Anti-glare laminate with controlled surface roughness
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Solution Overview
Problem
Existing anti-glare laminates for liquid crystal display devices struggle to balance image reflection prevention, blurred character suppression, scratch resistance, and shape stability, often compromising on one or more of these properties.
Innovation Solution
An anti-glare laminate structure comprising a polycarbonate resin base material layer, a high-hardness resin layer, and a hard coat layer, with specific surface roughness and thickness parameters, and a production method involving a patterned PET film transfer process to achieve the desired balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fine particles are added to form surface unevenness for anti-glare effect, then image reflection prevention is improved, but scratch resistance is reduced due to particles acting as abrasives
Solution Approach 1:
The patent extracts and removes the fine particles from the hard coat layer composition. By eliminating the particle addition step, the hard coat layer maintains high scratch resistance while the anti-glare effect is achieved through the inherent unevenness of the hard coat surface formed during the curing process, without particles acting as abrasives
Solution Approach 2:
Instead of adding particles to create surface unevenness (conventional approach), the patent inverts the approach by forming unevenness through the curing process itself without any additive particles. The anti-glare effect is generated by the surface morphology developed during UV irradiation curing rather than by embedded particles
2Object-affected harmful factors
If haze is increased to achieve anti-glare performance, then image reflection prevention is improved, but visibility is reduced due to whitish impression
Solution Approach 1:
The patent optimizes the haze parameter within a specific range (5% ≤ haze < 15%) to achieve the desired balance. By controlling the haze value rather than maximizing it, the patent prevents excessive light scattering that causes whitening, while still achieving sufficient anti-glare effect. The surface unevenness parameters (Sq and Sdq) are also precisely controlled to regulate light scattering behavior
Solution Approach 2:
The patent applies partial action by using a moderate amount of surface unevenness (controlled Sq and Sdq values) rather than excessive unevenness. This partial unevenness is sufficient to scatter reflected light and prevent image reflection, while avoiding excessive scattering that would cause whitening and reduce visibility
3Strength
If hard coat layer is made thicker to improve scratch resistance, then durability is improved, but shape stability is reduced due to warpage
Solution Approach 1:
The patent optimizes the hard coat layer thickness within a specific range (1-10 μm) to balance scratch resistance and shape stability. By controlling the thickness parameter and combining it with controlled surface unevenness (Sq: 0.05-0.40 μm, Sdq: 0.020-0.10), the patent achieves sufficient scratch protection while minimizing warpage during storage and use
4Object-affected harmful factors
If surface unevenness is increased to prevent image reflection, then anti-glare performance is improved, but transmitted light scattering increases causing blurred characters
Solution Approach 1:
The patent precisely controls the surface unevenness parameters (Sq and Sdq) within specific ranges to optimize the balance between anti-glare effect and character clarity. By limiting Sq to 0.05-0.40 μm and Sdq to 0.020-0.10, the patent ensures that light scattering is sufficient to prevent image reflection but not excessive to cause blurred characters
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 achieves a balance between preventing image reflection, suppressing blurred characters, ensuring high scratch resistance, and maintaining excellent shape stability, while maintaining visibility and durability.
Implementation Method 1
The anti-glare film can scatter outside light by the uneven shape of the surface, thereby preventing reduction of visibility due to outside light reflection or image reflection
Implementation Method 2
a patterned PET film is pressed onto the surface of the hard coat layer to transfer an uneven shape
Data Source
AI summary
The present invention provides an anti-glare laminate that has, in order, a base material layer that includes at least a polycarbonate resin (a1), a high-hardness resin layer that includes a high-hardness resin (B), and a hard coat layer, wherein the root mean square gradient (Sdq) and the root mean square height (Sq) of the hard coat layer satisfy (i) and (ii), respectively. 0.010≤Sdq≤0.10 0.040≤Sq≤0.40