Laminated Film Moldability via Uncured Layer Drying
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Solution Overview
Problem
Conventional laminated films used for display protection are difficult to mold into complex shapes due to their hard coat and optical interference layers being cured before the preform step, leading to cracking and reduced hard coat performance.
Innovation Solution
The method involves manufacturing a laminated film with uncured hard coat and optical interference layers, which are dried and then bonded together to prevent mixing and maintain desired reflectivity and hardness, allowing the film to be molded into complex shapes without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the hard coat layer and optical interference layer are cured before lamination, then the layers maintain their shape and structural integrity, but the laminated film cannot be molded into complicated shapes and cracks occur
Solution Approach 1:
The patent applies preliminary drying to remove solvent from both layers before lamination, creating a preliminary stabilized structure that prevents mixing during molding while maintaining moldability. The drying step is performed before the layers are bonded together, establishing a stable yet flexible structure.
Solution Approach 2:
The patent changes the physical state of the layers by controlling the drying process and curing timing. The layers are dried to reduce solvent content while remaining uncured, then laminated and subsequently cured. This parameter change allows the layers to be moldable during lamination but stable after curing.
2Adaptability or versatility
If the hard coat layer and optical interference layer are laminated in uncured state without drying, then the film can be molded into complicated shapes, but the layers mix to generate mixed phase and lose reflectivity
Solution Approach 1:
The patent applies preliminary drying to remove solvent from both layers before lamination, creating a preliminary stabilized structure that prevents mixing during molding while maintaining moldability. The drying step is performed before the layers are bonded together, establishing a stable yet flexible structure.
Solution Approach 2:
The patent changes the physical state of the layers by controlling the drying process and curing timing. The layers are dried to reduce solvent content while remaining uncured, then laminated and subsequently cured. This parameter change allows the layers to be moldable during lamination but stable after curing.
3Strength
If the layers are cured before lamination, then hard coat performance is maintained, but the film cracks when molded into complicated shapes
Solution Approach 1:
The patent applies preliminary drying to remove solvent from both layers before lamination, creating a preliminary stabilized structure that prevents mixing during molding while maintaining moldability. The drying step is performed before the layers are bonded together, establishing a stable yet flexible structure.
Solution Approach 2:
The patent changes the physical state of the layers by controlling the drying process and curing timing. The layers are dried to reduce solvent content while remaining uncured, then laminated and subsequently cured. This parameter change allows the layers to be moldable during lamination but stable after curing.
4Strength
If adhesive is used to bond the layers, then the layers are securely joined, but transparency is reduced and costs increase
Solution Approach 1:
The patent enables the layers to bond to each other through direct contact after drying, without requiring an external adhesive material. The dried uncured layers have sufficient adhesion to bond together, eliminating the need for additional adhesive substances and maintaining transparency.
Solution Approach 2:
The patent changes the physical state of the layers by controlling the drying process and curing timing. The layers are dried to reduce solvent content while remaining uncured, then laminated and subsequently cured. This parameter change allows the layers to be moldable during lamination but stable after curing.
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 enables the production of laminated films that can be molded into intricate shapes while maintaining high hard coat performance and reflectivity, improving the appearance and durability of the laminated member, and reducing the need for adhesives, thus enhancing transparency and reducing costs.
Implementation Method 1
a first uncured hard coat layer is dried to remove at least part of a solvent contained in the hard coat layer
Implementation Method 2
The laminated film is cured to obtain a laminated member
Data Source
Figure 1
AI summary
Provided is a method for manufacturing a laminated film that can be molded into a complicated shape. A method for manufacturing a laminated film comprising: a step of forming an uncured hard coat layer by applying an active energy-ray curable composition for forming a hard coat layer to one side of a first support substrate having a thickness of 50 µm or more and 600 µm or less, and then drying the composition; a step of forming an uncured optical interference layer by applying an active energy-ray curable composition for forming a optical interference layer on one surface of a second support substrate so that the thickness of the uncured optical interference layer is between 15 nm or more and 200 nm or less, and then drying the composition; and a lamination step of laminating a surface of the uncured hard coat layer opposite the first support substrate and a surface of the uncured optical interference layer opposite the second support substrate to obtain a laminated film, wherein a stretch ratio of the laminated film at 160°C is 50% or more.