Gas Barrier Film Light Diffusion Layer Wavelength Conversion
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Solution Overview
Problem
Existing gas barrier films with light diffusion layers for LCDs face challenges such as deterioration due to heat and light, leading to reduced transmittance and luminance, and are difficult to handle due to curling issues, especially when used in wavelength conversion films with quantum dots.
Innovation Solution
A gas barrier film with a light diffusion layer composed of a support, an inorganic layer, an organic layer, and a light diffusion layer containing a binder with specific components like graft copolymers, urethane acrylate polymers, and silicone resin particles, which provides high transparency, light scattering properties, and durability against heat and light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light scattering layer is provided in addition to a quantum dot layer to improve luminance, then the luminance can be improved, but the film becomes more complex and difficult to handle due to curling issues
Solution Approach 1:
The patent combines the light scattering layer and quantum dot layer into a single integrated wavelength conversion film structure. The light scattering particles are dispersed within the binder matrix that also contains the quantum dots, eliminating the need for separate layers and reducing handling complexity while maintaining luminance improvement benefits
Solution Approach 2:
The binder material serves multiple functions simultaneously: it acts as the matrix for dispersing quantum dots, provides adhesion between layers, and contains the light scattering particles. This multi-functionality reduces the number of separate components needed and simplifies the overall film structure
2Reliability
If quantum dots are protected by sandwiching between gas barrier films to prevent deterioration, then the emission intensity is maintained, but the film structure becomes more complex and handling becomes difficult
Solution Approach 1:
The patent introduces a barrier layer as an intermediary component between the wavelength conversion film and the external environment. This single barrier layer provides protection against moisture and oxygen while avoiding the need for complex multi-layer sandwich structures, thus maintaining quantum dot stability without excessive structural complexity
Solution Approach 2:
The wavelength conversion film uses a composite binder system combining acrylic resin and epoxy resin, which provides both mechanical strength and barrier properties. This composite material approach allows a single film to provide both structural support and protection, reducing the need for additional protective layers
3Illumination intensity
If a light diffusion layer is formed on the surface of gas barrier films to improve luminance, then light diffusion is enhanced, but the quantum dot layer is damaged by heat during the drying process
Solution Approach 1:
The patent incorporates light scattering particles within the binder matrix during the initial film formation process, before any drying or curing steps. This preliminary incorporation of light scattering functionality eliminates the need for subsequent high-temperature drying processes that would damage quantum dots, while still achieving the desired light diffusion effect
Solution Approach 2:
The patent uses UV irradiation instead of thermal drying to cure the binder and form the film. This parameter change from thermal to photonic curing allows the film to be formed without exposing quantum dots to damaging high temperatures, while still achieving complete binder curing and film formation
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 enhances the luminance of LCDs by improving light diffusion and transmittance while maintaining durability and handling ease, preventing curling and deterioration, thus improving the overall performance and productivity of wavelength conversion films.
Implementation Method 1
a light diffusion layer which is on a second surface of the support opposite to the first surface side and contains a binder in which a light diffusion agent is dispersed
Implementation Method 2
the quantum dots are excited and emit fluorescence
Implementation Method 3
a wavelength conversion member that contains phosphors emitting fluorescence by being excited with the light emitted from the light source
Implementation Method 4
the quantum dot layer is sandwiched between two sheets of gas barrier films so as to protect the quantum dots
Implementation Method 5
a first component which is a graft copolymer having an acryl polymer as a main chain and at least one of an acryloyl group-terminated urethane polymer or an acryloyl group-terminated urethane oligomer as a side chain
Data Source
AI summary
A gas barrier film has a support, an inorganic layer and an organic layer on one surface of the support, and a light diffusion layer containing a binder and a light diffusion agent on the other surface of the support. The binder has a graft copolymer which has an acryl polymer as a main chain and a urethane polymer or a urethane oligomer having an acryloyl group terminal as a side chain, an acryl polymer which has methacrylate as a side chain, and a graft copolymer which has an acryl polymer as a main chain and a urethane polymer or a urethane oligomer having a polycarbonate group terminal as a side chain.