and length of the projected portion at the edge, ensuring clear images and easy cleaning, while maintaining adhesion and surface properties.
Implementation Method 1
an active energy ray curable resin composition is applied onto the substrate and curing the active energy ray curable resin composition to form the primer layer
Implementation Method 2
the active energy ray curable resin composition includes a surfactant
Data Source
AI summary
Provided is a laminate including a substrate, a primer layer disposed on the substrate, and a functional layer disposed on the primer layer, where the functional layer has a function of at least one of an anti-fogging property and an anti-fouling property, wherein a surface of an edge portion of the laminate at the side of the functional layer has a projected portion having an apex formed along an edge side of the edge portion, and on a cross-section orthogonal to a direction of the edge side and a planar direction of the surface, a height of the projected portion is 10 μm or less, a width of the projected portion is 15 mm or less, and a length between the edge side and the apex is 5.0 mm or less.