Optical Laminate Micro Concave-Convex Structure Transfer
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Solution Overview
Problem
Current technologies fail to form anti-reflection films with high accuracy and efficiency on partial regions of electronic devices, such as smartphones, due to limitations in thickness reduction and production efficiency, especially for micro concave-convex structures used for anti-reflection purposes.
Innovation Solution
An optical laminate is developed with a micro concave-convex structure on one surface and a bonding layer on the other, where the bonding layer has a peeling force less than 70% of the force between the optical body and the transfer body, allowing for precise transfer and thin film formation with a total thickness of less than 15 μm, using an ultraviolet-curing resin and mold release treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If Wet-AR film technology is used to form anti-reflection film on partial region, then the anti-reflection function is achieved, but the laminate film thickness is significantly increased
Solution Approach 1:
The invention extracts only the essential functional layer with micro concave-convex structure from the complex Wet-AR laminate, transferring it to a thin transparent resin film. This removes unnecessary layers (low refractive index material, high refractive index material layers) that contribute to thickness while preserving the anti-reflection function through the micro structure alone.
Solution Approach 2:
The invention uses a thin transparent resin film (total thickness less than 15 μm) as the substrate for the micro concave-convex structure, replacing the thick Wet-AR laminate. This thin film approach directly addresses the thickness reduction requirement while maintaining the anti-reflection functionality through the micro structure.
2Object-affected harmful factors
If Dry-AR film technology is used to form anti-reflection film on partial region, then the anti-reflection function is achieved, but production efficiency is very poor due to mask requirements
Solution Approach 1:
The micro concave-convex structure is pre-formed on a transfer body before bonding to the transparent resin film. This preliminary formation of the anti-reflection structure eliminates the need for time-consuming mask alignment and sputtering processes during production, significantly improving manufacturing efficiency.
Solution Approach 2:
The invention uses a transfer body with an inverted micro concave-convex structure that copies the desired anti-reflection pattern onto the transparent resin film through bonding and peeling. This copying process replaces the complex mask-based direct formation method, enabling faster production without sacrificing pattern accuracy.
3Manufacturing precision
If existing function transfer body technology is used to form micro concave-convex structure on adherend, then the structure is transferred, but transfer accuracy is less than sufficient
Solution Approach 1:
The invention introduces a bonding layer as an intermediary between the transfer body and the transparent resin film. This bonding layer enables precise transfer of the micro concave-convex structure by providing controlled adhesion during the transfer process, ensuring high transfer accuracy that directly improves anti-reflection function quality.
Solution Approach 2:
The invention carefully controls the peeling force parameter during the transfer process, ensuring it is less than or equal to 70% of the bonding force between the optical body and the bonding layer. This parameter control prevents premature peeling and ensures complete, accurate transfer of the micro structure, achieving the required manufacturing precision.
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 enables high-accuracy formation of micro concave-convex structures on adherends, improving anti-reflection functionality while reducing the thickness and size of electronic devices, and enhancing production efficiency by ensuring precise peeling and transfer of the optical body.
Implementation Method 1
a bonding layer which bonds the optical body to the adherend, wherein 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
Implementation Method 2
using an ultraviolet-curing resin and mold release treatment
Data Source
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.