Optical Laminate Void Layer Adhesion via Intermediate Mediator

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Solution Overview

Problem

Conventional optical laminates with void spaces suffer from insufficient film strength and easy peeling from pressure-sensitive adhesive layers, making it difficult to achieve both high strength and low refractive index.

Innovation Solution

An optical laminate structure comprising a void-provided layer, an intermediate layer, and a pressure-sensitive adhesive layer, where the intermediate layer is formed by reacting the adhesive layer with the void-provided layer, enhancing the anchoring property and preventing peeling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a void-provided layer is used to achieve low refractive index, then the refractive index is reduced, but the film strength becomes insufficient and peeling occurs

Engineering Contradiction:

Improverefractive indexVSAvoidfilm strength

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

An intermediate layer is introduced between the void-provided layer and the pressure-sensitive adhesive layer. This intermediate layer acts as a mediator that chemically bonds to both layers, preventing peeling while preserving the low refractive index property of the void-provided layer. The intermediate layer contains functional groups that react with both the void-provided layer and the adhesive layer, creating strong interfacial bonding.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The optical laminate is constructed as a composite structure combining multiple materials with different functions: the void-provided layer (low refractive index), the intermediate layer (bonding function), and the pressure-sensitive adhesive layer (adhesion). This composite structure allows each layer to optimize its specific function while working together to achieve both low refractive index and high film strength.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If components are disposed at regular spacings to form air layers, then low refractive index is achieved, but production time increases and complexity rises

Engineering Contradiction:

Improverefractive indexVSAvoidproduction efficiency

Core Design Contradiction:

Illumination intensityVSProductivity

Solution Approach 1:

Multiple functional layers (void-provided layer, intermediate layer, and pressure-sensitive adhesive layer) are combined into a single integrated laminate structure. This merging allows sequential stacking during production without requiring precise regular spacing between components, thereby improving production efficiency while maintaining the low refractive index function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The intermediate layer serves as a mediator that enables direct bonding between the void-provided layer and the pressure-sensitive adhesive layer without requiring complex spacing mechanisms. This simplifies the production process by allowing continuous lamination while maintaining the optical properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Illumination intensity

If a spacer or frame is used to maintain air layer, then low refractive index is achieved, but the thickness of the whole film increases

Engineering Contradiction:

Improverefractive indexVSAvoidfilm thickness

Core Design Contradiction:

Illumination intensityVSLength of stationary object

Solution Approach 1:

The spacer or frame structure is removed from the design. Instead of using physical spacers to maintain the air layer, the invention uses a chemical bonding approach where the intermediate layer directly bonds the void-provided layer to the pressure-sensitive adhesive layer, eliminating the need for additional thickness-consuming spacer structures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The laminate uses a composite structure where the intermediate layer provides both bonding and structural integration functions, replacing the need for separate spacer components. This composite approach achieves the low refractive index function with minimal overall thickness.

Inventive Principle:

Principle #40Composite materials

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 achieves superior film strength and prevents peeling between the void-provided layer and the adhesive layer, enabling efficient production of optical laminates for use in optical elements and image displays.

Implementation Method 1

the intermediate layer is formed by forming the pressure-sensitive adhesive/adhesive layer on the void-provided layer

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS11460610B2Optical laminate, method of producing optical laminate, optical element, and image display

Publication Date: 2022.10.04 NITTO DENKO CORP

AI summary

The present invention is intended to provide an optical laminate that achieves a superior film strength and a property that a void-provided layer and a pressure-sensitive adhesive/adhesive layer are not easily peeled from each other. The optical laminate of the present invention includes: a void-provided layer; an intermediate layer; and a pressure-sensitive adhesive/adhesive layer, wherein the void-provided layer, the intermediate layer, and the pressure-sensitive adhesive/adhesive layer are stacked in this order, and the intermediate layer is formed by forming the pressure-sensitive adhesive/adhesive layer on the void-provided layer.