Transparent Film with Ultrathin Scratch-Resistant Layer

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Solution Overview

Problem

Current transparent films used for protecting mobile displays and flexible displays lack sufficient scratch resistance and resistance to repetitive bending, failing to meet market demands for durability and flexibility.

Innovation Solution

A transparent film with a scratch-resistant layer having an indentation hardness of 300 MPa or greater, featuring fine particles with a polygonal surface and a binder resin, and a relaxation layer between the scratch-resistant layer and the base material, which provides excellent pencil hardness and resistance to repetitive bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a hard coat layer is coated on a transparent resin film to achieve glass-like scratch resistance, then scratch resistance is improved, but flexibility is reduced

Engineering Contradiction:

Improvescratch resistanceVSAvoidflexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent uses an ultrathin scratch-resistant layer (50-1000 nm) instead of a thick hard coat layer, allowing the film to maintain flexibility while providing scratch resistance. The thin film structure can bend without cracking, solving the contradiction between hardness and flexibility.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure combining a transparent resin base material with a scratch-resistant layer containing fine particles (such as silica or alumina) dispersed in a binder resin. This composite structure provides both scratch resistance from the hard particles and flexibility from the resin matrix.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the scratch resistant layer is made thinner to improve flexibility, then resistance to repetitive bending is improved, but scratch resistance is reduced

Engineering Contradiction:

Improveresistance to repetitive bendingVSAvoidscratch resistance

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent optimizes the thickness of the scratch-resistant layer to be between 50-1000 nm, which is thin enough to allow flexibility and repeated bending but thick enough to maintain scratch resistance. This precise parameter control resolves the contradiction between thickness-related flexibility and protective function.

Inventive Principle:

Principle #35Parameter changes

3Strength

If a high molecular weight acrylic resin layer is provided on a cyclic olefin resin film to achieve scratch resistance, then scratch resistance is improved, but resistance to repetitive bending remains low

Engineering Contradiction:

Improvescratch resistanceVSAvoidresistance to repetitive bending

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the high molecular weight acrylic resin layer with an ultrathin scratch-resistant layer (50-1000 nm) that does not hinder the flexibility and bending resistance of the underlying cyclic olefin resin film. The thin layer is thin enough to follow the film's bending without causing stress concentration.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS10585225B2Transparent film, polarizing plate, and image displaying device

Publication Date: 2020.03.10 FUJIFILM CORP

AI summary

A transparent film includes: a base material; and at least one scratch resistant layer of which indentation hardness is 300 MPa or greater and of which a thickness is 50 to 1,000 nm on an outermost surface of the transparent film at one side or both sides of the base material, and a number of times of folding endurance of the transparent film measured by an MIT testing machine according to JIS P8115 (2001) is 1,000 times or greater.