Optical Laminate Transfer for Thin Partial Anti-Reflection Films
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Solution Overview
Problem
Current technologies fail to form anti-reflection films with high accuracy and low thickness on partial regions of electronic apparatuses, such as smartphones, due to inefficiencies in existing methods like Wet-AR and Dry-AR films, and insufficient transfer accuracy of micro concave-convex films.
Innovation Solution
A method involving a transfer laminate with a micro concave-convex structure, comprising a base material film and a micro concave-convex structure, where the optical body with a moth-eye structure is transferred to an adherend with a bonding layer, achieving high accuracy and low thickness by controlling the peeling forces and using a roll-to-roll process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a Wet-AR film is used to form an anti-reflection film on a partial region, then the anti-reflection function is achieved, but the laminate film thickness is significantly increased
Solution Approach 1:
The patent divides the anti-reflection film into multiple layers: a micro concave-convex structure layer (moth-eye structure) and a separate bonding layer. This segmentation allows the micro concave-convex structure to provide anti-reflection function while the bonding layer provides adhesion, enabling thinner overall thickness compared to conventional Wet-AR films that require thick laminate structures.
Solution Approach 2:
The patent introduces a transfer body as an intermediary carrier that temporarily holds the micro concave-convex structure during the bonding process. The transfer body enables precise positioning and transfer of the micro concave-convex structure to the adherend, allowing thin film formation while maintaining manufacturing precision.
2Length of stationary object
If a Dry-AR film is used to form an anti-reflection film on a partial region, then the film thickness is reduced, but production efficiency deteriorates due to masking requirements
Solution Approach 1:
The patent forms the micro concave-convex structure on a transfer body before bonding to the adherend. This preliminary action allows the entire micro concave-convex structure to be prepared in advance, and then transferred as a complete pattern to the desired region, eliminating the need for time-consuming masking processes during deposition and significantly improving production efficiency.
3Length of stationary object
If a micro concave-convex film is transferred to an adherend, then film thickness is reduced, but transfer accuracy is insufficient
Solution Approach 1:
The transfer body serves as an intermediary carrier that maintains the micro concave-convex structure during handling and transfer. It provides a stable platform for precise positioning and alignment, enabling high-accuracy transfer to the adherend while maintaining thin film thickness. The transfer body is designed with specific peeling force characteristics to ensure accurate transfer.
Solution Approach 2:
The patent controls the peeling force between the micro concave-convex structure and the transfer body to be less than or equal to 70% of the peeling force between the bonding layer and the adherend. This parameter control ensures that during peeling, the micro concave-convex structure remains attached to the adherend rather than the transfer body, achieving high transfer accuracy.
4Manufacturing precision
If the peeling force between the optical body and transfer body is too high, then transfer accuracy deteriorates, but if too low, then structural integrity is compromised
Solution Approach 1:
The patent precisely controls the peeling force parameter by designing the bonding layer with specific material properties and thickness. The peeling force between the micro concave-convex structure and transfer body is set to be less than or equal to 70% of the peeling force between the bonding layer and adherend, creating an optimal balance that ensures accurate transfer while maintaining structural integrity during the bonding process.
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 method allows for the precise transfer of a micro concave-convex optical body to an adherend with an initial 90° peeling force less than or equal to 70% of the peeling force between the optical body and the bonding layer, enabling high-accuracy anti-reflection film formation and reducing the thickness of electronic apparatuses.
Implementation Method 1
the uncured resin layer is cured, thereby the optical body and the bonding layer are formed
Data Source
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AI summary
To form an optical body having a micro concave-convex structure on at least part of an adherend with high accuracy. Provided is an optical laminate including an adherend, a bonding layer formed on at least part of a surface of the adherend, and an optical body bonded to the adherend with the bonding layer. A micro concave-convex structure in which concavities and convexities are arranged at an average cycle less than or equal to a visible light wavelength is formed in at least one surface of the optical body. The bonding layer is provided on the other surface of the optical body. An initial 90° peeling force when peeling the optical body from a transfer body having an inverted concave-convex structure fitted in the micro concave-convex structure of the optical body is less than or equal to 70% of a 90° peeling force between the optical body and the bonding layer.