CN101749644A - Diffusion membrane and manufacturing method thereof - Google Patents
Diffusion membrane and manufacturing method thereof Download PDFInfo
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- CN101749644A CN101749644A CN200910265795A CN200910265795A CN101749644A CN 101749644 A CN101749644 A CN 101749644A CN 200910265795 A CN200910265795 A CN 200910265795A CN 200910265795 A CN200910265795 A CN 200910265795A CN 101749644 A CN101749644 A CN 101749644A
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Abstract
The invention provides a diffusion membrane and a manufacturing method thereof, the diffusion membrane comprises a base material and a concave-convex micro structure layer and the concave-convex micro structure layer which is arranged at least one side of the base material; the diffusion membrane is measured according to JIS K7136 standard method, and the measurement result shows the mist degree of the diffusion membrane is not smaller than 5% and the full light transmittance is not smaller than 50%; the concave-convex micro structure layer is formed by using a coating composition containing the polymer containing the material which is identical to or similar to principle component of the base material and a material which is incompatible with the polymer, and coating the composition on the base material.
Description
Technical field
The present invention be on a kind of diffusion barrier, it is particularly a kind of for liquid crystal display and the diffusion barrier of the diffusion of tool bloom and high transparency characteristic, and on a kind of method for manufacturing such a diffusion barrier.
Background technology
In general, the primary structure of liquid crystal display (referred to as " LCD ") includes panel and backlight module two large divisions.Wherein faceplate part mainly includes transparent electrode plate, liquid crystal, alignment film, colored filter, polaroid and drive integrated circult etc., and the part of backlight module is mainly comprising fluorescent tube, light guide plate and various blooming pieces etc..
In order to allow light to be more evenly distributed on panel, the more normal practice of current industry is that diffusion barrier or diffuser plate are added in backlight module；Or further the function that light spreads integrated with concentration piece (prism film) or other blooming pieces, for example, forming concave-convex micro-structure to provide diffusion effect on the surface of reflectance coating or reflecting plate.
Known diffusion diaphragm plate, which is mainly, is coated on the composition of an organic or inorganic particle comprising resin-bonded agent and as granule proliferation on base material to form diffusion layer.Light can produce refraction, reflection and scatter when passing through this diffusion layer, therefore, it is such spread diaphragm plate can effective diffusing light, reach effect of equalizing light rays.However, during diffusion layer is formed, granule proliferation is easily assembled or sticked mutually, influence the uniformity of diffusing light and easily display surface is produced dim spot.Furthermore, if granule proliferation inorganic particle, because the density of inorganic matter is typically greater than the resin-bonded agent being made up of organic matter, therefore inorganic particle process easy to process is settled because Action of Gravity Field is produced, and causes quality after coating to differ.In addition, granule proliferation may also come off, and then influence the optical property of diaphragm.
Another conventional method is to form concave-convex micro-structure on optical film surface in the prior art, and light is reached into the homogenized effect of light toward light extraction from all directions by the micro-structural.One of conventional known method is the mould using the groove for having concaveconvex structure, resin is reprinted required concaveconvex structure is formed on optical film surface, for example：Sandblasting wheel coating method.But the method is limited to the release between resin and mould, for example, when using the polyester resin, because of polyester resin and between reprinting mould, release effect is not good, therefore resin is easily remained on mould, makes obtained concaveconvex structure not as expected, so as to influence the quality of optical film.
The conventional base material of optical film is formed by polyester resin (polyester resin), and resin used in diffusion layer or concave-convex micro-structure is generally acryl resin (acrylate resin), if this resinoid is machined directly on polyester base material, will be not good because of adherence, and make the easy warpage of diaphragm.To solve this problem, first base material can be surface-treated more than general industry, then carry out follow-up processing.Conventional surface treatment method includes：Corona, plasma-based or one prime coat of another application (primer layer) on base material.Above-mentioned surface treatment step respectively has its limitation in addition to it can improve manufacturing cost.For example, the surface nature that plasma-based mode processing speed is slow and cost is high, corona mode is handled can time to time change and unfavorable storage, the thickness of prime coat can then influence coating tack.
The content of the invention
The purpose of the present invention is the defect for above-mentioned prior art, and the present invention provides a kind of method of diffusion barrier and its manufacture without diffusion particle.
To reach above-mentioned purpose, the present invention is adopted the technical scheme that：A kind of diffusion barrier is provided, it includes a base material and the concave-convex micro-structure layer positioned at the base material at least side, the diffusion barrier is measured with the mist degree not less than 5% and the total light transmittance not less than 50% according to JIS K7136 standard methods, wherein concave-convex micro-structure layer is formed by the method comprised the following steps：
(a) following component is mixed to form a coating composition：
(i) a kind of polymer by being constituted with the same or analogous material of base material principal component；
(ii) material incompatible with component (i)；And
(iii) solvent；
(b) coating composition is coated at least side of the base material and forms a coating；
(c) coating is dried to remove component (iii), and wherein component (i) produces phase separation during drying with component (ii)；And
(d) component (ii) is removed to form the concave-convex micro-structure.
The method for forming concave-convex micro-structure layer is further included：After step (c) and before step (d), use energy ray curing component (ii).
The base material is made up of by plastic basis material and the resin selected from the group being made up of polyester resin, polyacrylate resin, vistanex, polycyclic alkene resin, polyimide resin, polycarbonate resin, polyurethane resin, Triafol T, PLA and combinations thereof.
The base material is polyester resin, and component (i) is polyester resin or alkyd resin or its mixing.
The base material is PET, and component (i) is the alkyd resin being modified through toluene di-isocyanate(TDI).
Wherein component (ii) is selected from the group being made up of acrylate monomer, acrylate oligomer, acrylate polymer and combinations thereof.
The coating composition further includes additive.
Wherein the weight ratio of component (i) and component (ii) is between 0.1 to 0.8.
Wherein the proportion of component (i) is more than the proportion of component (ii).
Wherein component (iii) is benzene class, esters or ketone or its mixture.
It has the mist degree between 15% to 75% and the total light transmittance between 70% to 95% with JIS K7136 standard methods measurement.
The present invention separately provides a kind of method for the diffusion barrier for manufacturing tool concave-convex micro-structure, and it includes：
(a) base material is provided；
(b) following component is mixed to form a coating composition：
(i) a kind of polymer by being constituted with the same or analogous material of base material principal component；
(ii) a kind of material incompatible with component (i)；And
(iii) solvent；
(c) with coating method, the coating composition is coated at least side of the base material and forms a coating；
(d) coating is dried to remove component (iii), and wherein component (i) produces phase separation during drying with component (ii)；And
(e) component (ii) is removed to form the concave-convex micro-structure.
The coating method be selected from being coated with by scraper type, roller coating, micro- gravure, flow coat, impregnation coating, spraying coating and the constituted group of curtain painting.
The coating method is roller coating.
It is further included：After step (d) and before step (e), use energy ray curing component (ii).
The energy-ray is selected from by heat energy, radiation energy and electron beam or and the constituted group of combination.
The energy-ray is ultraviolet.
The present invention separately provides a kind of diffusion barrier, it includes a PET base material, the base material at least side includes concave-convex micro-structure layer, wherein described concave-convex micro-structure layer is formed with phase disengagement method, and the concave-convex micro-structure is made up of the alkyd resin being modified through toluene di-isocyanate(TDI), the diffusion barrier is measured with the mist degree not less than 5% and the total light transmittance not less than 50% according to JIS K7136 standard methods.
The diffusion barrier of the present invention is free of diffusion particle, and diffusion barrier of the invention can not only improve the uniformity of light diffusion and have light diffusion property concurrently, therefore can effectively solve problems of the prior art.In addition, the diffusion barrier of the present invention is not required to extra surface treatment step and need not use diffusion particle, and the adherence of gained microstructured layers and base material is good, it is possible to decrease manufacturing cost, lifts industrial utilization.
Brief description of the drawings
Fig. 1 is the displaing micro photo figure of the surface micro-structure of the diffusion barrier of embodiment 1；
Fig. 2 is the displaing micro photo figure of the surface micro-structure of the diffusion barrier of embodiment 2；
Fig. 3 is the displaing micro photo figure of the surface micro-structure of the diffusion barrier of embodiment 3；
Fig. 4 is the displaing micro photo figure of the surface micro-structure of the diffusion barrier of embodiment 4.
Embodiment
Term used in herein is only the embodiment described in description, and is not used to limit the scope of the present invention.For example, term used in the description " one ", unless clear and definite explanation, otherwise term " one " is to cover odd number and most forms.
Concave-convex micro-structure layer of the diffusion barrier of the present invention comprising a base material and positioned at the base material at least side.Above-mentioned " base material at least side " refer to the exiting surface of base material, incidence surface or its both.
Suitable for the present invention base material have no it is specifically limited, its can for any the technical field of the invention tool usually intellectual known to person, for example：Plastic basis material.Constitute above-mentioned plastic basis material resin can be homopolymer (homopolymer) or copolymer (copolymer), its species have no it is specifically limited, such as, but not limited to：Polyester resin (polyester resin), such as PET (polyethylene terephthalate, PET) or PEN (polyethylene naphthalate, PEN)；Polyacrylate resin (polyacrylate resin), such as polymethyl methacrylate (polymethyl methacrylate, PMMA)；Vistanex (polyolefin resin), such as polyethylene (PE) or polypropylene (PP)；Polycyclic alkene resin (polycycloolefin resin)；Polyimide resin (polyimide resin)；Polycarbonate resin (polycarbonate resin)；Polyurethane resin (polyurethane resin)；Triafol T (triacetylcellulose, TAC)；PLA (Polylactic acid)；Or its combination.Preferably polyester resin, polycarbonate resin or its combination, are more preferably PETs.The thickness of base material generally depends on the demand for thinking obtained optical articles, generally 15 microns to 300 microns.
The concave-convex micro-structure layer of diffusion barrier of the present invention is to be formed through the following steps：
(a) following component is mixed to form a homogeneous coating composition：
(i) a kind of polymer by being constituted with the same or analogous material of base material principal component；
(ii) a kind of material incompatible with component (i)；And
(iii) solvent；
(b) coating composition is coated at least side of the base material and forms a coating；
(c) coating is dried to remove component (iii), and wherein component (i) produces phase separation during drying with component (ii)；And
(d) component (ii) is removed to form the concave-convex micro-structure.
In order to improve the adherence between concave-convex micro-structure and base material, the present invention use it is a kind of by the polymer that is constituted with the same or analogous material of base material principal component as component (i).Because material character is same or similar with base material, the tack between component (i) and base material is good, after (iii) is removed, can anchor on base material and be not easily stripped.In addition, component (ii) is set to be difficult to remove with component (i) and from base material in order to avoid polymerisation occurs in curing schedule with component (ii) for component (i), component (i) is preferably the polymer or saturation (saturated) polymer not reacted with component (ii).
The species of component (i) used in the present invention can be after base material species be determined, depending on base material species, and selection is with the material with the same or analogous characteristic of base material, and above-mentioned characteristic refers to the physical property and/or the property changed of material.For example, when base material is made up of polyester resin, component (i) is preferably polyester resin or other polymer (such as alkyd resin) with similar quality, or combinations thereof, and is not limited to the form of homopolymer or copolymer.Above-mentioned polyester resin is such as, but not limited to oil-free polyester resin (oil free polyesterresin), such as saturated polyester resin (saturated polyester)；Or high molecular weight polyester resins (a polyesterresin with a high molecular weight).Preferably polyester resin is PET (PET) or PEN (PEN).Above-mentioned alkyd resin is such as, but not limited to long oil alkyd resin (long oil alkyd resin), such as soybean oil (soya bean oil) alkyd resin or linseed oil (linseed oil) alkyd resin；Medium oil alkyd resin (medium oil alkyd resin), such as soya bean fatty acid (soya fatty acid) alkyd resin；Short oil alkyd resin (short oil alkyd resin), such as castor oil (castor oil) alkyd resin or coconut fatty acid (coconut fatty acid) alkyd resin；Or modified alkyd resin (modified alkydresin), such as through toluene di-isocyanate(TDI) (tolylene diisocyanate, TDI) modified ricinoleyl alcohol acid resin, the alkyd resin through phenylethene modified (styrene modified) or epoxy-ester (epoxy ester) alkyd resin.It is preferred that alkyd resin be ricinoleyl alcohol acid resin or the ricinoleyl alcohol acid resin that is modified through toluene di-isocyanate(TDI), be more preferably the ricinoleyl alcohol acid resin being modified through toluene di-isocyanate(TDI).
According to an embodiment of the present invention, base material is mainly made up of PET, and component (i) is modified alkyd resin, is preferably the alkyd resin being modified through toluene di-isocyanate(TDI).
The commercially available prod that component (i) of the present invention can be used in is such as, but not limited to：Eternal companies
1101-M-70-5、
1102-M-70-5、
1103-M-70、
1106-M-70、
1107-M-70、
1105-M-55、
2105-M-55、
2105-M-70、2109-M-70、3304-X-70、
3306-X-70、
3403-B-65、
3401-XT-70、
1170-XM-70、
242-XM-60、
NP1020-R-47、
NP1021-R-60、5010-S-50、
5016-R-33、
5021-R-40、
5081-R-40、
5082-R-40、5000A、
5051-R-60、
5052-R-50 and
5054-TS-40；TOYOBO companies
103、
200、
220、
226、
600、
660、GK640、GK680 and
GK810；Unitika companies
UE-3500、
UE-3210 andUE-3800；The ATR2010 and ATR2009 of Kao companies.
Component (ii) used in the present invention is a kind of material with component (i) incompatible (incompatible), therefore, under solvent is not present, component (i) and component (ii) poor compatibility can produce phenomenon of phase separation.Therefore, component (ii) can be removed from coating after the drying, leaves component (i) and concave-convex micro-structure is formed on base material.
The species of component (ii) used in the present invention can have person known to usually intellectual for any the technical field of the invention, but it need to be the material incompatible with component (i), and it is preferred that the adhesive force of itself and base material is less than the adhesive force of component (i) and base material after the drying.Above-mentioned component (ii) can be monomer, oligomer or polymer or the form of its mixture.According to the embodiment of the present invention, when component (i) is polyester resin or other polymer with similar quality, component (ii) is preferably the mixture of acrylic ester monomer, acrylate quasi-oligomer or its mixture, more preferably acrylic ester monomer and acrylate quasi-oligomer.
Acrylic ester monomer available for the present invention is such as, but not limited to：Epoxy diacrylate (epoxydiacrylate),Halogenated epoxy diacrylate (halogenated epoxy diacrylate),Methyl methacrylate (methyl methacrylate),Iso-bornyl acrylate (isobornyl acrylate),2- phenoxyethyl acrylates (2-phenoxy ethyl acrylate),Ethoxyethoxyethyl acrylate (2- (2-ethoxyethoxy) ethyl acrylate),Laurate acrylate (lauyl acrylate),Stearic acid acrylate (stearyl acrylate),Acrylamide (acrylamide),Acrylic acid (acrylic acid),(methyl) acrylonitrile ((meth) acrylonitrile),Fluorene derivative diacrylate (fluorene derivative diacrylate),Acrylic acid biphenyl epoxy ethyl ester (biphenylepoxyethyl acrylate),1,6- hexanediyl esters (1,6-hexanediol diacrylate),Tripropylene glycol diacrylate (tripropylene glycol diacrylate),Trimethylolpropane trimethacrylate (trimethylolpropane triacrylate),Pentaerythritol triacrylate (pentaerythritol triacrylate),Dipentaerythritol acrylate (dipentaerythritol hexaacrylateDPHA),Biphenylyloxy ethyl propylene acid esters (polyethylene glycol o-phenylphenyl etheracrylate),Halogenated propene acid biphenyl epoxy ethyl ester (halogenated biphenylepoxyethyl acrylate),Alkoxide epoxy diacrylate (alkoxylated epoxy diacrylate),Halogenation alkoxide epoxy diacrylate (halogenated alkoxylated epoxy diacrylate),Aliphatic urethane diacrylate (aliphaticurethane diacrylate),The acrylate of aliphatic polyurethane six (aliphatic urethane hexaacrylate),The acrylate of aromatic urethane six (aromatic urethane hexaacrylate),Or the mixture of they.It is preferred that monomer be iso-bornyl acrylate, 2- phenoxyethyl acrylates, tripropylene glycol diacrylate, trimethylolpropane trimethacrylate, pentaerythritol triacrylate, dipentaerythritol acrylate or its mixture.
The example of commercial acrylate class monomer includes：Produced by Eternal companies, trade name 
Or
Person.
Molecular weight available for acrylate quasi-oligomer of the invention is about between 1,000 to 100,000, and its species is such as, but not limited to：Acrylate (acrylate), such as 2- hydroxyl -3- benzene oxygen propyl acrylates (2-hydroxy-3-phenoxypropyl acrylate)；Methacrylate (methacrylate)；The polyurethane of urethane acrylate (urethane acrylate), such as aliphatic urethane acrylate (aliphaticurethane acrylate), aliphatic urethane diacrylate (aliphatic urethanediacrylate), the acrylate of aliphatic polyurethane six (aliphatic urethane hexaacrylate), the acrylate of aromatic urethane six (aromatic urethane hexaacrylate) or acrylate ended；Epoxy acrylate (epoxy acrylate), such as bisphenol A epoxy diacrylate (bisphenol-A epoxy diacrylate) or Epoxy Phenolic Acrylates (novolac epoxyacrylate)；Or its mixture.Preferably acrylate, methacrylate, aliphatic urethane acrylate, aliphatic urethane diacrylate, the acrylate of aliphatic polyurethane six, the acrylate of aromatic urethane six, bisphenol A epoxy diacrylate or its mixture.
The example of commercial acrylate quasi-oligomer includes：Produced by Sartomer Company, trade name
OrPerson；Produced by Eternal companies, trade name 6101-
611A-
6112-
6144-
6145-6150-
6160B-
621A-
Or 621-
Person；And produced by UCB. S.A. (BE) Bruxelles Belgium, trade name Ebecryl
Ebecryl
Ebecryl
Or EbecrylPerson.
The weight ratio (Rw) of component (i) and component (ii) is defined as follows in coating composition of the present invention：
Wherein Wi is the weight of component (i), and Wii is the weight of component (ii).Rw can be used to adjust the surface roughness (or difference of height of concave-convex micro-structure) of the concave-convex micro-structure layer of diffusion barrier of the present invention, and pass through the light scattering effect of the obtained diffusion barrier of this control.For example, according to an embodiment of the present invention, component (i) is modified alkyd resin, component (ii) is the mixture of acrylic ester monomer and acrylate quasi-oligomer, and Rw is preferably the scope between about 0.1 to about 0.8, the more preferably scope between 0.1 5 to about 0.6.In this embodiment, when Rw is less than 0.1, component (i) content is very few, excessively sparse and protrusion is too small in the protrusion density of substrate surface formation, it is impossible to reach the required light scattering effect of the present invention；When Rw is more than 0.8, component (i) easily forms a continuous level in substrate surface, and surface roughness is not enough, it is impossible to reach required light scattering effect.
According to the embodiment of the present invention, component (i) has the proportion more than component (ii).In this embodiment, because the proportion of component (i) is more than the proportion of component (ii), during forming coating and drying removal solvent, component (i) is easier to, effectively it can not only be attached on base material, utilization ratio is lifted, the contact area of component (ii) and base material can be more reduced, it is easily peeled off (peeling) with base material.According to the better embodiment of the present invention, the proportion of component (i) is about 1.25 to about 1.4, and the proportion of component (ii) is about 0.8 to about 1.2.According to another embodiment of the present invention, the adhesive force of component (ii) and base material is less than the adhesive force of component (i) and base material, now more favourable removal in component (ii).
To make coating composition to be uniformly coated on base material, component (iii) used in the present invention be one kind can simultaneously dissolved constituents (i) and component (ii) to produce a homogeneous solvent.The solvent of inventor's the theoretical analysis and widely studied discovery dissolved constituents (i) and component (ii) can be selected according to following principle：1. polarity phase approximately principle, solubility parameter 2. (solubility parameter) phase approximately principle, solvation 3. (solvation) principle, in general, component (i) and component (ii) have the solubility parameter and/or polarity close with component (iii) respectively, now component (iii) easy effectively dissolved constituents (i) and component (ii), forms a homogeneous phase solution.For example, if the alkyd resin that component (i) selection is modified through toluene di-isocyanate(TDI), solubility parameter is about 8.7 (cal/cm3)0.5To about 11.1 (cal/cm3)0.5, component (ii) selection acrylic ester monomer and acrylate quasi-oligomer mixture, solubility parameter is about 8.8 (cal/cm3)0.5To about 9.9 (cal/cm3)0.5, then solubility parameter may be selected between above-mentioned component (i) and component (ii) between the two or with both above-mentioned close solvents as component (iii), such as, but not limited to：Xylene solvent (solubility parameter 8.8 (cal/cm3)0.5), toluene solvant (solubility parameter 8.9 (cal/cm3)0.5) or methyl ethyl ketone solvent (solubility parameter 9.3 (cal/cm3)0.5)。
Solvation refers to that the active force between solute and solvent molecule is more than the active force between solute molecule, so that solute molecule is separated and dissolved in a solvent each other.Therefore, if strong dipole effect is produced between component (i) and component (ii) and component (ii), can occur solvation, in other words, component (iii) molecule produces interaction to component (i) molecule and component (ii) molecule respectively, when active force is more than the cohesive force of component (i) and component (ii) itself, component (iii) is also possible to dissolved constituents (i) and component (ii).
The species of visual component (i) and component (ii) of the invention selects appropriate solvent to be used as component (iii).For example, when it is the mixture of acrylic ester monomer and acrylate quasi-oligomer that component (i), which is modified alkyd resin and component (ii), solvent (iii) can be benzene class, esters or ketone or its mixture.Above-mentioned benzene kind solvent is such as, but not limited to：Benzene, toluene, ortho-xylene, meta-xylene, paraxylene, trimethylbenzene, styrene or its mixture.Above-mentioned esters solvent is such as, but not limited to：Ethyl acetate, butyl acetate, diethyl carbonate, Ethyl formate, methyl acetate, ethoxyethyl acetate(EA), ethoxypropyl ester, monomethyl ether propylene glycol ester or its mixture.Above-mentioned ketones solvent is such as, but not limited to：Acetone, methyl ethyl ketone, methyl iso-butyl ketone (MIBK) or its mixture.
The coating composition of the present invention can optionally include additive known to any persond having ordinary knowledge in the technical field of the present invention, its be such as, but not limited to antistatic additive, curing agent, light initiator, fluorescent whitening agent, ultra-violet absorber, inorganic particles, wetting agent (wetting agent), defoamer (defoamer), flat dose, levelling agent (leveling agent), lubrication prescription (slipping agent), dispersant (dispersant) or stabilization agent.
According to an embodiment of the present invention, coating composition of the invention further includes light trigger (photo initiator).Suitable for the light trigger of the present invention, it is that free radical can be produced after light irradiation, and pass through the transmission initiated polymerization person of free radical, it is such as, but not limited to benzophenone (benzophenone), diphenylhydroxyethanone (benzoin), benzil (benzil), 2, 2- dimethoxys -1, 2- diphenyl second -1- ketone (2, 2-dimethoxy-1, 2-diphenylethan-1-one), 1- hydroxycyclohexylphenylketones (1-hydroxy cyclohexyl phenyl ketone), 2, 4, 6- trimethylbenzene first anilides diphenyl phosphine oxide (2, 4, 6-trimethylbenzoyl diphenyl phosphine oxide；TPO) or its combination.
The solid content of the coating composition of the present invention, with the gross weight meter of coating composition, typically about 15 weight % to about 75 weight %, preferably from about 30 weight % to about 65 weight %.When solid content is less than 15 weight %, because solid content is very few, easily occurs the flow phenomenon that hangs down；When solid content is more than 75 weight %, because solid content is too high, easily cause that viscosity is too high, the not good shortcoming of coating.
The preparation method of the coating composition of the present invention, can be person known to any persond having ordinary knowledge in the technical field of the present invention, and can be allocated according to the difference of component under appropriate environment.According to an embodiment of the present invention, coating composition of the invention is prepared after each component is sufficiently mixed at about 25 DEG C.
It is person known to persond having ordinary knowledge in the technical field of the present invention by the mode that aforementioned coating composition is applied to base material formation coating, it is such as, but not limited to：Scraper type coating (knife coating), roller coating (roller coating), micro- gravure (micro gravure coating), flow coat (flow coating), impregnation coating (dip coating), spraying coating (spray coating) and curtain apply (curtain coating).According to one of present invention embodiment, coating method is to adopt roller coating.
After coating, the present invention removes solvent from coating using drying.Because solvent is removed during drying, component (i) produces phase separation with component (ii) based on characteristic incompatible to each other, therefore component (ii) can be removed from coating after the drying, the concave-convex micro-structure based on component (i) is left on base material.Depending on the temperature and time of above-mentioned drying, the species of visual solvent.According to an embodiment of the present invention, drying temperature is typically about 60 DEG C to about 140 DEG C, and preferably from about 100 DEG C to about 120 DEG C, drying time is typically about 10 seconds to about 80 seconds, preferably from about 20 seconds to about 60 seconds.
In addition, to be more beneficial for component (ii) stripping, particularly when component (ii) is the form of monomer or oligomer, after the present invention can be if necessary in removal solvent, using energy ray curing component (ii), then by component (ii) from coating stripping.Energy-ray used, can have person known to usually intellectual, such as, but not limited to for any the technical field of the invention：Heat energy, radiation energy and electron beam (e-beam), it is possible to use more than two kinds of energy-ray is simultaneously or sequentially solidified.Above-mentioned radiation energy includes infrared light, visible ray, ultraviolet (UV light) and laser (laser).According to an embodiment of the present invention, curing mode used is ultraviolet curing (UV curing), and its exposure intensity may generally be 100 to 1000 millijoules/square centimeter (mJ/cm2), preferably 200 to 800 mJ/cm2。
As described earlier in this article, can be by surface roughness or the difference of height of concave-convex micro-structure of the weight than the concave-convex micro-structure layer obtained by adjustment of component (i) in coating composition and component (ii), to obtain preferably light scattering effect.In addition, the condition that can be also processed by control, such as drying temperature or time, the surface roughness or the difference of height of concave-convex micro-structure of the obtained concave-convex micro-structure layer of adjustment.According to an embodiment of the present invention, the arithmetic mean roughness (Ra) of the concave-convex micro-structure layer is about 0.2 μm to about 2 μm, preferably from about 0.4 μm to 1.5 μm, its 10 mean roughness (Rz) are about 2 μm to about 12 μm, preferably from about 3 μm to about 7 μm.
The present invention diffusion barrier manufacture the concave-convex micro-structure except that can be coated on coating composition on plastic basis material, can also other well known optical film (for example：Scattered reflection film (diffusion reflectivefilm), condensing film (brightness enhance film), reflection polarizing film (reflectivepolarizing film) or any light requirement homogenize the blooming piece of function) it is processed as base material, the concave-convex micro-structure is manufactured, passes through the light diffusion effect of this lifting diaphragm.
The diffusion barrier of the present invention has according to JIS K7136 standard methods measurement is not less than 5%, is preferably the mist degree (haze) between about 15% to about 75%；And be preferably the total light transmittance (total light transmittance) between about 70% to about 95% with being not less than 50%.
According to an embodiment of the present invention, the diffusion barrier of the present invention includes PET base material, the base material at least side includes concave-convex micro-structure layer, wherein described concave-convex micro-structure layer is with such as the phase disengagement method of present invention formation and is made up of the alkyd resin being modified through toluene di-isocyanate(TDI), and the diffusion barrier is measured with the mist degree not less than 5% and the total light transmittance not less than 50% with JIS K7136 standard methods.
The diffusion barrier of the present invention is not required to extra surface treatment step, and the adherence of gained microstructured layers and base material is still good, therefore can reduce manufacturing cost, lifts industrial utilization.Diffusion barrier obtained by the present invention has concave-convex micro-structure, using in light supply apparatus, such as being used in there is provided light diffusion effect in LCD backlight module, above-mentioned concave-convex micro-structure can be located at the exiting surface of base material, incidence surface or its both, the preferably exiting surface of base material.In addition, the diffusion barrier of the present invention is free of diffusion particle, it can avoid assembling or sticking because of diffusion particle influenceing the problem of uniformity of diffusing light, and diffusion particle settle or come off caused.
Following examples be used for the invention will be further described, and be not used to limit the scope of the present invention.It is any to be familiar with modification and change that the personage of this skill be easily achievable and be included in the range of this case specification disclosure and appended claim.
Preparation example 1
One 250 milliliters of vials are taken, 30.0 grams of dipentaerythritol acrylates, 6.0 grams of trimethylolpropane trimethacrylates, 42.0 grams of pentaerythritol triacrylates, 84.0 grams of acrylate of aliphatic polyurethane six are sequentially added【Etercure 6145-100, Eternal companies】And light trigger：18.0 grams of 1- hydroxycyclohexylphenylketones.Finally obtained solid is 100% and always weighs about 180 grams of mixture.
Preparation example 2
One 100 milliliters of vials are taken, component (iii) is sequentially added：46.5 grams of toluene solvants, component (ii) and light trigger：Mixture, the component (i) of 26.6 grams of preparation examples 1：26.6 grams of ricinoleyl alcohol acid resins for being modified through toluene di-isocyanate(TDI)【Eterkyd 5010-S-50, Eternal companies, solid about 50%】.Solid 40% finally is made and the coating composition of 100 grams of clears is always weighed about.
Preparation example 3
One 100 milliliters of vials are taken, component (iii) is sequentially added：52.0 grams of toluene solvants, component (ii) and light trigger：Mixture, the component (i) of 32.0 grams of preparation examples 1：16.0 grams of ricinoleyl alcohol acid resins [Eterkyd 5010-S-50, Eternal companies, solid about 50%] for being modified through toluene di-isocyanate(TDI).Solid 40% finally is made and the coating composition of 100 grams of clears is always weighed about.
Preparation example 4
One 100 milliliters of vials are taken, component (iii) is sequentially added：54.4 grams of toluene solvants, component (ii) and light trigger：Mixture, the component (i) of 34.2 grams of preparation examples 1：11.4 grams of ricinoleyl alcohol acid resins [Eterkyd 5010-S-50, Eternal companies, solid about 50%] for being modified through toluene di-isocyanate(TDI).Solid 40% finally is made and the coating composition of 100 grams of clears is always weighed about.
Embodiment 1
Coating composition obtained by preparation example 2 is coated on as 188 μm of transparent PET base material [TAIRILIN BH116 by thickness using RDS paint daubs #8, South Asia Plastics Company] coating is formed on surface, dried through 100 DEG C after removing solvent within 1 minute, again with UV exposure bench [Fusion UV, F600V, 600 W/inch, H types lamp source], the mJ/cm2 of energy-ray 200 is solidified, followed by adhesive tape [Scotch #610, 3M companies] paste the component (ii) after coating surface stripping solidification, diffusion barrier of the gross thickness for 190 μm of tool concave-convex micro-structure is made.
Embodiment 2
30 seconds removal solvents are dried using method same as Example 1, but using 110 DEG C of temperature, diffusion barrier of the gross thickness for 190 μm of tool concave-convex micro-structure is made.
Embodiment 3
Using method same as Example 1, but change and be coated with the coating composition obtained by preparation example 3, diffusion barrier of the gross thickness for 190 μm of tool concave-convex micro-structure is made.
Embodiment 4
Using method same as Example 1, but change and be coated with the coating composition obtained by preparation example 4, diffusion barrier of the gross thickness for 190 μm of tool concave-convex micro-structure is made.
Comparative example 1
Ricinoleyl alcohol acid resin [the Eterkyd 5010-S-50 that will be modified through toluene di-isocyanate(TDI), Eternal companies, solid about 50%], thickness is coated on as 188 μm of transparent PET base material [TAIRILIN BH116 using RDS paint daubs #8, South Asia Plastics Company] on surface, dried through 100 DEG C after removing solvent within 1 minute, the diffusion barrier that gross thickness is 190 μm is made.
Comparative example 2
The mixture of preparation example 1 is coated on the transparent PET base material [TAIRILINBH116 that thickness is 188 μm, South Asia Plastics Company] on surface, again with UV exposure bench [Fusion UV, F600V, 600 W/inch, H types lamp source], the mJ/cm2 of energy-ray 200 is solidified, and the diffusion barrier that gross thickness is 190 μm is finally made.
Comparative example 3
Ricinoleyl alcohol acid resin [the Eterkyd 5010-S-50 that will be modified through toluene di-isocyanate(TDI), Eternal companies, solid about 50%], thickness is coated on as 188 μm of transparent PET base material [TAIRILIN BH116 using the roller that the surface of blasting treatment has concaveconvex structure indentation, South Asia Plastics Company] on surface, dried through 100 DEG C after removing solvent within 1 minute, the diffusion barrier that average thickness is 190 μm is finally made.
Method of testing：
Thickness is tested：Utilize film thickness gauge【Model PIM-100, TESA companies】, the thickness that the way of contact measures coating to be measured is pushed with 1N.
Mist degree/total light transmittance test：Utilize haze meter【Model NDH 5000W, Japanese electricity Se companies】, according to JIS K-7136 standard methods, the mist degree (Hz%) and total light transmittance (Tt%) of coating to be measured are measured, test acquired results are as shown in following table 1.
Surface roughness is tested：Utilize roughmeter [model Surftest SJ-201, Mitsutoyo companies], arithmetic mean roughness (the Ra of coating to be measured is measured according to JIS B-0601 standard methods, unit μm) and 10 mean roughness (Rz, unit μm), test acquired results are as shown in following table 1.
Adherence is tested：Utilize hundred lattice scrapers [model C ross-cut Guide CCJ-1, CHUO SEIMITSUKIKI companies] scratch film coated surface, then with adhesive tape sticking film, torn up again with 90 °, judge to peel off lattice number, adherence of the coating to be measured for PET base material is measured according to JIS K-5400 standard methods, test acquired results are as shown in following table 1.
The diffusion barrier Nature comparison table of the embodiment of table 1 and comparative example
| The weight ratio (Rw) of component (i) and component (ii) | Hz % | Tt % | Adherence is tested | R a | R z | |
| Embodiment 1 | 0.56 | 60. 12 | 89. 15 | Coating is without coming off | 0. 51 | 3. 77 |
| Embodiment 2 | 0.56 | 70. 77 | 91. 33 | Coating is without coming off | 0. 85 | 5. 45 |
| Embodiment 3 | 0.28 | 33. 04 | 89. 14 | Coating is without coming off | 1. 11 | 5. 42 |
| Embodiment 4 | 0.19 | 17. 35 | 89. 13 | Coating is without coming off | 0. 47 | 5. 11 |
| The weight ratio (Rw) of component (i) and component (ii) | Hz % | Tt % | Adherence is tested | R a | R z | |
| Comparative example 1 | 1/0 | 2.3 0 | 88. 19 | Coating is without coming off | ||
| Comparative example 2 | 0/1 | 2.5 0 | 89. 42 | Coating shedding | ||
| Comparative example 3 | 1/0 |
* part resin residue occurs in coating process for comparative example 3 on roller, causes coating to fail.
Embodiment 1 is observed respectively with light microscope to the surface micro-structure of the diffusion barrier of embodiment 4, gained figure is as shown in Figures 1 to 4.From Fig. 1 to 4 result, when component (i) ratio is lower, the ups and downs density of obtained diffusion barrier is more sparse.
From the result of embodiment 1 to 4：The weight of component (i) and component (ii) is than that can influence the mist degree and total light transmittance of diffusion barrier.Component (i) ratio is lower, and the mist degree of obtained diffusion barrier is relatively low.Therefore, the need for visually actually applying, by adjusting component (i) from the ratio of component (ii) to prepare the various diffusion barriers with different mist degrees and total light transmittance.
From the result of embodiment 1 and 2：Embodiment 1 and 2 uses identical coating composition, but embodiment 2 is dried with higher temperature and short period, and the diffusion barrier of gained has higher mist degree.Therefore, in addition to it can adjust scattering nature of the component (i) with the ratio of component (ii) to control diffusion barrier, also, to adjust the property of gained diffusion barrier, it can be made more to meet the demand in practical application by controlling the process parameters such as drying temperature and/or time.
Transparent PET base material is close with component (i) material character used in embodiment 1 to 4, and adhesive force is good, can be tested by adherence, and obtained concave-convex micro-structure layer occurs with base material without obscission.
As shown in Table 1：The diffusion barrier of comparative example 1 and 2 only has the coating formed by component (i) or component (ii), and surface is generated without obvious concave-convex micro-structure, therefore its mist degree is only respectively 2.3% and 2.5%, it is impossible to provide effective light diffusion effect.In addition, the coating of comparative example 1 is made up of component (i), material character is close with base material, and adhesive force is good, can be tested by adherence；Conversely, the coating of comparative example 2 is made up of component (ii), the poor adhesive force after its solidification with base material is completely fallen off after adherence test.
Claims (18)
1. a kind of diffusion barrier, it includes a base material and the concave-convex micro-structure layer positioned at the base material at least side, the diffusion barrier is measured with the mist degree not less than 5% and the total light transmittance not less than 50% according to JIS K7136 standard methods, wherein concave-convex micro-structure layer is formed by the method comprised the following steps：
(a) following component is mixed to form a coating composition：
(i) a kind of polymer by being constituted with the same or analogous material of base material principal component；
(ii) material incompatible with component (i)；And
(iii) solvent；
(b) coating composition is coated at least side of the base material and forms a coating；
(c) coating is dried to remove component (iii), and wherein component (i) produces phase separation during drying with component (ii)；And
(d) component (ii) is removed to form the concave-convex micro-structure.
2. diffusion barrier as claimed in claim 1, it is characterised in that the method for the formation concave-convex micro-structure layer is further included：After step (c) and before step (d), use energy ray curing component (ii).
3. diffusion barrier as claimed in claim 1, characterized in that, the base material is made up of by plastic basis material and the resin selected from the group being made up of polyester resin, polyacrylate resin, vistanex, polycyclic alkene resin, polyimide resin, polycarbonate resin, polyurethane resin, Triafol T, PLA and combinations thereof.
4. diffusion barrier as claimed in claim 1, it is characterised in that the base material is polyester resin, component (i) is polyester resin or alkyd resin or its mixing.
5. diffusion barrier as claimed in claim 4, it is characterised in that the base material is PET, component (i) is the alkyd resin being modified through toluene di-isocyanate(TDI).
6. diffusion barrier as claimed in claim 4, it is characterised in that component (ii) is selected from the group being made up of acrylate monomer, acrylate oligomer, acrylate polymer and combinations thereof.
7. diffusion barrier as claimed in claim 1, it is characterised in that the coating composition further includes additive.
8. diffusion barrier as claimed in claim 1, it is characterised in that the weight ratio of component (i) and component (ii) is between 0.1 to 0.8.
9. diffusion barrier as claimed in claim 1, it is characterised in that the proportion of component (i) is more than the proportion of component (ii).
10. diffusion barrier as claimed in claim 6, it is characterised in that component (iii) is benzene class, esters or ketone or its mixture.
11. diffusion barrier as claimed in claim 1, it is characterised in that it has the mist degree between 15% to 75% and the total light transmittance between 70% to 95% with JIS K7136 standard methods measurement.
12. a kind of method for the diffusion barrier for manufacturing tool concave-convex micro-structure, it is included：
(a) base material is provided；
(b) following component is mixed to form a coating composition：
(i) a kind of polymer by being constituted with the same or analogous material of base material principal component；
(ii) a kind of material incompatible with component (i)；And
(iii) solvent；
(c) with coating method, the coating composition is coated at least side of the base material and forms a coating；
(d) coating is dried to remove component (iii), and wherein component (i) produces phase separation during drying with component (ii)；And
(e) component (ii) is removed to form the concave-convex micro-structure.
13. method as claimed in claim 12, it is characterised in that the coating method be selected from being coated with by scraper type, roller coating, micro- gravure, flow coat, impregnation coating, spraying coating and the constituted group of curtain painting.
14. method as claimed in claim 13, it is characterised in that the coating method is roller coating.
15. method as claimed in claim 12, it is characterised in that it is further included：After step (d) and before step (e), use energy ray curing component (ii).
16. method as claimed in claim 15, it is characterised in that the energy-ray is selected from by heat energy, radiation energy and electron beam or and the constituted group of combination.
17. method as claimed in claim 15, it is characterised in that the energy-ray is ultraviolet.
18. a kind of diffusion barrier, it includes a PET base material, the base material at least side includes concave-convex micro-structure layer, wherein described concave-convex micro-structure layer is formed with phase disengagement method, and the concave-convex micro-structure is made up of the alkyd resin being modified through toluene di-isocyanate(TDI), the diffusion barrier is measured with the mist degree not less than 5% and the total light transmittance not less than 50% according to JISK7136 standard methods.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103939844A (en) * | 2013-01-17 | 2014-07-23 | 鸿富锦精密工业（深圳）有限公司 | Diffusion sheet and backlight module |
| CN109581577A (en) * | 2019-01-03 | 2019-04-05 | Oppo（重庆）智能科技有限公司 | Display screen component and electronic device with it |
| CN113015934A (en) * | 2019-08-29 | 2021-06-22 | 京东方科技集团股份有限公司 | Polaroid, display panel and display device |
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| WO1995031737A1 (en) * | 1994-05-18 | 1995-11-23 | Dai Nippon Printing Co., Ltd. | Glare-proof film |
| US6352759B2 (en) * | 1998-08-20 | 2002-03-05 | Physical Optics Corporation | Non-lambertian glass diffuser and method of making |
| JP4384506B2 (en) * | 2004-01-06 | 2009-12-16 | ダイセル化学工業株式会社 | Antiglare film |
| KR101154807B1 (en) * | 2004-01-29 | 2012-06-18 | 닛폰 비 케미컬 가부시키 가이샤 | Antidazzle coating composition, antidazzle film and process for producing the same |
| JP4826069B2 (en) * | 2004-05-31 | 2011-11-30 | 凸版印刷株式会社 | Light diffusing sheet, lenticular sheet and transmissive screen provided with the light diffusing sheet |
| JP2006078808A (en) * | 2004-09-10 | 2006-03-23 | Nippon Sheet Glass Co Ltd | Manufacturing method of article formed of protruding part group on surface, and article manufactured thereby |
| WO2006035649A1 (en) * | 2004-09-27 | 2006-04-06 | Nitto Denko Corporation | Process for producing surface-roughened sheet, surface-roughened sheet, and antiglare sheet |
| US20060148915A1 (en) * | 2004-12-30 | 2006-07-06 | Floyd Robert M | Microporous materials and methods of making |
| TWI318172B (en) * | 2005-11-23 | 2009-12-11 | Eternal Chemical Co Ltd | Optical thin sheet |
| US7842376B2 (en) * | 2006-05-24 | 2010-11-30 | Zhijian Lu | Diffusers and methods of manufacture |
| TWI607231B (en) * | 2007-07-04 | 2017-12-01 | 琳得科股份有限公司 | Hard coat film |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103939844A (en) * | 2013-01-17 | 2014-07-23 | 鸿富锦精密工业（深圳）有限公司 | Diffusion sheet and backlight module |
| CN109581577A (en) * | 2019-01-03 | 2019-04-05 | Oppo（重庆）智能科技有限公司 | Display screen component and electronic device with it |
| CN113015934A (en) * | 2019-08-29 | 2021-06-22 | 京东方科技集团股份有限公司 | Polaroid, display panel and display device |
| CN113015934B (en) * | 2019-08-29 | 2024-01-05 | 京东方科技集团股份有限公司 | Polarizer, display panel and display device |
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Address after: China's Taiwan City, Kaohsiung three people's District, 578 road construction Patentee after: Changxing material industry limited-liability company Address before: China's Taiwan City, Kaohsiung three people's District, 578 road construction Patentee before: Changxing Chemical Industrial Co., Ltd. |
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