Surface-Textured Transparent Film via Anti-Glare Transfer Curing
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Solution Overview
Problem
Existing methods for producing transparent resin films, such as cell casting and flow casting on a steel belt, face inefficiencies in continuous production and difficulty in achieving uniform physical properties.
Innovation Solution
A film with a controlled uneven surface is produced by using an energy beam-curable composition layer in contact with an anti-glare film, where the anti-glare film's uneven surface is transferred to the cured material layer, achieving desired optical and mechanical properties through controlled skewness and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cell casting method is used to produce transparent resin film, then the film can be produced, but continuous production efficiency is poor
Solution Approach 1:
The patent replaces the mechanical cell casting method with a flow casting method where the curable composition flows under its own weight or applied force to form a uniform film on a mold, enabling continuous production while maintaining manufacturing capability
Solution Approach 2:
The patent modifies the physical parameters of the curable composition (viscosity, flow characteristics) to enable smooth flow and uniform film formation during the casting process, facilitating continuous production
2Manufacturing precision
If flow casting method is used on steel belt, then continuous production is possible, but uniform physical properties cannot be achieved
Solution Approach 1:
The patent applies different surface treatments or coatings to different regions of the mold to control the flow and curing characteristics of the composition locally, ensuring uniform physical properties across the entire film while maintaining continuous production
Solution Approach 2:
The patent uses a mold with a predetermined surface structure that copies the desired uniform physical properties onto the film during the casting and curing process, achieving consistency while enabling continuous production
3Adaptability or versatility
If surface shape is controlled for various uses, then versatility is improved, but surface durability and shape retention become challenging
Solution Approach 1:
The patent creates a composite structure with a base layer providing durability and a surface layer with controlled shape providing versatility, combining the strengths of different material properties to achieve both shape retention and adaptability
Solution Approach 2:
The patent applies surface treatments or coatings before the final curing process to establish the desired surface shape, ensuring that the shape is set early and maintained throughout subsequent processing and use, thereby preserving durability
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 film exhibits excellent durability, scratch resistance, and maintains shape stability with controlled surface characteristics, including haze, gloss, and roughness, suitable for various applications.
Implementation Method 1
irradiation with energy beams while in contact with an anti-glare film, which transfers its surface characteristics to the cured material layer
Data Source
AI summary
The present application relates to a film. The present application can provide a film having excellent optical characteristics such as transparency or haze, mechanical properties such as hardness, and flexibility, wherein the shape of the surface is controlled to be suitable for various uses, and the controlled surface shape has excellent durability.