Optical Laminate Crystallizable Amorphous Polymer Layers
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Solution Overview
Problem
Large-area optical films for display devices face challenges with deformation and delamination when bonded, particularly due to the low thickness and high rigidity requirements, which complicates production and stability during stretching processes.
Innovation Solution
An optical layered body comprising a substrate layer of crystallizable polymer and a surface layer of amorphous polymer, with specific relationships between glass transition and crystallization temperatures, plane orientation coefficient, and thickness ratios, to enhance rigidity and prevent delamination while allowing for stable production through a stretching method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the area of the optical film is increased, then it can meet the requirement for large screen display devices, but the tendency to cause deformation such as distortion increases
Solution Approach 1:
The optical film is divided into multiple layers (substrate layer and surface layer) with different material properties. The substrate layer provides rigidity to prevent deformation, while the surface layer provides stretchability for production, allowing the large-area film to maintain stability without excessive distortion
Solution Approach 2:
The patent uses a composite structure combining a crystallizable polymer substrate layer with an amorphous polymer surface layer. This composite material approach allows the film to exhibit both high rigidity (from the crystallizable substrate) and good stretchability (from the amorphous surface), resolving the contradiction between large area and deformation resistance
2Length of moving object
If the thickness of the optical film is decreased, then it can reduce weight and improve flexibility, but the deformation occurs more easily
Solution Approach 1:
The film is segmented into functional layers where the substrate layer thickness is optimized for rigidity while the surface layer provides protective and stretchable properties, allowing thin overall design without sacrificing deformation resistance
Solution Approach 2:
The composite structure with crystallizable substrate and amorphous surface layers enables the film to achieve both thinness and high rigidity, as the crystallizable polymer provides structural support even at small thicknesses
3Strength
If the rigidity of the optical film is increased, then it can prevent deformation, but the tendency to cause delamination when bonded to another optical film increases
Solution Approach 1:
Different layers of the film have different material properties: the substrate layer has high rigidity to prevent deformation, while the surface layer has appropriate adhesion properties to prevent delamination during bonding, allowing each layer to optimize its local function
Solution Approach 2:
The composite structure with amorphous polymer surface layer provides good bonding reliability while the crystallizable substrate layer provides rigidity, resolving the contradiction between strength and bonding reliability
4Strength
If a layered body including crystallizable polymer layer and amorphous polymer layer is used, then it can achieve high rigidity and low delamination tendency, but the stretching suitability decreases causing defects like wrinkles and breakages
Solution Approach 1:
The surface layer made of amorphous polymer provides localized stretchability during production while the substrate layer maintains overall rigidity, enabling the film to be stretched without wrinkles or breakages while retaining high rigidity and anti-delamination properties
Solution Approach 2:
The composite structure with specific glass transition temperature relationship (TgB > TgA) and crystallization temperature relationship (TcA - 60°C ≥ TgB ≥ TcA - 10°C) enables both high rigidity and good stretching suitability, resolving the contradiction between strength and ease of manufacture
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 an optical layered body with high rigidity, low delamination tendency, and improved stretching suitability, enabling the production of large-area optical films for display devices without defects like wrinkles or breakages.
Implementation Method 1
a substrate layer formed of a resin containing a crystallizable polymer A
Implementation Method 2
a first surface layer formed of a resin containing an amorphous polymer B
Implementation Method 3
can be easily produced by a production method including a stretching step
Data Source
AI summary
An optical layered body including: a substrate layer formed of a resin containing a crystallizable polymer A; and a first surface layer formed of a resin containing an amorphous polymer B, wherein a glass transition temperature TgA of the crystallizable polymer A and a glass transition temperature TgB of the amorphous polymer B satisfy TgB>TgA, a crystallization temperature TcA of the crystallizable polymer A and the glass transition temperature TgB of the amorphous polymer B satisfy TcA−10° C.≥TgB≥TcA−60° C., the first surface layer has a plane orientation coefficient P that satisfies P≤0.01, and a ratio of a thickness of the substrate layer relative to a total thickness of the optical layered body is 25% or more.