Thin Polarizer Manufacturing via Controlled Swelling and Stretching
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Solution Overview
Problem
Current methods for manufacturing thin polarizers with excellent optical properties and reduced thickness face challenges such as breakage during stretching and degradation of physical properties due to high peel strength requirements and variability in manufacturing conditions.
Innovation Solution
A method involving forming a film laminate by attaching a polyvinyl alcohol-based film to a polymer film using attraction force or adhesive, swelling to a specific degree of 0.36 to 0.44, dyeing with iodine or dichromatic dye, and stretching at controlled conditions to achieve a thickness of 10 μm or less with optimal optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the polyvinyl alcohol-based film before stretching is reduced to manufacture a thin polarizer, then the thickness of the polarizer is reduced, but the degree of swelling increases and the modulus per unit area increases causing breakage during stretching
Solution Approach 1:
The patent applies preliminary swelling treatment to the polyvinyl alcohol-based film before stretching. By controlling the degree of swelling to 0.36 to 0.44, the film is pre-conditioned to reduce the modulus per unit area during subsequent stretching, preventing breakage while enabling thin polarizer production with thickness of 10 μm or less.
Solution Approach 2:
The patent changes the physical state parameters of the polyvinyl alcohol-based film by controlling the degree of swelling within the specific range of 0.36 to 0.44. This parameter control modifies the film's mechanical properties, reducing the modulus per unit area and enabling successful stretching of thin films without breakage.
2Volume of moving object
If coating or co-extruding method is used to manufacture thin polarizing plate, then thin polarizer can be produced, but high peel strength is required for separation causing damage or deformation of the polyvinyl alcohol layer
Solution Approach 1:
The patent extracts the polyvinyl alcohol-based film from the laminate structure by utilizing low peel strength between the film and base material. This allows easy separation without requiring high peel strength, thereby preventing damage or deformation of the polyvinyl alcohol layer that would occur with coating or co-extruding methods.
3Volume of moving object
If coating or co-extruding method is used to manufacture thin polarizing plate, then thin polarizer can be produced, but physical properties are easily changed according to manufacturing conditions causing degradation
Solution Approach 1:
The patent uses a pre-manufactured polyvinyl alcohol-based film with uniform properties as the starting material. This homogeneous film is then laminated onto a base material, ensuring that the physical properties remain consistent and uniform throughout the manufacturing process, unlike coating or co-extruding methods where conditions cause variability.
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 results in a thin polarizer with transmittance of 40% to 45% and a degree of polarization of 99.9% or more, minimizing breakage and ensuring uniform physical properties.
Implementation Method 1
swelling the film laminate so that a degree of swelling of the polyvinyl alcohol-based film is 0.36 to 0.44
Implementation Method 2
a polyvinyl alcohol-based polarizing film where molecular chains containing an iodine-based compound or a dichromatic dye are aligned in a predetermined direction
Data Source
AI summary
The present invention relates to a method of manufacturing a thin polarizer, including: forming a film laminate by attaching a polyvinyl alcohol-based film to at least one surface of a polymer film by using attraction force or an adhesive; swelling the film laminate so that a degree of swelling of the polyvinyl alcohol-based film is 0.36 to 0.44; dyeing at least one of iodine and a dichromatic dye on the film laminate; and stretching the film laminate.