Laminate Sheet With Sub-50 Nm Protrusion For Optical Homogeneity
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Solution Overview
Problem
Existing PSA sheets struggle to achieve high optical homogeneity, particularly in high-resolution display equipment, due to the focus on preventing open pore formation rather than ensuring optical clarity.
Innovation Solution
A laminate sheet comprising a PSA layer with first and second films laminated on its faces, where the first film has a release face with a maximum protrusion height of less than 50 nm, and the combined thickness of the first and second films is 80 µm or greater, effectively reducing optical distortion and enhancing optical homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a release film with a highly smooth surface is used to prevent open pore formation on the PSA layer, then the surface smoothness of the PSA layer is improved, but the optical homogeneity is not sufficiently fulfilled
Solution Approach 1:
The patent transitions from focusing solely on two-dimensional surface smoothness to considering three-dimensional optical properties by controlling the protrusion height (Rp1A < 50 nm) and combining it with sufficient total film thickness (T SUM ≥ 80 µm). This dimensional approach ensures both surface smoothness and optical homogeneity are achieved simultaneously.
Solution Approach 2:
The patent specifies precise parameter ranges: maximum protrusion height Rp1A of less than 50 nm and combined thickness T SUM of 80 µm or greater. By controlling these parameters within defined ranges, the invention achieves both surface smoothness and optical homogeneity, resolving the contradiction between manufacturing precision and optical reliability.
2Object-generated harmful factors
If the focus is solely on preventing open pore formation, then surface defects are reduced, but the demand for high-resolution display equipment is not sufficiently fulfilled
Solution Approach 1:
The patent defines specific parameter thresholds (Rp1A < 50 nm and T SUM ≥ 80 µm) that simultaneously address both open pore prevention and optical homogeneity requirements for high-resolution displays. This quantitative approach ensures both surface quality and optical performance are satisfied.
Solution Approach 2:
The invention uses a composite structure comprising a PSA layer combined with release films having specific surface properties. This composite approach integrates surface smoothness control with adequate thickness to achieve both defect prevention and optical homogeneity required for high-resolution display applications.
3Length of stationary object
If a thin release film is used to reduce overall thickness, then handling convenience is improved, but optical distortion increases
Solution Approach 1:
The patent establishes a minimum combined thickness threshold (T SUM ≥ 80 µm) that prevents optical distortion while maintaining reasonable overall thickness. This parameter control ensures the release film structure provides sufficient optical stability without excessive thickness.
Solution Approach 2:
The invention shifts the focus from minimizing thickness in one dimension to optimizing the balance between thickness and surface quality (protrusion height control). By controlling Rp1A < 50 nm and T SUM ≥ 80 µm, the patent achieves optical homogeneity without excessive overall thickness.
Data Source
Figure 1~2
AI summary
Provided is a laminate sheet comprising a PSA layer as well as first and second films laminated on first and second faces of the PSA layer. The first film is a release film having a face A in contact with the PSA layer, with the face A being a release face. The face A of the first film has a maximum protrusion height Rp1A of less than 50 nm. The first and second films have a combined thickness TSUM of 80 µm or greater.