Mirror Optical Film Adhesion Silicon Barrier
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Solution Overview
Problem
Conventional mirrors in head-up display devices face issues with the adhesion between optical films and the base material, leading to potential air bubbles and peeling, due to volatilized gases from the base material, which increases manufacturing costs and reduces adhesion strength.
Innovation Solution
A mirror configuration that includes a synthetic resin base material with an adhesion layer and a protective silicon layer between the base material and the adhesion layer, reducing the passage of volatilized gases and enhancing the adhesion of the optical film, thereby preventing air bubbles and peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesion layer is provided directly on the base material, then the structure is simple, but the adhesion between the optical film and base material is insufficient due to volatilized gases
Solution Approach 1:
A protective layer comprising silicon is introduced as an intermediary between the base material and the adhesion layer. This protective layer acts as a barrier that prevents volatilized gases from the base material from reaching the adhesion layer and optical film interface, thereby eliminating the root cause of adhesion failure while maintaining overall structural simplicity
Solution Approach 2:
The harmful element (volatilized gases) is blocked by the protective layer, effectively extracting or removing the harmful effect from the system. The protective layer selectively allows beneficial adhesion while blocking harmful gas transmission
2Reliability
If the adhesion layer is applied directly on the base material, then manufacturing is simpler, but air bubbles and peeling occur due to gas passage
Solution Approach 1:
The protective layer serves as a mediator that simplifies the overall manufacturing process by preventing adhesion failures, thereby reducing the need for complex defect repair processes and rework
Solution Approach 2:
The protective layer is formed in advance on the base material before applying the adhesion layer and optical film. This preliminary action prevents adhesion problems from occurring in the first place, eliminating the need for subsequent defect correction
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 provides a more robust adhesion of the optical film to the base material, reducing the likelihood of air bubbles and peeling, while maintaining cost-effectiveness by using a silicon-based protective layer that minimizes gas passage and enhances the reflection performance.
Implementation Method 1
a protective layer including silicon is formed between the base material and the adhesion layer
Implementation Method 2
an optical film that adheres to the base material by the adhesion layer and reflects light
Data Source
AI summary
To provide a mirror in which an optical film more firmly adheres to a base material, and a head-up display device including the mirror. A mirror disclosed herein includes a base material that is formed of a synthetic resin material, an adhesion layer that is provided on one surface of the base material, and an optical film that adheres to the base material by the adhesion layer and reflects light, wherein an adhesion surface including silicon is formed between the base material and the adhesion layer. Further, a head-up display device disclosed herein includes a display unit that emits display light, the mirror described above that reflects the display light, and a housing that houses the display unit and the minor and in which an opening portion through which the display light passes to a windshield is formed.