Substrate Film for Thin Polarizing Layers
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Solution Overview
Problem
Polarizing films based on polyvinyl alcohol (PVA) resins are sensitive to temperature and humidity changes, leading to expansion, contraction, and defects such as curls, especially when thicker, and face challenges in thin device applications with high demand for low energy consumption.
Innovation Solution
A substrate film with specific physical properties, such as a thermoplastic polyurethane (TPU) film, is used in conjunction with a polarizable material layer to create a laminate that can be elongated, ensuring a high-functional, thin polarizing film with reduced thickness and preventing tearing or curling during the elongation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PVA resin polarizing film is made thicker to improve durability and reduce sensitivity to temperature and humidity, then the film's stability improves, but the device thickness increases and energy consumption increases
Solution Approach 1:
The patent uses a composite structure consisting of a PVA resin layer containing dichroic material for polarization function, and a substrate film layer (such as TAC or PET) for mechanical support. This composite structure allows the thin PVA layer (10-30 μm) to maintain its polarization functionality while the substrate film provides the necessary mechanical stability and resistance to temperature and humidity changes, thereby achieving both thinness and reliability simultaneously
2Length of moving object
If a PVA resin polarizing film is made thinner to reduce device thickness and energy consumption, then device thinness improves, but the film becomes more sensitive to temperature and humidity causing expansion, contraction, and curls
Solution Approach 1:
The patent employs a composite structure where a thin PVA resin layer (10-30 μm) provides polarization function while a substrate film layer (such as TAC or PET with specific tensile strength and elongation properties) provides mechanical stability. This allows the overall film to be thin (reducing device thickness and energy consumption) while the substrate film compensates for the PVA layer's sensitivity to temperature and humidity, preventing expansion, contraction, and curls
3Reliability
If a PVA resin polarizing film is made thicker to suppress expansion and contraction, then stability improves, but stress is caused during adhesion resulting in stains and defects on the screen
Solution Approach 1:
The patent uses a composite structure with a thin PVA resin layer and a substrate film layer having specific mechanical properties (tensile strength of 20-100 MPa and elongation of 20-100%). This composite allows suppression of expansion and contraction through the substrate film while maintaining thin overall thickness, thereby avoiding stress-related stains and defects during adhesion to the liquid crystal panel
Solution Approach 2:
The patent specifies particular parameter ranges for the substrate film including tensile strength (20-100 MPa) and elongation (20-100%) to optimize the balance between suppressing expansion/contraction and minimizing adhesion stress, thereby preventing screen stains and defects while maintaining film stability
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 effectively manufactures very thin polarizing films with excellent polarization performance and transmittance, preventing defects like tearing and curling, and achieving a thickness of 10 μm or less, suitable for thin devices with high functionality.
Implementation Method 1
a layer 102 (hereinafter referred to as a 'polarizable material layer') including a material (hereinafter referred to as a 'polarizable material') capable of exhibiting a polarization function due to elongation
Data Source
AI summary
There are provided a substrate film, a laminate, and method of manufacturing a polarizing film. The present application provides a substrate film capable of effectively manufacturing a polarizing film having a thickness of about 10 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, or about 5 μm or less and having an excellent function such as polarization performance, a laminate, and a method of manufacturing the same. According to the invention, it is possible to prevent tearing, curling, or the like from occurring in the elongation process and manufacture a polarizing film by easily elongating a polarization material such as a PVA-based resin.