Double-Sided Polarizing Plate Adhesive Curing via UV and Thermal Conduction
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Solution Overview
Problem
The existing methods for manufacturing double-sided polarizing plates face challenges with adhesive strength and curing rates, particularly when using non-aqueous photocurable adhesives, as the non-light-irradiated surfaces often have lower curing rates and adhesive strength, leading to deteriorated optical and durability issues.
Innovation Solution
A method involving the simultaneous use of active energy rays and thermal treatment of the non-light-irradiated surface at a temperature of 25° C. to 65° C. to improve the curing rate and adhesive strength of adhesive layers on both surfaces of the polarizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a non-aqueous photocurable adhesive is used to attach protective films to both surfaces of a polarizer, then adhesive strength is improved, but the curing rate of non-light-irradiated surfaces deteriorates
Solution Approach 1:
The patent combines light irradiation and thermal treatment into a single integrated curing process. The light-irradiated surface is cured by UV light while the non-light-irradiated surface is simultaneously cured by thermal conduction from a heated roller, achieving uniform curing of both adhesive layers in one operation.
Solution Approach 2:
The patent introduces a heated roller as an intermediary thermal source. This roller contacts the non-light-irradiated surface and acts as a mediator to transfer heat to the adhesive layer, enabling curing without direct light exposure and solving the problem of uneven curing rates.
2Device complexity
If adhesive layers on both surfaces are cured through a single light irradiation process, then manufacturing complexity is reduced, but adhesive strength of non-light-irradiated surfaces deteriorates
Solution Approach 1:
The patent merges light irradiation and thermal conduction curing into a single integrated process. By combining these two curing mechanisms, the system maintains simple single-pass manufacturing while ensuring both adhesive layers achieve sufficient curing and strength.
Solution Approach 2:
The patent changes the curing parameter from light-only to a combination of light and heat. The heated roller introduces thermal energy as an additional curing parameter, allowing the non-light-irradiated adhesive layer to cure effectively without requiring separate processing steps.
3Adaptability or versatility
If different materials are used for protective films on both surfaces, then adaptability is improved, but curling occurs during adhesive drying
Solution Approach 1:
The patent changes the drying parameter from ambient air drying to controlled thermal drying. By using a heated roller that provides uniform, controlled heating, the drying process becomes more stable and predictable, preventing curling even when different protective film materials are used on each 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
This approach enhances the adhesive strength and optical properties of the double-sided polarizing plate, simplifying the manufacturing process and reducing the risk of curling and wrinkles, while maintaining excellent aesthetic characteristics.
Implementation Method 1
irradiating the adhesive layers with active energy rays emitted by an energy source disposed in a single direction with respect to the polarizer
Implementation Method 2
thermally treating a surface of the transparent film disposed opposite to the energy source at a temperature of 25° C. to 65° C.
Data Source
AI summary
A method of manufacturing a double-sided polarizing plate and a double-sided polarizing plate manufactured using the same are provided. The method of manufacturing a double-sided polarizing plate includes attaching transparent films to both surfaces of a polarizer by means of adhesive layers, irradiating the adhesive layers with active energy rays emitted by an energy source disposed in a single direction with respect to the polarizer, and thermally treating a surface of the transparent film disposed opposite to the energy source at a temperature of 25° C. to 65° C.