Antiglare Antireflection Plate Coating Uniformity
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Solution Overview
Problem
Existing methods for imparting antiglare properties to surfaces, such as embossing, suffer from variations in antiglare performance due to non-uniform processing, substrate type dependency, limited machine size constraints, and reduced effective usable area, leading to inefficiencies and increased costs.
Innovation Solution
The development of an antiglare antireflection plate with a specific layer structure, including a hard coat layer, an antiglare layer made from a cured composition containing inorganic particles of a specific diameter, and an antireflection coat, which are laminated on a transparent resin base material. This structure achieves controlled line roughness characteristics and enhanced antiglare properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If embossing method is used to impart antiglare properties, then antiglare effect is achieved, but antiglare properties vary due to non-uniform processing
Solution Approach 1:
The patent replaces the mechanical embossing system with a chemical coating system. Instead of using physical embossing rollers or hot presses to create surface irregularities, the invention applies a curable composition containing inorganic particles that, when cured, form an antiglare layer with controlled surface roughness. This chemical approach eliminates the non-uniformity issues inherent in mechanical embossing processes.
Solution Approach 2:
The patent controls antiglare properties by adjusting parameters of the curable composition, specifically the particle diameter (500 nm to 700 nm) and particle content (0.1 to 15.0 parts by mass per 100 parts polymerizable acrylate compound). By changing these compositional parameters, the surface roughness and antiglare effect can be precisely controlled to achieve uniform results across the entire substrate.
2Adaptability or versatility
If embossing method is used, then antiglare properties are imparted, but antiglare properties vary depending on substrate type
Solution Approach 1:
The curable composition formulation is designed to be universally applicable to various transparent resin substrates. The composition contains polymerizable acrylate compounds that can adhere to different substrate types, and the inorganic particles provide consistent antiglare functionality regardless of the underlying substrate material, thereby achieving both versatility and reliability.
3Area of stationary object
If embossing machine is used, then antiglare processing is achieved, but embossing range is limited due to machine size
Solution Approach 1:
By replacing the large-scale mechanical embossing machine with a coating application system, the patent eliminates the size constraints of embossing equipment. Coating methods can be scaled more easily to accommodate larger substrate areas, allowing the entire substrate to be processed without being limited by machine footprint.
4Area of moving object
If embossing method is used, then antiglare properties are achieved, but edges have to be cut off reducing effective usable area
Solution Approach 1:
The coating method allows the curable composition to be applied uniformly across the entire substrate surface including edges, whereas embossing cannot effectively treat edge regions. This eliminates the need to cut off edges, maximizing the effective usable area while maintaining consistent antiglare properties throughout the substrate.
5Productivity
If batch processing is used, then antiglare treatment is completed, but production efficiency decreases and costs increase
Solution Approach 1:
The coating process enables continuous production where substrates can be sequentially coated, dried, and cured in an uninterrupted flow. This eliminates the batch processing steps and waiting times associated with embossing, thereby improving productivity and reducing overall processing time and costs.
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 proposed solution effectively controls line roughness and achieves excellent antiglare properties, improving production efficiency and reducing costs by allowing for uniformity across larger substrates and maintaining consistent performance.
Implementation Method 1
an antiglare layer made of a cured product of a composition containing 0.1 to 15.0 parts by mass of inorganic particles having an average particle diameter (D50) of 500 nm to 700 nm relative to 100 parts by mass of a polymerizable acrylate compound
Data Source
AI summary
An antiglare antireflection plate having excellent antireflection and antiglare properties is provided as following:the said plate is an antiglare antireflection plate including a hard coat layer, an antiglare layer, and an antireflection coat, in which the hard coat layer, the antiglare layer, and the antireflection coating are laminated in this order on a transparent resin base material, the antiglare layer is made of a cured product of a composition containing 0.1 to 15.0 parts by mass of inorganic particles having an average particle diameter (D50) of 500 nm to 700 nm relative to 100 parts by mass of a polymerizable acrylate compound, and line roughness characteristics defined in JIS B 0601 on a surface of the antiglare antireflection plate are as follows. An arithmetic average roughness (Ra) is 0.03 μm or more and 0.20 μm or less, an average length (RSm) is 10 μm or more and 70 μm or less, a skewness (Rsk) is −0.05 or more and 1.50 or less, a kurtosis (Rku) is 2.0 or more and 5.0 or less, and a maximum peak height (Rp)/maximum valley depth (Rv) is 1.0 or more and 3.0 or less. A haze value of the antiglare antireflection plate is 0.5% to 20.0%.