Functional Composite Film Adhesion for Quantum Dot Gas Barriers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing laminated quantum dot films face issues with adhesiveness between the gas barrier film and the quantum dot layer, leading to interlayer peeling and deterioration of the quantum dot layer due to moisture and oxygen penetration, especially during processing steps like slit cutting and punching, which reduces the effectiveness of the gas barrier properties.
Innovation Solution
A functional composite film with an inorganic layer and an organic layer configuration, where the outermost surface is formed using an ultraviolet-curable urethane polymer with a weight-average molecular weight of 5,000 to 30,000 and a double bond equivalent of 300 g/mol or more, incorporating a phosphoric acid compound or a silane coupling agent, and a lubricant like silicon particles, to enhance adhesiveness and protect the inorganic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an inorganic gas barrier film is used to protect the quantum dot layer, then gas barrier properties are improved, but adhesiveness to the quantum dot layer deteriorates
Solution Approach 1:
An organic layer is introduced as an intermediary between the inorganic gas barrier film and the quantum dot layer. This organic layer contains silane coupling agents that form chemical bonds with both the inorganic film surface and the quantum dot layer, serving as a mediator that transfers adhesive force between the inorganic and organic components, thereby resolving the incompatibility between gas barrier properties and adhesiveness.
Solution Approach 2:
The patent creates a composite film structure combining inorganic gas barrier materials with organic adhesive materials. The organic layer contains a mixture of silane coupling agents and other adhesive components that work synergistically to bond the inorganic film to the quantum dot layer, achieving both gas barrier functionality and strong adhesion through material composition.
2Ease of manufacture
If the quantum dot layer is processed through slit cutting and punching, then product formation is enabled, but interlayer peeling occurs reducing gas barrier properties
Solution Approach 1:
The organic layer with silane coupling agents is applied to the inorganic film surface before the quantum dot layer is formed. This preliminary preparation creates a pre-bonded interface that is already strengthened against peeling forces, enabling the film to withstand subsequent processing operations like slit cutting and punching without losing gas barrier integrity.
Solution Approach 2:
The organic adhesive layer acts as a cushioning buffer between the inorganic film and quantum dot layer, absorbing mechanical stresses during processing. This beforehand cushioning prevents direct stress transmission that would cause interlayer peeling, thereby maintaining gas barrier properties through processing operations.
3Strength
If silane coupling agents are used to improve adhesiveness, then bonding strength is improved, but processing complexity increases
Solution Approach 1:
Multiple functions are merged into the organic layer: it serves as both an adhesive layer and a coupling agent carrier. The silane coupling agents are incorporated directly into the organic layer composition, combining the adhesive and coupling functions in a single layer application, thereby reducing processing steps while maintaining strong bonding.
Solution Approach 2:
The organic layer performs multiple functions simultaneously: it provides adhesion to the quantum dot layer, acts as a coupling agent bridge to the inorganic film, and serves as a protective barrier. This multi-functionality reduces the need for separate processing steps, simplifying the overall manufacturing process while achieving strong bonding.
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 provides high adhesiveness to the quantum dot layer and prevents damage to the inorganic gas barrier layer, resulting in improved durability and reduced edge brightness reduction in quantum dot films, maintaining effective gas barrier properties even after processing.
Implementation Method 1
ultraviolet-curable urethane polymer
Implementation Method 2
incorporating a phosphoric acid compound or a silane coupling agent
Implementation Method 3
When excitation light is incident to a quantum dot layer from the backlight, the quantum dots are excited to emit fluorescent light
Implementation Method 4
an inorganic layer expressing gas barrier properties
Data Source
AI summary
A functional composite film includes one or more combinations of an inorganic layer and an organic layer as underlying base of the inorganic layer on a support, and having the outermost surface with an organic layer thereon, where the organic layer on the outermost surface is formed using an ultraviolet-curable urethane polymer having a weight-average molecular weight of 5,000 to 30,000 and a double bond equivalent of 300 g/mol or more, which has a urethane polymer as the main chain and a side chain having a (meth)acryloyl group at a terminal; a curable urethane polyester; and at least one phosphoric acid compound containing two or less (meth)acryloyl groups and/or a silane coupling agent containing one (meth)acryloyl group, and a quantum dot film using the same. High adhesiveness is obtained between the organic layer and the inorganic layer, and when a quantum dot layer or the like is laminated thereon.