Photosensitive Laminate with Differential Exposure Sensitivity
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Solution Overview
Problem
Existing photosensitive laminates face complications in patterning multiple layers simultaneously due to alignment issues and peeling problems, especially when using transfer materials for decorative or refractive index adjusting layers, leading to inconvenient processes and suboptimal characteristics.
Innovation Solution
A photosensitive laminate is designed with a first resin layer, an interlayer, and a second resin layer laminated on a support, where at least one layer includes 20 mass % or greater of inorganic particles, and the second resin layer has higher exposure sensitivity than the first, allowing for simultaneous patterning and reducing peeling and alignment complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple photosensitive layers are laminated for decorative materials or refractive index adjusting layers, then the functional requirements are met, but alignment operation becomes complicated and peeling occurs
Solution Approach 1:
A release layer is introduced between the transfer material and the photosensitive laminate to facilitate alignment and prevent peeling during the lamination process. The release layer acts as an intermediary that allows for easier handling and positioning of multiple layers without direct adhesion issues between the photosensitive layers themselves.
Solution Approach 2:
The patent divides the structure into separate functional components: a transfer material with photosensitive layers, a release layer, and the final photosensitive laminate. This segmentation allows each component to be optimized independently and simplifies the overall alignment and lamination process by reducing direct interactions between complex layers.
2Adaptability or versatility
If pigment is added to resin layer to form decorative material, then decorative function is achieved, but patterning becomes inconvenient and pigment comes out during development
Solution Approach 1:
The decorative pigment is extracted from the photosensitive resin layer and placed in a separate decorative layer. This allows the photosensitive layer to maintain its patterning properties without pigment interference, while the decorative layer provides the desired aesthetic function. The pigment comes out during development because it is no longer bound within the resin matrix of the photosensitive layer.
Solution Approach 2:
The patent uses composite material structures where the decorative layer contains pigment particles dispersed in a binder, separate from the photosensitive resin layer. This composite approach allows each layer to perform its specific function optimally: the photosensitive layer for patterning and the decorative layer for aesthetics, without the complications of mixing these functions in a single layer.
3Productivity
If first photosensitive layer and second photosensitive layer are applied without interlayer, then manufacturing steps are reduced, but layers coalesce and intended characteristics are not obtained
Solution Approach 1:
A release layer is positioned between the first and second photosensitive layers to prevent coalescence during lamination. This intermediary layer maintains the intended separation and characteristics of each photosensitive layer while still allowing for a streamlined manufacturing process. The release layer can be easily removed or integrated depending on the specific application requirements.
4Productivity
If transfer material is used for decorative material, then manufacturing efficiency is improved, but alignment and peeling problems occur
Solution Approach 1:
The release layer serves as a mediator between the transfer material and the photosensitive laminate, enabling the manufacturing efficiency benefits of transfer materials while eliminating alignment and peeling problems. The release layer allows the transfer material to be positioned and laminated without direct adhesion issues, maintaining high productivity while reducing complexity.
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 configuration enables satisfactory patterning of multiple layers at once, suppresses peeling, and simplifies the alignment process, resulting in improved patterning properties and manufacturing efficiency for touch panels and image display devices.
Implementation Method 1
a photopolymerization initiator and a polymerizable compound
Data Source
AI summary
An object of the invention is to provide a photosensitive laminate in which two or more layers can be collectively patterned, a transfer material, a patterned photosensitive laminate, a method for manufacturing the patterned photosensitive laminate, a touch panel, and an image display device. According to the invention, there are provided a photosensitive laminate in which a first resin layer, an interlayer, and a second resin layer are laminated on a support in this order, at least one of the first resin layer or the second resin layer includes 20 mass % or greater of inorganic particles, and exposure sensitivity of the second resin layer is higher than that of the first resin layer, a transfer material, a patterned photosensitive laminate, a method for manufacturing the patterned photosensitive laminate, a touch panel, and an image display device.