Optical Film Light Diffusion Layer Particle Separation
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Solution Overview
Problem
The existing optical films face issues with light-diffusing particles separating from the light diffusion layer during production or in contact with second members, potentially damaging them, leading to reduced production yield and productivity.
Innovation Solution
An optical film design featuring a light diffusion layer with 10% or more of light-diffusing particles protruding, where 90% or more of these protrusions are covered by a binder resin, ensuring a thickness of 50 nm to 1 μm, and an average particle size of 0.5 μm to 10 μm, along with a surface resistivity of 1.0×10^13 Ω/□, to prevent particle separation and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light-diffusing particles are made to protrude from the light diffusion layer surface, then light diffusion performance is improved, but the risk of particle separation and damage to second members increases
Solution Approach 1:
The binder resin acts as an intermediary substance that fills the gaps between protruding light-diffusing particles and the layer surface. This intermediary layer prevents direct contact between the particles and external objects while maintaining the protruding structure necessary for light diffusion, thus resolving the contradiction between light diffusion performance and particle separation risk
Solution Approach 2:
The patent controls the thickness of the binder resin covering the protruding particles within a specific range (50 nm to 1 μm). By optimizing this parameter, the binder resin provides sufficient coverage to prevent particle separation and damage while allowing the protruding particles to maintain their light diffusion function, thus resolving the technical contradiction
2Illumination intensity
If light-diffusing particles protrude from the surface, then light diffusion function is enhanced, but the risk of damaging second members like light guide plates increases
Solution Approach 1:
The binder resin serves as a protective intermediary layer that covers the protruding light-diffusing particles. This layer prevents the hard particles from directly contacting and damaging second members such as light guide plates, while still allowing the particles to protrude sufficiently to maintain effective light diffusion function
Solution Approach 2:
The binder resin provides beforehand cushioning by covering the protruding particles before they can cause damage to second members. This protective layer is formed in advance during the light diffusion layer fabrication process, preventing potential damage during subsequent assembly and operation
3Reliability
If binder resin thickness is increased to cover protruding particles, then particle separation is prevented, but light diffusion performance may deteriorate
Solution Approach 1:
The patent optimizes the binder resin thickness parameter to a specific range (50 nm to 1 μm). This optimized parameter ensures sufficient coverage to prevent particle separation while maintaining the protruding particles' ability to diffuse light effectively, thus resolving the contradiction between reliability and light diffusion performance
Solution Approach 2:
The binder resin is applied locally only to cover the protruding portions of light-diffusing particles rather than the entire surface. This local application ensures that particles are covered to prevent separation while maintaining the overall light diffusion capability of the layer
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 design significantly reduces the risk of particle separation and damage to second members, enhancing production yield and productivity by maintaining optimal haze values and antistatic properties.
Implementation Method 1
a light diffusion layer having a function of converting light emitted from a light source into a more uniform surface light source (diffuse illumination)
Implementation Method 2
of the light diffusing particles which cause the binder resin to be protruded and have a protruded portion, 90% or more by number of the protruded portion of light-diffusing particles is covered by the binder resin
Implementation Method 3
the light diffusion layer has a function of preventing interference spots and preventing blocking (adhesion)
Data Source
AI summary
An optical film including a first film substrate, and a light diffusion layer that is formed on the first film substrate, wherein the light diffusion layer contains a binder resin and light-diffusing particles, of the light-diffusing particles, 10% or more by number of the light-diffusing particles form an uneven structure on a surface of the light-diffusing layer by the 10% or more of the light-diffusing particles protruding more than a surrounding area not containing any light-diffusing particles, and of the light diffusing particles which cause the binder resin to be protruded and have a protruded portion, 90% or more by number of the protruded portion of light-diffusing particles is covered by the binder resin.