Anti-glare Coating Composition Single Wet Process Phase Separation
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Solution Overview
Problem
Conventional anti-reflective coating films face challenges in achieving improved interface adhesion and scratch resistance while being manufactured through a single wet coating process, often resulting in phase separation issues and weak adhesion at the film interface.
Innovation Solution
An anti-reflective coating composition comprising specific ratios of (meth)acrylate-based compounds with varying molecular weights, fluorine-based (meth)acrylate compounds, inorganic nanoparticles, and hollow particles, which allows for the formation of a crosslinked polymer structure that infiltrates into the substrate and forms a hard coat layer, while the remaining components form a low refractive index layer on top, enhancing adhesion and scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single wet coating composition is used to form multiple layers, then production cost is reduced and process is simplified, but phase separation does not properly occur and adhesion at film interface deteriorates
Solution Approach 1:
The invention divides the single coating composition into distinct functional regions through controlled phase separation. The composition contains multiple polymers with different solubility characteristics that spontaneously separate into a first region (hard coat layer) and a second region (low refractive index layer) after coating, achieving layer differentiation without multiple coating steps.
Solution Approach 2:
The invention utilizes changes in physical-chemical parameters (solubility, molecular weight, glass transition temperature) of polymer components during the drying and curing process to induce phase separation. By selecting polymers with specific parameter differences, the system automatically segregates into distinct layers with appropriate properties for each functional region.
2Reliability
If hard coat layer and low refractive index layer are formed as separate layers, then each layer can be optimized for its function, but production process becomes complicated and interface adhesion becomes weak
Solution Approach 1:
The invention merges multiple coating processes into a single wet coating step by formulating a composite composition containing both hard coat polymers and low refractive index polymers. The distinct functional layers are formed simultaneously from this unified composition through phase separation, eliminating the need for separate coating, drying, and curing steps for each layer.
Solution Approach 2:
The invention creates a composite coating composition comprising multiple polymer types (polyester resin, polyurethane resin, silane-modified polymer) with different functions integrated in a single formulation. This composite material approach allows both hard coat and low refractive index functionalities to be present in one coating application, which then segregates into functionally optimized layers.
3Object-affected harmful factors
If conventional anti-reflective coating is applied, then reflection of external light is minimized, but scratch resistance and interface adhesion are insufficient
Solution Approach 1:
The invention applies local quality by creating distinct regions with different properties within the coating film. The first region (hard coat layer) is concentrated at the substrate interface with high polymer concentration and crosslinking for mechanical strength, while the second region (low refractive index layer) is positioned at the outer surface with low refractive index for optical performance. Each region has locally optimized properties for its specific function.
Solution Approach 2:
The invention performs preliminary action by forming the hard coat layer first at the substrate interface through phase separation before the low refractive index layer forms at the outer surface. This sequential self-organization during a single coating process ensures strong substrate adhesion is established before the outer anti-reflective layer develops, providing both mechanical strength and optical functionality.
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 enables the production of anti-reflective coating films with improved interface adhesion and scratch resistance, achieving effective phase separation and distribution of hollow particles, resulting in enhanced mechanical properties and anti-reflective performance.
Implementation Method 1
a crosslinked polymer structure that infiltrates into the substrate and forms a hard coat layer
Implementation Method 2
phase separation does not properly occur upon applying the compositions during the production process
Implementation Method 3
hollow particles in the crosslinked copolymer, and which covers the first layer
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
The present invention relates to an anti-reflective coating composition that can be used to form at least two layers by a single coating process and is allowed to provide an anti-reflective coating film having more improved interface adhesion between the formed layers and scratch resistance, and an anti-reflective coating film manufactured using the same.