Antireflection Laminate with Low Elastic Modulus Surface
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Solution Overview
Problem
Existing antireflection films with fine relief structures face challenges in effectively removing dirt from concave portions and maintaining excoriation resistance, especially when exposed to indoor light or used in display applications, where dirt adherence and decomposition issues persist, and the adjustment of convex portion spacing and height is difficult.
Innovation Solution
A laminate with a surface layer formed from a cured active energy ray-curable resin composition containing tri- or higher functional (meth)acrylate and bifunctional (meth)acrylate, with an elastic modulus less than 160 MPa and a specific friction coefficient slope, which allows for easy dirt removal and enhanced excoriation resistance without water or alcohol application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fine relief structure is formed on the antireflection film surface, then the refractive index is lowered and antireflection performance is improved, but dirt accumulates in the concave portions and becomes difficult to remove
Solution Approach 1:
The patent changes the elastic modulus parameter of the antireflection film material from a high value to a low value (less than 160 MPa). This parameter change allows the film to be soft enough to easily expel dirt from concave portions while maintaining the fine relief structure for antireflection performance. The low elastic modulus enables the material to deform and push dirt outward during cleaning processes.
Solution Approach 2:
The patent creates local quality differences by having the fine relief structure (convex and concave portions) on the film surface while maintaining a uniformly low elastic modulus throughout the film. This allows different regions of the film to serve different functions: the surface relief structure provides antireflection, while the bulk material properties enable dirt expulsion.
2Ease of operation
If the elastic modulus of the antireflection film is reduced to facilitate dirt removal, then excoriation resistance may deteriorate, but the patent achieves both low elastic modulus and high excoriation resistance
Solution Approach 1:
The patent changes the elastic modulus parameter to a specific low range (less than 160 MPa) that simultaneously enables dirt removal while maintaining excoriation resistance. This optimized parameter range allows the material to be soft enough for dirt expulsion but sufficiently durable for practical use in display devices and other applications.
Solution Approach 2:
The patent uses composite material composition, specifically incorporating fluorine-containing compounds and other additives into the polymer matrix to achieve the desired combination of low elastic modulus and high excoriation resistance. The composite formulation allows independent optimization of different material properties.
3Object-affected harmful factors
If multiple layers of films with different refractive indices are laminated to reduce reflection, then reflectivity decreases, but the number of manufacturing steps and cost increase
Solution Approach 1:
The patent extracts the antireflection function from multiple-layer laminated structures and implements it in a single film with a fine relief structure on the surface. By creating convex and concave portions on the film surface, the patent achieves antireflection performance without requiring multiple layers of different materials, thus simplifying the manufacturing process.
Solution Approach 2:
The fine relief structure with convex and concave portions creates a porous-like surface morphology that gradually transitions the refractive index from air to the film material. This single-structure approach achieves the optical gradient effect traditionally requiring multiple laminated layers.
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 provides excellent antifouling properties and excoriation resistance, enabling easy dirt removal and maintaining antireflection performance, even when subjected to external forces like rubbing with a cloth, while preventing convex portion coalescence.
Implementation Method 1
a surface layer which has a surface formed in a fine relief structure, wherein the surface layer includes a layer composed of a cured product of an active energy ray-curable resin composition
Data Source
Figure 1~4
AI summary
The purpose of this embodiment is to provide a laminate equipped with a surface layer excellent in antifouling property that dirt can be easily removed and excoriation resistance. This embodiment is a laminate including a surface layer having a surface formed in a fine relief structure, wherein an elastic modulus of the surface layer is less than 250 MPa and a slope of a friction coefficient of the surface layer is 0.0018 or less.