Thin Polarizer Manufacturing via Stretched Laminate Orientation
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Solution Overview
Problem
Current methods for manufacturing thin polarizers face challenges in achieving a thickness of 10 μm or less while maintaining superior optical characteristics and preventing film breakages, as they struggle to increase the degree of orientation of the polyvinyl alcohol-iodine complex effectively.
Innovation Solution
A stretched laminate is formed by stretching a laminate comprising a non-stretched polymer film and a polyvinyl alcohol-based film, with a specific width ratio and stretching conditions to achieve a high degree of orientation, allowing for a thin polarizer with a thickness of 10 μm or less and improved optical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of polyvinyl alcohol-based film is reduced to manufacture thin polarizer, then the thickness of polarizer is reduced, but the film is prone to breakage during stretching process
Solution Approach 1:
The invention uses a composite laminate structure consisting of a polyvinyl alcohol-based film (providing polarizing function) and a polymer film (providing mechanical strength). This composite structure allows the polarizer to achieve thin thickness while preventing film breakage during stretching, as the polymer film reinforces the inherently weaker polyvinyl alcohol-based film.
2Manufacturing precision
If the degree of orientation of polyvinyl alcohol-iodine complex is increased to improve optical characteristics, then the optical characteristics are improved, but it becomes difficult to achieve high degree of orientation
Solution Approach 1:
The invention changes the physical state parameters during stretching by controlling temperature and using wet stretching with aqueous boric acid solution or aqueous iodine solution. This creates optimal conditions for the polyvinyl alcohol-iodine complex to achieve high degree of orientation (99% or more), thereby improving optical characteristics while making the process more controllable.
3Manufacturing precision
If wet stretching process is used to increase degree of orientation, then the degree of orientation is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention uses wet stretching with aqueous boric acid solution or aqueous iodine solution at controlled temperatures to achieve high degree of orientation of the polyvinyl alcohol-iodine complex. The specific parameter changes (temperature control, use of stretching solution) enable improved optical characteristics while maintaining a manageable manufacturing process.
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 method enables the production of thin polarizers with a thickness of 10 μm or less, achieving a single transmittance of 40% to 45% and a degree of polarization of 99.0% or greater, while minimizing film separation and surface damage during the stretching process.
Implementation Method 1
stretching the laminate such that P, expressed by Formula 1 below, ranges from 0.85 to 1.15
Implementation Method 2
increasing the degree of orientation of a polyvinyl alcohol-iodine complex
Implementation Method 3
polyvinyl alcohol-based polarizing films, containing an iodine-based compound or a dichroic dye
Implementation Method 4
optical devices for polarizing natural light or arbitrarily polarized light in a particular direction
Data Source
AI summary
Provided is a stretched laminate for manufacturing a thin polarizer while increasing the degree of orientation of a polyvinyl alcohol-iodine complex without problems such as breakage. In addition, there are provided a method of manufacturing a thin polarizer having superior optical characteristics by using the stretched laminate, a thin polarizer manufactured by the method, and a polarizing plate including the thin polarizer.