UV-Cured Polymer Resin for Distortion-Resistant Angular Selective Films
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Solution Overview
Problem
Existing light control polymer films with micro-louvers suffer from distortion under physical stress and temperature, irregular surfaces due to skiving, and require expensive lamination processes, limiting their application size and versatility.
Innovation Solution
A polymer composition comprising (meth)acrylate monomers or oligomers, a phase separating agent, a photoinitiator, and a photosensitizer, which can be polymerized in situ using UV light to form a porous polymer resin with broadband angular selective properties, allowing for tunable translucent angles and flexible application sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If micro-louvered plastic films are used to create angular selective privacy film, then broadband angular selectivity is achieved, but the films are subject to distortion from physical stress and temperatures
Solution Approach 1:
The patent changes the physical state and composition parameters by using a liquid polymer composition that is photopolymerized in-situ. The composition contains (meth)acrylate monomers/oligomers, phase separating agents, photoinitiators, and photosensitizers. By controlling the photopolymerization process and phase separation, the invention creates a crosslinked polymer resin network that is inherently resistant to distortion from physical stress and temperature while maintaining angular selective properties.
Solution Approach 2:
The patent creates a composite polymer resin system combining multiple functional components: (meth)acrylate monomers/oligomers for polymerization, phase separating agents for creating the angular selective microstructure, photoinitiators for UV-curing, and photosensitizers for enhancing the photopolymerization. This composite approach allows the material to simultaneously achieve angular selectivity, distortion resistance, and processability.
2Adaptability or versatility
If skiving process is used to produce louvered plastic films, then micro-louver structures are created, but irregular surfaces result which prevent clear optic image transmission
Solution Approach 1:
The patent replaces the mechanical skiving process with a chemical photopolymerization process. Instead of mechanically cutting and shaping plastic films into louvers, the invention uses UV light to polymerize a liquid composition containing phase separating agents that self-organize into the desired micro-louver structures. This chemical approach eliminates the surface irregularities inherent in mechanical skiving while achieving the same angular selective function.
Solution Approach 2:
The patent utilizes phase separation during photopolymerization to create the micro-louver structures. The phase separating agent undergoes phase transition as the polymerization proceeds, self-organizing into distinct microdomains that form the angular selective structures. This phase transition approach creates smooth, regular surfaces unlike mechanical skiving.
3Adaptability or versatility
If lamination process is used to laminate louvered plastic films between clear films, then angular selective film is produced, but expensive press equipment is required and resulting laminates cannot be larger than the platens
Solution Approach 1:
The patent performs preliminary action by formulating the polymer composition with all necessary components (monomers, phase separating agents, photoinitiators, photosensitizers) mixed together before application. The composition is ready for direct photopolymerization in-situ, eliminating the need for separate lamination steps. This allows the film to be cured directly on the substrate in various sizes without being limited by press platen dimensions.
Solution Approach 2:
The patent replaces the expensive mechanical lamination press with a UV photopolymerization system. The liquid composition is applied and then cured using UV light sources, which can be scaled to any size without requiring large platen presses. This substitution dramatically reduces equipment cost and enables production of films in any size, including large-area applications.
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 resulting polymer resin exhibits high uniformity of angular selective properties, is resistant to distortion, and can be fabricated without expensive lithography techniques, enabling larger-scale, cost-effective production and broader applications in light control and privacy films.
Implementation Method 1
polymerizing a solution of at least one (meth)acrylate polymer or oligomer, a photoinitiator, a photosensitizer and a phase separating agent in the presence of UV light to form the polymer resin
Implementation Method 2
a phase separating agent, wherein the weight percent ratio of the sum of said (meth)acrylate monomer(s) or oligomer(s), said phase separating agent, said photoinitiator and said photosensitizer is in the range of 90:4:1:0.1 to 60:30:1:0.1
Data Source
AI summary
There is provided a polymer composition comprising at least one (meth)acrylate monomer or oligomer, a phase separating agent, a photoinitiator and a photosensitizer. There is also provided a method of preparing a polymer resin comprising the step of polymerizing a solution of at least one (meth)acrylate polymer or oligomer, a photoinitiator, a photosensitizer and a phase separating agent in the presence of UV light to form the polymer resin. There is also provided a polymer resin and uses of the polymer composition.