Optical Laminated Body Interface Structure for Adhesion and Interference Control
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Solution Overview
Problem
Existing optical laminated bodies for image display devices face issues with adhesiveness between acrylic base materials and hard coat layers, leading to interference patterns due to refractive index differences, and existing solutions increase manufacturing complexity and productivity costs.
Innovation Solution
An optical laminated body with a resin layer formed on an acrylic base material, incorporating organic fine particles that move into the resin layer, achieving a vertical difference of 150 nm to 500 nm between the interface crests and troughs, and a particle diameter ratio of 1.05 to 1.80, ensuring improved adhesiveness and preventing interference patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard coat layer is formed on an acrylic base material, then hardness and mechanical strength are improved, but adhesiveness between the base material and hard coat layer deteriorates
Solution Approach 1:
The patent applies preliminary surface treatments (corona discharge treatment or oxidization treatment) to the acrylic base material before forming the hard coat layer. This preliminary action modifies the surface properties of the base material to enhance chemical bonding between the base material and the hard coat layer, thereby improving adhesiveness while maintaining the desired hardness and mechanical strength.
Solution Approach 2:
The patent introduces an anchoring agent or primer as an intermediary layer between the acrylic base material and the hard coat layer. This intermediary substance improves the bonding interface by providing better adhesion properties, allowing the hard coat layer to bond effectively to the base material while maintaining the required hardness and mechanical strength.
2Strength
If a hard coat layer is formed on an acrylic base material, then mechanical strength is improved, but interference patterns are generated due to refractive index difference
Solution Approach 1:
The patent introduces protrusions and recesses at the interface between the acrylic base material and the hard coat layer. This local structural modification creates optical path differences that compensate for the refractive index difference between the two materials, thereby reducing or eliminating interference patterns while maintaining the mechanical strength provided by the hard coat layer.
3Reliability
If paint treatment or physical treatment is applied to improve adhesiveness, then adhesiveness between base material and hard coat layer is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple surface treatment methods (corona discharge treatment and/or oxidization treatment) into a single integrated process step. By merging these treatments and potentially combining them with the hard coat layer formation process, the patent reduces the total number of separate manufacturing steps while achieving the desired adhesiveness improvement.
4Object-generated harmful factors
If protrusions and recesses are formed to prevent interference pattern, then appearance quality is improved, but productivity deteriorates
Solution Approach 1:
The protrusions and recesses are formed as a preliminary feature on the acrylic base material before the hard coat layer is applied. This preliminary formation of the surface structure allows the interference pattern prevention to be achieved without requiring additional complex processing steps after hard coat layer formation, thereby maintaining productivity.
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 effectively enhances adhesiveness and suppresses interference patterns, improving the manufacturing efficiency and optical properties of the laminated body while maintaining mechanical strength and heat resistance.
Implementation Method 1
organic fine particles which are included in the acrylic base material are moved into the resin layer
Implementation Method 2
the adhesiveness between the acrylic base material and the resin layer is improved
Implementation Method 3
an interference pattern is generated and thus the appearance becomes poor due to the refractive index difference between the acrylic base material and the hard coat layer
Data Source
AI summary
Provided are an optical laminated body including a resin layer on an acrylic base material in which the generation of an interference pattern is suppressed and the adhesiveness between the acrylic base material and the resin layer is improved and a method for efficiently manufacturing the optical laminated body. Provided are an optical laminated body including a resin layer including a binder resin and organic fine particles B on one surface of an acrylic base material including organic fine particles A, in which, in a standard length of 30 μm taken in a direction perpendicular to a thickness direction of the optical laminated body on a cross-section of the optical laminated body in the thickness direction, when an average depth of three deepest troughs selected from plural troughs in an interface between the acrylic base material and the resin layer is considered as a standard depth and then an average height of three highest crests selected from plural crests in the interface is considered as a standard height, a vertical difference between the standard height and the standard depth is in a range of 150 nm to 500 nm, a polarization plate and a liquid-crystal display device using the optical laminated body, and a method for manufacturing the optical laminated body.