Anti-abrasion Optical Diffusion Film with Varied Particle Sizes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Optical diffusion films face significant abrasion and shedding of diffusion particles due to external forces, leading to reduced performance and increased damage during handling and use in LCD and lighting devices, despite prior attempts to enhance anti-abrasion properties by strengthening the resin binder.
Innovation Solution
The use of diffusion particles with a diameter variation coefficient of 10%-100% in the diffusion coating, which are either protruded out of or embedded within the adhesive layer, made from materials like silicon compounds, silicone resin, polystyrene, or polymethyl methacrylate, helps distribute the abrasive force, minimizing large-area abrasion and shedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the strength of the resin binder is increased by using resin reinforcing agent, then the anti-abrasion property of the film is improved, but the binding strength between the resin and diffusion particles cannot be guaranteed, causing diffusion particles to be detached or abraded during service
Solution Approach 1:
The patent changes the physical parameters of diffusion particles by controlling their diameter to have a standard deviation of 5μm or more, creating a diverse size distribution. This parameter change allows the resin binder to effectively bind particles of varying sizes, preventing particle detachment while maintaining film anti-abrasion strength
Solution Approach 2:
The patent creates a composite structure in the diffusion coating layer where resin binder and diffusion particles with diverse diameters form an integrated system. The resin binder encapsulates particles of different sizes, forming a composite material that simultaneously achieves strong particle binding and high anti-abrasion resistance
2Manufacturing precision
If diffusion particles of single diameter or narrow disperse diameter are used in diffusion coating, then the optical diffusion film can be manufactured with consistent properties, but the diffusion particles tend to be abraded or detached in large area when the film receives external force such as friction or abrasion
Solution Approach 1:
The patent deliberately changes the parameter of particle diameter uniformity by allowing a standard deviation of 5μm or more, creating a diverse particle size distribution. This controlled non-uniformity prevents large-area abrasion by ensuring that when external force is applied, the varied particle sizes and resin binding create a more resistant structure that reduces particle detachment
Solution Approach 2:
The patent applies local quality by having resin binder selectively encapsulate diffusion particles of different diameters throughout the coating layer. The resin forms localized protective structures around individual particles, creating varying binding configurations that collectively resist large-area abrasion while maintaining manufacturing consistency
Data Source
AI summary
An anti-abrasion optical diffusion film (2), an LCD device and a light source using the anti-abrasion optical diffusion film (2) are disclosed, in order to solve the problem of the prior art that the diffusion particles are abraded or detached in large area, when an optical diffusion thin film receives external force. The anti-abrasion optical diffusion film (2) includes a substrate (21) and a diffusion coating (22); the diffusion coating (22) includes diffusion adhesive layer (24) and diffusion particles (23). The variation coefficient of the diameter of the particles is 10-100%. The invention improves the anti-abrasion ability of the optical diffusion thin film.