Optical Laminate Primer Layer Adhesion Barrier Film
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Solution Overview
Problem
Phosphor layers containing quantum dots in wavelength conversion sheets experience poor adhesion to barrier films, leading to peeling issues that deteriorate performance and gas barrier properties.
Innovation Solution
An optical laminate with a curable resin and a barrier film featuring a primer layer formed by curing a primer composition containing a silane coupling agent with reactive functional groups, ensuring a total content of 1.5×10^-6 mol to 3.5×10^-3 mol per unit area, which enhances adhesion and suppresses moisture and oxygen penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a barrier film is bonded directly to a phosphor layer containing quantum dots, then gas barrier properties are provided, but adhesion between the barrier film and phosphor layer is poor causing peeling
Solution Approach 1:
The patent introduces a primer layer as an intermediary between the barrier film and the phosphor layer. This primer layer contains silane coupling agents that chemically bond to both the inorganic phosphor layer and the organic barrier film, creating a bridging interface that significantly improves adhesion while preserving the gas barrier properties of the barrier film.
Solution Approach 2:
The patent employs composite material strategy by creating a multi-layer structure consisting of the phosphor layer, primer layer with silane coupling agents, and barrier film. This composite structure combines the gas barrier properties of the barrier film with the adhesion-promoting characteristics of the silane-based primer layer, resolving the adhesion problem while maintaining barrier functionality.
2Strength
If the content of reactive functional groups in the primer layer is increased to improve adhesion, then adhesion between barrier film and adherend improves, but excessive reaction with curable resin impedes curing and deteriorates cohesion
Solution Approach 1:
The patent precisely controls the concentration parameter of reactive functional groups in the primer layer, specifying it to be within 1.5×10^-6 mol to 3.5×10^-3 mol per 1 m2×D. This optimized parameter range ensures sufficient adhesion promotion while preventing excessive consumption of curable resin functional groups, thereby maintaining proper curing and cohesion of the phosphor 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
The solution provides improved adhesion between the barrier film and the adherend, maintaining good gas barrier properties and preventing peeling, thus enhancing the longevity and effectiveness of the wavelength conversion sheet.
Implementation Method 1
the silane coupling agent generates a silanol group in the primer layer by hydrolysis
Implementation Method 2
Reaction between this silanol group with a polar functional group such as a hydroxyl group on the surface of another layer in the barrier film in contact with the primer layer contributes to the improvement of adhesion
Implementation Method 3
a primer layer formed by curing a primer composition containing a silane coupling agent having a reactive functional group capable of reacting with the curable resin
Implementation Method 4
penetration of moisture, oxygen, and the like from the interface between the primer layer and the layer in contact therewith can be suppressed
Data Source
AI summary
An optical laminate comprising an adherend including a curable resin, and a barrier film laminated on at least one surface of the adherend, wherein the barrier film comprises, on an outermost surface facing the adherend, a primer layer formed by curing a primer composition containing a silane coupling agent having a reactive functional group capable of reacting with the curable resin, other than an alkoxysilane group and a silanol group, and assuming that a thickness of the primer layer is D, a total content of the reactive functional group and the reactive functional group that has reacted with the curable resin per 1 m2×D of the primer layer is 1.5×10−6 mol or higher and 3.5×10−3 mol or lower.