Optical Resin Panel With UV-Cured Hard Coat for Curved Surfaces
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Solution Overview
Problem
Conventional methods for manufacturing optical functional resin panels with curved surfaces face challenges in achieving high surface hardness and uniform low reflectance, as they often result in layer thickness variations leading to color unevenness and reduced moldability, especially when using aftercure type hard coat materials or sputtering techniques.
Innovation Solution
The proposed solution involves an optical functional resin panel with an injection molding resin, a base film, a semi-cured ultraviolet curable hard coat layer, and a reflectance control layer with a thickness variation of 10% or less, where the hard coat and reflectance control layers are simultaneously cured and applied in a three-dimensional shape using ultraviolet curable resin materials, ensuring high surface hardness and uniform reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional aftercure type hard coat materials or sputtering techniques are used to achieve high surface hardness, then surface hardness is improved, but layer thickness variations occur leading to color unevenness and reduced moldability
Solution Approach 1:
The patent changes the curing parameter timing by using ultraviolet curable resin that is cured during the injection molding cycle itself, rather than after curing. This timing parameter change ensures uniform thickness because the resin is molded in its uncured state and then cured uniformly throughout the mold cavity, eliminating the thickness variations that occur with aftercure methods
Solution Approach 2:
The patent applies the ultraviolet curable resin to the mold cavity before injection molding, and the resin is cured as part of the molding process itself. This preliminary preparation and integrated curing approach ensures that the hard coat layer is formed with uniform thickness from the beginning, preventing the thickness variations that plague conventional aftercure methods
2Object-affected harmful factors
If conventional methods are used to form antireflection layers on curved surfaces, then reflectance control is achieved, but the layers exhibit thickness variations causing color unevenness
Solution Approach 1:
The patent changes the refractive index parameter by selecting specific ultraviolet curable resin materials with refractive indices of 1.3-1.7, optimized for antireflection performance. Combined with curing during molding, this ensures uniform thickness and consistent reflectance control across curved surfaces without color unevenness
Solution Approach 2:
The patent replaces mechanical sputtering deposition with a chemical curing process using ultraviolet curable resin. The resin is applied in liquid form to conform to curved surfaces, then cured in place by ultraviolet irradiation during molding, eliminating the thickness variations inherent in mechanical sputtering methods
3Strength
If hard coat layers with high hardness are applied to curved surfaces, then scratch resistance is improved, but the layers crack during stretching and deformation
Solution Approach 1:
The patent prepares the mold cavity with release agents or specific surface treatments before applying the ultraviolet curable resin. This preliminary preparation ensures that the resin can be easily removed from the curved surface after curing, preventing adhesion-related cracking and maintaining layer integrity during the demolding process
Solution Approach 2:
The patent adjusts the curing parameter by using ultraviolet irradiation during injection molding rather than aftercure methods. This allows the resin to be cured while still supported by the mold cavity, preventing the layer from cracking during the stretching and deformation that occurs with high-hardness aftercure coatings
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
This approach provides an optical functional resin panel with high surface hardness and uniform low reflectance on three-dimensional curved surfaces, maintaining reflection color uniformity and enhancing appearance quality, suitable for in-vehicle displays and other applications.
Implementation Method 1
a semi-cured ultraviolet curable hard coat layer, and a reflectance control layer with a thickness variation of 10% or less, where the hard coat and reflectance control layers are simultaneously cured and applied in a three-dimensional shape using ultraviolet curable resin materials
Data Source
AI summary
An optical functional resin panel includes an injection molding resin, a base film, an ultraviolet curable hard coat layer provided on a surface of the base film, and a reflectance control layer provided on a surface of the hard coat layer, in which the reflectance control layer has a thickness variation of 10% or less, and the base film, the hard coat layer, and the reflectance control layer have a surface hardness increasing in this order.