Resin Pattern Ionic Depth Control for Scratch Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin patterns used as protective films for electrodes, such as those in touch panels, face challenges in achieving both scratch resistance and maintaining edge quality, particularly in preventing edge lift, where the edge of the resin pattern separates from the base material.
Innovation Solution
A laminate comprising a base material and a resin pattern with a specific depth of presence of sodium or potassium ions, ranging from 0.3 μm to 3.0 μm, which is achieved through a manufacturing method involving the use of a developer containing these ions, enhancing scratch resistance and reducing edge lift.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin pattern is formed with high crosslinking density to improve scratch resistance, then the resin pattern becomes more resistant to physical damage, but edge lift occurs due to excessive internal stress
Solution Approach 1:
The patent controls the depth distribution of sodium or potassium ions within the resin pattern to achieve optimal scratch resistance while preventing edge lift. By adjusting the ionic composition profile (0.3-3.0 μm depth), the internal stress is balanced, allowing high crosslinking density without edge separation.
Solution Approach 2:
The resin pattern is formulated as a composite containing polymerizable compounds, polymerization initiators, and specific ionic additives (sodium or potassium ions at controlled depths). This composite structure enables simultaneous achievement of high strength through crosslinking and edge quality through stress distribution.
2Manufacturing precision
If the resin pattern is made thinner to improve transparency and reduce stress, then edge lift is reduced, but scratch resistance deteriorates
Solution Approach 1:
The patent introduces ionic composition control as a new parameter to decouple the trade-off between thickness and strength. By optimizing the depth distribution of sodium or potassium ions, thin resin patterns (with sufficient transparency) can achieve high scratch resistance through enhanced crosslinking density without suffering from edge lift.
3Strength
If a developer containing sodium or potassium ions is used to improve resin pattern formation, then scratch resistance and edge quality are enhanced, but additional processing steps are required
Solution Approach 1:
The developer containing sodium or potassium ions serves multiple functions: it removes unexposed photosensitive material, controls the ionic composition profile for stress management, and enables crosslinking enhancement. This multi-functionality reduces the need for separate treatment steps despite the added complexity of ionic control.
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 laminate exhibits improved scratch resistance and reduced edge lift, ensuring the resin pattern's integrity and performance as a protective film.
Implementation Method 1
a photopolymerizable compound and a photopolymerization initiator... curing a predetermined portion of the photosensitive layer by irradiation with actinic ray
Data Source
AI summary
Provided are a laminate including a base material and a resin pattern, in which, in a case where, based on a depth direction analysis of the resin pattern performed along a direction from the resin pattern toward the base material, an intensity of at least one component selected from the group consisting of a sodium ion and a potassium ion, which is detected on a surface of the resin pattern, is defined as 100%, a depth of presence of the at least one component selected from the group consisting of a sodium ion and a potassium ion in the resin pattern is 0.3 μm to 3.0 μm, the depth of presence being defined by a distance from the surface of the resin pattern to a point where the intensity of the at least one component selected from the group consisting of a sodium ion and a potassium ion first reaches 90%; and a manufacturing method of the laminate.