Double-Sided Adhesive Carrier Modulus for Optical Conformability
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Solution Overview
Problem
Conventional double-sided adhesive tapes and transfer adhesive tapes face challenges in bonding optical components with large topographical differences, as they either fail to compensate for such variations or result in air pockets, optical quality issues, and processing difficulties due to stiffness and high layer thickness.
Innovation Solution
The use of double-sided pressure-sensitive adhesive products with a carrier made of triblock copolymers of polymethyl methacrylate end blocks and polybutyl acrylate middle blocks, having a modulus of elasticity between 2.5 - 500 MPa, and (meth)acrylate-based pressure-sensitive adhesive layers, which provide improved adaptability and reduced adhesive bleeding, enabling effective compensation of topographical differences without air pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional double-sided adhesive tapes with rigid carriers are used, then handling and processing is easier, but conformability to topographical features is insufficient leading to air inclusions
Solution Approach 1:
The patent changes the modulus of elasticity parameter of the carrier material from rigid (typical polyester) to flexible (2.5-500 MPa range), enabling the carrier to conform to topographical features while maintaining ease of handling. This parameter change resolves the contradiction between rigidity for handling and flexibility for conformability.
Solution Approach 2:
The patent uses composite carrier materials with specific modulus of elasticity ranges that combine flexibility for conformability with sufficient structural integrity for handling. The carrier materials are selected to have optimized properties that balance both requirements.
2Adaptability or versatility
If transfer tapes of high thickness are used to compensate for large topographical differences, then adaptability improves, but optical quality deteriorates due to manufacturing process problems
Solution Approach 1:
The patent optimizes the thickness parameter of the adhesive layer to achieve the right balance between compensating topographical differences and maintaining optical quality. The adhesive layer thickness is controlled to ensure proper filling capability while avoiding manufacturing defects that would compromise optical properties.
3Adaptability or versatility
If transfer tapes with high thickness are used, then topographical compensation improves, but processability worsens due to slow drying rates and adhesive oozing
Solution Approach 1:
The patent changes the composition and physical parameters of the adhesive layer to achieve optimal drying characteristics. The adhesive formulation is designed to provide sufficient tackiness for bonding while maintaining appropriate drying rates and preventing oozing, even when compensating for significant topographical variations.
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
These products achieve high optical quality by ensuring good processability, reduced adhesive bleeding, and excellent die-cutability, effectively filling structural gaps and compensating for topographical differences in optical components with topographical height variations up to 500 µm.
Implementation Method 1
the carrier has a modulus of elasticity of 2.5–500 MPa
Implementation Method 2
a first adhesive layer arranged on the first surface of the carrier, and a second adhesive layer arranged on the second surface of the carrier
Data Source
AI summary
The invention relates to a double-sidedly pressure-sensitively adhesive product having a haze value (measured by test method B) of 5% or less, comprising a carrier having a first surface and a second surface, and also a first layer of pressure-sensitive adhesive, disposed on the first surface of the carrier, and a second layer of pressure-sensitive adhesive, disposed on the second surface of the carrier, characterized in that the carrier has a modulus of elasticity of 2.5 - 500 MPa.