Light Polarizing Articles With Coupling Layer Adhesion
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Solution Overview
Problem
Existing light polarizing articles face issues such as distortion of optical surfaces, delamination between layers, leaching of substrate components into the polarizing layer, hazing, and poor adhesion between the polarizing dye layer and additional functional layers, particularly under environmental exposure to water, sweat, and light.
Innovation Solution
A light polarizing article is developed with a first coupling layer comprising polysiloxane or polyepoxysilane, which includes immobilized ions to pair with polarizing dye molecules, enhancing adhesion between the polarizing dye layer and additional functional layers, and an inorganic adhesion layer to improve durability and resistance to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pre-formed polarizing layer is laminated to a substrate, then the polarizing layer can be applied to the substrate, but the optical surface becomes distorted and cannot curve to a perfect fit with a contoured surface
Solution Approach 1:
The substrate surface is pre-treated by forming microgrooves through brushing or abrasion before applying the polarizing dye layer. This preliminary surface modification ensures that the polarizing layer can conform precisely to the contoured substrate surface, eliminating distortion while maintaining ease of application.
Solution Approach 2:
The polarizing dye layer is applied locally to the microgrooved surface areas where it is needed, allowing the dye molecules to orient themselves within the grooves and achieve precise fit with the contoured substrate, rather than attempting to conform the entire pre-formed layer to complex shapes.
2Device complexity
If the polarizing layer is directly applied to the substrate, then the structure is simple, but adhesion is insufficient and delamination occurs during manufacture or product life
Solution Approach 1:
An inorganic adhesion layer is introduced as an intermediary between the substrate and the polarizing dye layer. This intermediate layer provides superior adhesion to both the substrate and the organic polarizing dye, preventing delamination while adding minimal structural complexity.
Solution Approach 2:
The patent employs a composite structure combining inorganic adhesion layer material with organic polarizing dye molecules. This composite approach leverages the adhesion properties of inorganic materials and the polarizing properties of organic dyes to create a stable, non-delaminating interface.
3Ease of manufacture
If the polarizing layer is applied without protection, then the manufacturing process is simple, but substrate components leak into the polarizing layer causing deterioration of mechanical and optical quality
Solution Approach 1:
The inorganic adhesion layer is applied to the substrate surface before the polarizing dye layer is applied. This preliminary protective barrier prevents substrate component migration into the polarizing layer during subsequent manufacturing and use, maintaining the optical and mechanical quality of the polarizing layer.
4Device complexity
If additional functional layers are applied directly over the polarizing dye layer, then the structure is simple, but delamination occurs between the polarizing layer and functional layers due to environmental exposure
Solution Approach 1:
The inorganic adhesion layer serves as a durable intermediary that remains stable under environmental conditions such as water, sweat, and light exposure. This intermediate layer maintains strong adhesion between the polarizing dye layer and subsequent functional layers, preventing delamination while adding minimal complexity.
5Ease of manufacture
If the polarizing dye layer is applied to a smooth surface, then the application is easy, but the alignment of polarizing molecules is insufficient for high polarization efficiency
Solution Approach 1:
The surface is modified locally by forming microgrooves through brushing or abrasion in the direction desired for molecule alignment. This local surface modification provides guidance for the polarizing dye molecules to orient themselves correctly, achieving high polarization efficiency while maintaining ease of application.
Solution Approach 2:
The microgroove structure is pre-formed on the substrate surface before applying the polarizing dye layer. This preliminary alignment guidance structure ensures that the dye molecules naturally orient themselves in the desired direction during application, achieving precise molecule alignment without complex processing.
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 strong adhesion and resistance to water, sweat, and high humidity, preventing delamination and maintaining optical quality over time, while allowing for precise alignment of polarizing dye molecules for high polarization efficiency.
Implementation Method 1
a first coupling layer (iii) between the first functional layer and the second functional layer, said first coupling layer comprising molecular structure bearing ionic groups having charges opposite to the polarizing dye molecules of the first functional layer
Implementation Method 2
an inorganic adhesion layer to improve durability and resistance to environmental factors
Implementation Method 3
Dichroic materials, when properly oriented, can preferentially transmit light polarized in a particular direction
Data Source
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Figure 2
AI summary
Light polarizing articles comprising a substrate, a light polarizing layer comprising ion-bearing polarizing dye molecules, a coupling layer, and a protective layer, and method of making the same. Due to the presence of the coupling layer bearing counter ions, adhesion of the polarizing layer to the protective layer is improved. The light polarizing article has advantageous chemical, mechanical and thermal resistance. The light polarizing article can be used, for example, as ophthalmic products and in display devices.