Antireflection Laminate with Buried Particles for Low Haze Transfer
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Solution Overview
Problem
Existing techniques for forming antireflection films using transfer methods fail to achieve low haze and satisfactory antireflection properties due to particle aggregation caused by exposure to air, leading to increased reflectivity and muddiness.
Innovation Solution
A laminate comprising a support, a pressure-sensitive adhesive layer, and particles with an average diameter of 100 nm to 380 nm, where the particles are buried in a resin layer and protrude from the interface, allowing for a low-haze antireflection film with a moth eye structure to be formed by a transfer method without exposing the particles to air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If particles are exposed to air during transfer, then transfer process becomes simpler, but particle aggregation occurs leading to increased haze and reduced antireflection properties
Solution Approach 1:
The patent applies the inert atmosphere principle by completely eliminating particle exposure to air during the transfer process. The particles are embedded in a resin layer that remains in contact with the support throughout transfer, peeling, and bonding operations. This prevents oxidative aggregation and maintains particle uniformity without requiring special atmospheric control measures.
Solution Approach 2:
The patent applies preliminary action by pre-embedding particles in a resin layer before the transfer process begins. This preliminary encapsulation protects particles from air exposure during subsequent handling operations, allowing simple transfer procedures while maintaining particle arrangement precision.
2Manufacturing precision
If particles are buried deep in resin layer, then particle aggregation is prevented, but antireflection function is reduced due to insufficient protrusion
Solution Approach 1:
The patent applies parameter changes by precisely controlling the resin layer thickness to create optimal burial depth. The resin layer is formulated to provide sufficient coverage for particle protection while maintaining adequate protrusion height for antireflection functionality. This parameter optimization resolves the contradiction between deep burial and sufficient protrusion.
Solution Approach 2:
The patent applies local quality by creating a resin layer with specific local thickness characteristics that provide differential protection and exposure. The resin layer locally covers particles to prevent aggregation while allowing controlled protrusion for optical function, achieving both uniformity and reliability through localized material distribution.
3Manufacturing precision
If haze is reduced by preventing particle aggregation, then antireflection properties improve, but particle exposure to air causes aggregation increasing haze
Solution Approach 1:
The patent converts the potentially harmful effect of air exposure into a beneficial protected state by using the resin layer as a barrier. The resin layer transforms the harmful interaction between particles and air into a beneficial encapsulation that prevents aggregation while maintaining particle functionality, effectively converting a harmful factor into a protective mechanism.
Solution Approach 2:
The patent introduces the resin layer as an intermediary between particles and air. This intermediary material prevents direct contact between particles and air that would cause aggregation, while still allowing the particles to maintain their antireflection function through controlled protrusion from the resin layer surface.
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 effectively reduces haze and enhances antireflection properties by preventing particle aggregation, resulting in a film with improved optical performance and reduced reflectivity.
Implementation Method 1
a layer (b) including a pressure sensitive adhesive
Implementation Method 2
an antireflection film having a fine uneven shape with a period equal to or less than the wavelength of visible light on the surface of a substrate, that is, an antireflection film having a so-called moth eye structure is known. The moth eye structure makes a refractive index gradient layer in which the refractive index successively changes in a pseudo manner from the air toward the bulk material inside the substrate
Data Source
AI summary
A laminate includes a support, a layer (b) including a pressure sensitive adhesive, particles (a2) having an average primary particle diameter of 100 nm to 380 nm, and a layer (ca) including a resin, in which the layer (b) is provided closer to the support than the layer (ca), the particles (a2) are buried in a layer obtained by combining the layer (b) and the layer (ca) and protrudes from an interface of the layer (ca) on the support side, and a portion including the particles (a2) and the layer (ca) is peelable from the layer (b).