CN110549706A - Optical sheet, method for manufacturing optical sheet, and display device - Google Patents

Optical sheet, method for manufacturing optical sheet, and display device Download PDF

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Publication number
CN110549706A
CN110549706A CN201910462421.9A CN201910462421A CN110549706A CN 110549706 A CN110549706 A CN 110549706A CN 201910462421 A CN201910462421 A CN 201910462421A CN 110549706 A CN110549706 A CN 110549706A
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CN
China
Prior art keywords
layer
optical sheet
polymer substrate
resin
quantum dot
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CN201910462421.9A
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Chinese (zh)
Inventor
金大植
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Kolon Industries Inc
Kolon Corp
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Kolon Corp
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Publication date
Priority claimed from KR1020190062081A external-priority patent/KR20190136956A/en
Application filed by Kolon Corp filed Critical Kolon Corp
Publication of CN110549706A publication Critical patent/CN110549706A/en
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/28—Multiple coating on one surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2551/00—Optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133614—Illuminating devices using photoluminescence, e.g. phosphors illuminated by UV or blue light

Abstract

The present invention provides an optical sheet, a method of manufacturing the same, and a display device including the same, the optical sheet of the present invention includes: a quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin; and a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer sequentially formed on at least one surface of the quantum dot resin layer, the quantum dot resin layer and the inorganic barrier layer being located on the optical sheet with a predetermined distance therebetween.

Description

Optical sheet, method for manufacturing optical sheet, and display device
Technical Field
The invention relates to an optical sheet, a method for manufacturing the optical sheet, and a display device.
Background
Quantum Dots (QDs) are semiconductor substances having a crystal structure of several nanometers in size, and have characteristics of emitting light of different wavelengths depending on the size, and when such Quantum dots are used as a fluorescent substance or a light-emitting substance, it is known that the characteristics of a display can be improved or the Quantum dots can be used as the display itself. The quantum dots as described above are incorporated and used in small amounts in, for example, a polymer optical sheet installed in a backlight Unit (BLU).
However, quantum dots have a problem of oxidation due to surface oxidation when exposed to moisture and oxygen in the air, and as a method for solving such a problem, a polymer resin in which quantum dots are dispersed is generally bonded between two inorganic barrier films and then cured to produce an optical sheet. Such an optical sheet is disposed above the light guide plate of the blue backlight unit BLU module (on-surface method), and can be applied to various screen sizes from a small display to a large display.
The optical sheet as described above has a barrier (barrier) performance to moisture and oxygen to some extent due to the inorganic barrier film, but has a problem in that the barrier performance of the barrier film is drastically reduced when exposed to high temperature and high humidity conditions. Therefore, there is a disadvantage that the luminance of the optical sheet cannot be stably maintained.
In particular, as shown in fig. 6, there has been known an optical sheet having a structure in which inorganic barrier layers are formed on both sides of a quantum dot resin layer and a substrate layer is formed thereon, and such an optical sheet may damage the inorganic barrier layers by coating using an embossing Roll (Pattern Roll) or the like in a manufacturing process, thereby causing a problem in that quantum dots are damaged by moisture or oxygen in the air.
Disclosure of Invention
Technical problem to be solved
The invention provides an optical sheet which has a more stable and firm structure, can protect a quantum dot resin layer from moisture and oxygen, and can prevent an inorganic barrier layer from being damaged due to the pressure of an embossing roller during lamination.
another object of the present invention is to provide a method for manufacturing an optical sheet having a more stable and strong structure, capable of protecting a quantum dot resin layer from moisture and oxygen, and capable of preventing an inorganic barrier layer from being damaged by pressure applied by an embossing roller when the quantum dot resin layer is laminated.
It is another object of the present invention to provide a display device including the optical sheet.
Means for solving the problems
The present invention provides an optical sheet comprising: a quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin; the quantum dot resin layer is formed on at least one surface of the substrate layer; the distance between the quantum dot resin layer and the inorganic barrier layer is 10 μm or more.
The first polymer substrate layer, the inorganic barrier layer, and the second polymer substrate layer may be sequentially stacked on both surfaces of the quantum dot resin layer.
The first polymeric substrate layer may have a thickness of 10 to 150 μm or 15 to 100 μm, and the second polymeric substrate layer may have a thickness of 3 to 50 μm or 5 to 25 μm.
The present invention may further comprise: and the bonding layer is positioned between the first high polymer substrate layer and the inorganic barrier layer and has the thickness of 1-10 mu m.
The present invention may further comprise: and a continuous coating layer (in-line coating layer) formed on at least one surface of the first polymer substrate layer and including a thermoplastic resin.
The continuous coating may have a thickness of 10nm to 300nm or 50nm to 120 nm.
The thermoplastic resin contained in the continuous coating layer may contain one or more polymer resins selected from the group consisting of polyurethane, polyacrylate, and polyester.
the present invention may further comprise: and the protective coating is positioned between the quantum dot resin layer and the continuous coating formed on one surface of the first polymer substrate layer.
The protective coating may have a thickness of 0.1 μm to 10 μm or 1 to 8 μm.
The protective coating may comprise a polymeric resin selected from the group consisting of epoxy resins, unsaturated polyester resins, polyurethane resins, polycarbonate polyurethanes, polyester polyurethanes, phenolic resins, melamine resins, urea resins, silicone resins, and mixtures thereof.
The first polymer substrate layer and the second polymer substrate layer may each include a polymer resin selected from the group consisting of olefin-based resins, polystyrene-based resins, acrylonitrile-styrene copolymers, acrylonitrile-butadiene-styrene copolymers, polymethacrylic resins, polycarbonate-based resins, polyester-based resins, nylon-containing polyamide-based resins, polyurethane-based resins, acetal-based resins, cellulose-based resins, and mixtures thereof.
the inorganic barrier layer may have a thickness of 10nm to 300 nm.
The inorganic barrier layer may include one or more metals selected from the group consisting of Si, Al, In, Sn, Zn, Zr, Ti, Cu, Ce, Yt, La, Ba, Mg, F2, Sb, Sr, and Ta, and oxides, nitrides, carbides, oxynitrides, oxycarbides, and nitrogen or oxynitride carbides thereof.
Further, the present invention provides a method of manufacturing an optical sheet, comprising: and a step of bonding a barrier laminate including a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer on a quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin.
The quantum dot resin layer and the barrier laminate may be bonded by a method selected from the group consisting of an embossing roll, a non-patterned lamination, and a direct coating.
Also, the present invention provides a display device including the optical sheet.
effects of the invention
According to the present invention, it is possible to provide an optical sheet, a method for manufacturing the same, and a display device including the same, which have a more stable and firm structure, can protect a quantum dot resin layer from moisture and oxygen, and can prevent an inorganic barrier layer from being damaged by pressing of an embossing roller when the quantum dot resin layer is laminated.
Drawings
FIG. 1 is a schematic view of an optical sheet of one embodiment of the invention.
FIG. 2 is another schematic view of an optical sheet of an embodiment of the invention.
Fig. 3 is a schematic view of an optical sheet manufactured in example 4.
Fig. 4 is a schematic view of an optical sheet manufactured in example 5.
Fig. 5 is a schematic view of an optical sheet manufactured in example 6.
Fig. 6 is a schematic view of an optical sheet including a previously known quantum dot resin layer.
Fig. 7 is a schematic view of an optical sheet manufactured in comparative example 1.
Detailed Description
The optical sheet, the method for manufacturing the optical sheet, and the display device according to the embodiment of the invention will be described in more detail below.
According to an embodiment of the present invention, there may be provided an optical sheet including: a quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin; and a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer sequentially formed on at least one surface of the quantum dot resin layer, wherein a distance between the quantum dot resin layer and the inorganic barrier layer is 10 μm or more.
There has been known a barrier film for QLED which has a problem that barrier (barrier) performance is drastically reduced when exposed to high temperature and high humidity conditions, and an inorganic layer in the barrier film is damaged when the barrier film is coated on a Quantum Dot (QD) resin by an embossing roll method, so that the QD is damaged by moisture or oxygen in the air after the QD Sheet is manufactured.
In view of the above, the present inventors have continued research on optical laminates including a quantum dot resin layer, and have experimentally confirmed that optical sheets including a quantum dot resin layer and a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer, and having a distance between the quantum dot resin layer and the inorganic barrier layer of 10 μm or more have a more stable and firm structure, and can protect the quantum dot resin layer from moisture and oxygen, and can prevent the inorganic barrier layer from being damaged by pressure applied by an embossing roller during lamination, and can stably protect the quantum dot resin layer from moisture, oxygen, and the like, thereby completing the present invention.
Fig. 1 is a schematic view generally showing a cross-sectional structure of an optical sheet of the embodiment.
In the optical sheet of the present embodiment, unlike other conventionally known optical laminates including barrier films for QLEDs or quantum dot resin layers, the first polymer substrate layer is located between the quantum dot resin layer and the inorganic barrier layer, and the distance between the quantum dot resin layer and the inorganic barrier layer is set to 10 μm or more, whereby the above-described effects can be achieved.
When the distance between the quantum dot resin layer and the inorganic barrier layer is less than 10 μm, the internal structure of the optical sheet may become relatively unstable, and the inorganic barrier layer may be damaged by the pressure applied by the embossing roller during lamination.
The distance between the quantum dot resin layer and the inorganic barrier layer may be 10 μm or more, 40 μm or more, 60 μm or more, or 10 μm to 150 μm, or 15 μm to 100 μm.
The distance between the quantum dot resin layer and the inorganic barrier layer may be determined according to the thickness of the first polymer substrate layer or another layer that may be additionally used.
Specifically, the thickness of the first polymer substrate layer may be 10 to 150 μm or 15 to 100 μm, and the thickness of the second polymer substrate layer may be 3 to 50 μm or 5 to 25 μm. When the thickness of each of the first polymer substrate layer and the second polymer substrate layer is too thin, the inorganic barrier layer may be damaged to cause a problem of lowering the barrier performance. When the thicknesses of the first polymer substrate layer and the second polymer substrate layer are too thick, the thickness of the entire optical sheet increases, which may cause a problem of reduction in optical characteristics.
The optical sheet according to the embodiment may have a structure in which a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer are sequentially stacked on both surfaces of the quantum dot resin layer. Fig. 2 is a schematic diagram generally showing a cross-sectional structure of such an optical sheet.
The optical sheet of the embodiment may further include: and the bonding layer is positioned between the first high polymer substrate layer and the inorganic barrier layer and has the thickness of 1-10 mu m. Fig. 3 is a schematic view schematically showing a cross-sectional structure of such an optical sheet, and a first polymer substrate layer, an adhesive layer, an inorganic barrier layer, and a second polymer substrate layer may be formed in this order on both surfaces of the quantum dot resin layer.
The adhesive layer is a component used for bonding the first polymer substrate layer and the inorganic barrier layer, and can improve the adhesion between the first polymer substrate layer and the inorganic barrier layer, and can have adhesion reliability (heat resistance) in a high-temperature and high-humidity environment. As the binder, a binder commonly used in the art can be used without limitation, and examples thereof include an epoxy-based binder, a clay having a nano size (or a nanoclay composite), and the like. More specifically, the specific components of the adhesive layer are not largely limited, and may be formed from a curable resin composition containing an epoxy acrylate resin, a urethane acrylate, a two-liquid type urethane adhesive, or the like.
The amount of the binder used is not particularly limited, and may be variously changed depending on the areas, types, and the like of the first polymer substrate layer and the inorganic barrier layer.
The thickness of the adhesive layer is also not greatly limited, and the adhesive layer preferably has a thickness of 1 to 10 μm in order to avoid greatly increasing the overall thickness while ensuring stability of the internal structure of the optical sheet of the embodiment.
In addition, the optical sheet of an embodiment of the invention may further include: and the continuous coating is formed on at least one surface of the first polymer substrate layer and comprises thermoplastic resin. That is, the continuous coating layer may be formed between the quantum dot resin layer and the first polymer substrate layer, or between the first polymer substrate layer and the inorganic barrier layer.
The continuous coating layer can improve the adhesion between the portions including the quantum dot resin layer and the first polymer substrate layer, the inorganic barrier layer, and the second polymer substrate layer, and more effectively prevent damage of the inorganic barrier layer based on the embossing roller.
Further, as compared with the case of using a conventional protective coating layer (comparative example 1), the adhesion between the quantum dot resin layer and the first polymer substrate layer, and the adhesion between the inorganic barrier layer and the second polymer substrate layer can be improved, and when an adhesive layer is additionally used, the adhesion between the first polymer substrate layer and the inorganic barrier layer can be remarkably improved, and interlayer bonding of the internal structure can be further strengthened.
the thermoplastic resin contained in the continuous coating layer may contain one or more polymer resins selected from the group consisting of polyurethane, polyacrylate, and polyester.
Specific examples of the polyurethane include urethane resins, copolymers of urethane resins and polyether resins, and copolymers of urethane resins and polyester resins. Specific examples of the polyacrylate include copolymers of acrylic resins and polyether resins, and copolymers of acrylic resins and polyester resins.
In addition, the thickness of the continuous coating layer is not largely limited, and the continuous coating layer may have a thickness of 10nm to 300nm or 50nm to 120nm in consideration of a bonding force between the quantum dot resin layer and the first polymer substrate layer or a bonding force between the first polymer substrate layer and the inorganic barrier layer, etc.
in addition, the optical sheet of an embodiment of the invention may further include: and the protective coating is positioned between the quantum dot resin layer and the continuous coating formed on one surface of the first polymer substrate layer.
The protective coating layer (Over coating layer) can improve the adhesion between the quantum dot resin layer and the first polymer substrate layer and improve the high-temperature and high-humidity adhesion reliability. The combination mechanism of the protective coating and the quantum dot resin layer is described simply, and unreacted functional groups (unreacted groups) of the protective coating and the quantum dot resin layer are combined with each other, so that the improvement of the adhesive force is realized.
Examples of the component contained in the protective coating layer include epoxy resin, unsaturated polyester resin, polyurethane resin, polycarbonate polyurethane, polyester polyurethane, phenol resin, melamine resin, urea resin, silicone resin, and a mixture thereof.
And, the protective coating layer may have a thickness of 0.1 to 10 μm or 1 to 8 μm in consideration of a bonding force between the quantum dot resin layer and the first polymer substrate layer, etc.
The first polymer substrate layer and the second polymer substrate layer may each include an olefin-based resin, a polystyrene-based resin, an acrylonitrile-styrene copolymer (AS resin), an acrylonitrile-butadiene-styrene copolymer (ABS resin), a polymethacrylic resin, a polycarbonate-based resin, a polyester-based resin such AS polyethylene terephthalate PET and polyethylene naphthalate PEN, a nylon-containing polyamide-based resin, a polyurethane-based resin, an acetal-based resin, a cellulose-based resin, and a mixture thereof, which have excellent optical characteristics.
In addition, the quantum dot resin layer may include a polymer resin and quantum dots dispersed in the polymer resin.
The thickness of the quantum dot resin layer may be 10um to 100 um. In the case where the thickness of the quantum dot resin layer is less than 10um, in order to satisfy a predetermined level of color conversion properties, the quantum dots need to be present at a higher density than the thick resin layer, and in such a case, the interval between the quantum dots becomes very narrow, so that there may occur a case where the efficiency is lowered due to acceleration of degradation (degradation) of the quantum dots caused by heat generated during light emission, or a case where the efficiency is lowered due to continuous absorption of light absorbed from a primary light source and secondarily emitted by other quantum dots present nearby. In addition, when the thickness of the quantum dot resin layer is greater than 100um, although there may be no or low efficiency reduction due to high-density quantum dots, there may be a problem of a reduction in thickness uniformity in a coating process, a problem of curling (curl) when a product is wound, a reduction in winding amount per roll, a defect in a final product using a large-diameter core, and an economic problem such as an increase in production cost when the product is manufactured.
Patterning may be performed on one or both sides of the quantum dot resin layer. The amount of quantum dots used can be significantly reduced by the patterning, so that economy can be ensured. When passing through such a pattern, a part of the light is reused by reflection, and the number of times and probability of meeting the quantum dots are increased, so that the amount of the quantum dots can be reduced to ensure economy.
The quantum dot is substantially a single crystalline nanostructure, and can absorb primary light emitted from a light source and emit secondary light, and can emit light having different wavelengths depending on the size of the quantum dot.
The quantum dots may have a representative size of 1nm to 10nm, may emit secondary light having red color after absorbing primary light from a light source in the case where the size of the quantum dots is 4nm to 5nm, and may emit secondary light having green color after absorbing primary light from a light source in the case where the size of the quantum dots is 2nm to 3 nm.
The quantum dots may be uniformly dispersed in the polymer resin, or when the polymer resin layer has a multilayer structure, quantum dots having different sizes may be arranged for each layer, or quantum dots having different sizes may be mixed and arranged in a single layer.
The quantum dots may comprise any suitable inorganic material, and may be, for example, cadmium-based quantum dots or non-cadmium-based quantum dots.
The non-cadmium quantum dots may include one or more inorganic materials selected from the group consisting of Si, Ge, Sn, Se, Te, B, C, P, BN, BP, Bas, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, InN, InP, InAs, InSb, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, ZnO, ZnS, ZnSe, ZnTe, HgS, HgSe, HgTe, BeS, BeSe, BeTe, MgS, MgSe, GeS, GeSe, GeTe, SnS, SnSe, SnTe, PbTe, PbO, PbS, PbSe, PbTe, CuF, CuCl, Br, CuI, Si 3 N 4, Ge 3 N 4, and combinations thereof.
the quantum dots may be organic or inorganic alone or a mixture (hybrid) of organic and inorganic.
The quantum dots may be individually composed of a core (core) and a shell (shell) surrounding the core, and the core and the shell may have a core, core/shell, core/first shell/second shell, alloy/shell, or the like, which is individually composed of group II-IV, group III-V, group IV-VI, group IV semiconductors, and mixtures thereof, or the like, respectively, but the present invention is not limited thereto.
For example, the core may include one or more selected from the group consisting of CdS, CdSe, CdTe, ZnS, ZnSe, ZnTe, HgS, HgSe, HgTe, GaN, GaP, GaAs, InP, InAs, and alloys thereof, but the present invention is not limited thereto. The shell surrounding the core may include one or more selected from the group consisting of CdSe, ZnSe, ZnS, ZnTe, CdTe, PbS, TiO, SrSe, HgSe, and alloys thereof, but the present invention is not limited thereto.
For example, the quantum dots having the core/shell structure or the alloy structure may be CdSe/ZnS, CdSe/ZnSe/ZnS, CdSe/CdSx (Zn1-yCdy) S/ZnS (x and y are respectively a real number greater than 0 and less than 1 individually), CdSe/CdS/ZnCdS/ZnS, InP/Ga/ZnS, InP/ZnSe/ZnS, PbSe/PbS, CdSe/CdS/ZnS, CdTe/CdS, CdTe/ZnS, CuInS 2/ZnS, Cu 2 SnS 3/ZnS, etc.
In addition, the inorganic barrier layer may have a thickness of 10nm to 300 nm. The thickness of the inorganic barrier layer may be 10nm to 300nm, preferably 100nm to 250nm, in consideration of the barrier property and the optical property (especially, luminance of QD Sheet). In the case where the thickness of the inorganic barrier layer is less than 10nm, oxygen and moisture permeation prevention characteristics may be degraded, and in the case where the thickness of the inorganic barrier layer is greater than 300nm, it may be difficult to maximize optical characteristics of the membrane.
More specifically, the inorganic barrier layer may include one or more metals selected from the group consisting of Si, Al, In, Sn, Zn, Zr, Ti, Cu, Ce, Yt, La, Ba, Mg, F 2, Sb, Sr, and Ta, and oxides thereof, nitrides thereof, carbides thereof, oxynitrides thereof, oxycarbides thereof, and nitrogen or oxynitride carbides thereof.
In addition, according to actual needs, the optical sheet of the embodiment may further include a back-coating (or anti-wet out) layer formed on the second polymer substrate layer.
the back coating layer may be used to prevent interference with the backlight panel, and a substance used in the art to achieve the above-described function may be used without particular limitation. In addition, in the case where barrier films are bonded to both surfaces of the quantum dot resin layer, respectively, the back coating layer may be laminated on only one of the two barrier films.
In addition, according to another embodiment of the present invention, there may be provided a method of manufacturing an optical sheet, including: and a step of bonding a barrier laminate including a first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer on a quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin.
According to the manufacturing method of the optical sheet, the optical sheet of the one embodiment having the above-described features can be provided.
In the method for producing an optical sheet, the quantum dot resin layer and the barrier layer laminate may be bonded by a method selected from the group consisting of embossing (pattern roll), non-pattern lamination (non-pattern lamination), and direct coating (direct coating).
In addition, the method of manufacturing the optical sheet may include: step a), coating a binding agent on one surface of a first polymer substrate layer; step b), coating an inorganic substance on one surface of the second polymer substrate layer to form an inorganic barrier layer; and c), laminating and bonding the adhesive coated on the first polymer substrate layer in the step a) and the second polymer substrate layer formed with the inorganic barrier layer in the step b).
The first polymer substrate layer and the second polymer substrate layer may be formed in various manners such as an extrusion process, and the lamination may be performed in a general manner known in the art.
In the method for manufacturing the QLED barrier film, the order of the step a) and the step b) is set for convenience of description, and the present invention is not limited thereto, and the step b) may be performed prior to the step a), and the step a) and the step b) may be performed simultaneously without departing from the scope of the present invention.
In addition, the manufacturing method of the optical sheet may further include, before or after the step a) of applying the adhesive, as needed: a step of forming a continuous coating layer (In-coating layer) on one surface or both surfaces of the first polymer substrate layer (In the case of forming a continuous coating layer on both surfaces of the first polymer substrate layer, it is preferable to form a continuous coating layer before applying an adhesive).
The continuous coating layer may be formed by wet-coating (wet-coating) or the like, and may be formed at a time by, for example, extrusion and stretching processes when the first polymer substrate layer is formed.
further, the method of manufacturing the optical sheet may further include: and forming a protective coating layer (Over coating layer) on the other side of the first polymer substrate layer which is not coated with the adhesive. The protective coating layer as described above may be formed by wet coating, UV curing, or the like, and for example, the protective coating layer may be formed by coating a certain amount of coating liquid on the substrate by MG Roll, drying (Dry) to remove a part of the solvent, and then UV curing.
In addition, according to still another embodiment of the present invention, a display device including the optical sheet may be provided.
The display device may be a liquid crystal display device, and may be a light emitting diode (light emitting diode) including a light source.
The present invention is explained in more detail in the following examples. However, the following examples are merely illustrative of the present invention, and the contents of the present invention are not limited to the following examples.
[ example 1]Preparation of Barrier laminates
An epoxy acrylate resin (Tesk, A-2697grade) was diluted with Methyl Ethyl Ketone (Methyl Ethyl Ketone) solvent, and 3 parts by weight of a photoinitiator (Igacure 184) was added based on 100 parts by weight of the epoxy acrylate resin and sufficiently dissolved, thereby preparing an adhesive layer composition having a solid content of 20 wt%.
further, the adhesive layer composition was coated on one surface of a polyethylene terephthalate (PET, first polymer) substrate having a thickness of 75 μm formed through an extrusion process, in a thickness of 5 μm.
One surface of a 12 μm-thick polyethylene terephthalate substrate formed by an extrusion process was subjected to plasma pretreatment using a roll-to-roll evaporator, and then Dry Coating (Dry Coating) was performed to a total thickness of 70nm of 10nm of AlO X/60nm of SiO X, followed by Coating of silicon oxide SiO 2 to form an inorganic barrier layer.
Next, the adhesive applied to the first polymer substrate and the inorganic barrier layer formed on the second polymer substrate were laminated and joined, thereby preparing a barrier laminate of example 1.
[ example 2]Preparation of Barrier laminates
In example 1 (before the adhesive is applied to the first polymer substrate), after Polyurethane (Polyurethane, elas 5700/KOLON) layers (continuous coating layers) as thermoplastic resins were formed on both sides of the first polymer substrate in a thickness of 80nm through an extrusion and stretching process, a barrier laminate was prepared in the same manner as in example 1 except that the adhesive layer composition of example 1 was applied to one of the continuous coating layers.
[ example 3]Preparation of Barrier laminates
(1) Production of protective coatings
A urethane acrylate (UV curable resin, 8BR/Taisei Fine Chemical) and 100 parts by weight of polyurethane (thermoplastic resin, elas 5700/KOLON) based on 100 parts by weight of the urethane acrylate were mixed with a Methyl Ethyl Ketone (MEK) solvent, and then 10 parts by weight of a Silane Coupling agent (OFS 6020/DOW), 1 part by weight of an anti-hydrolysis agent (ALTFONA5151/Green Chem), and 7.5 parts by weight of a photoinitiator (Irgacure184/CIBA) based on 100 parts by weight of the urethane acrylate were added as additives, and stirred to prepare a coating liquid.
(2) Manufacture of optical sheets
A barrier laminate was produced by performing the same as in example 2, except that in example 2, the prepared coating liquid was applied on the continuous coating surface not coated with the binder by means of a wire bar (mayer bar), a bar coater (bar coater), or an applicator (applicator) to form a protective coating (thickness: 5 μm).
[ examples 4 to 6]Manufacture of optical sheets
Each of the barrier laminates prepared in examples 1 to 3 was attached to both surfaces of two 95 μm layers of Quantum dot resin (UV curable, nano systems) by means of an emboss roller, thereby manufacturing an optical sheet (Quantum dot sheet).
Comparative example 1]manufacture of optical sheets
as shown in fig. 7, two general QLED barrier films, in which a 1 μm protective coating layer, a 0.1 μm inorganic layer, a 12 μm PET layer, an adhesive, and a 75 μm PET layer were sequentially laminated, were attached to both sides of a quantum dot resin layer by embossing rollers, thereby manufacturing an optical sheet.
[ Experimental example 1]Evaluation of moisture/oxygen permeation into Quantum dot resin layer
The optical sheets manufactured from examples 4 to 6 and comparative example 1 were placed on a BLUE LED panel and left under high temperature and high humidity (60 ℃, 90% r.h) conditions for 1000 hours, and then the surface shape was confirmed.
At this time, the number of black spots per m2 was confirmed to be several, and the moisture/oxygen permeability of the quantum dot resin layer in the quantum dot chip was confirmed using a wvtr, otr apparatus, and the results thereof are shown in table 1 below.
[ Table 1]
As a result of evaluating the moisture/oxygen permeability of the opposing quantum dot resin layers, as shown in table 1, it was confirmed that a very small amount of moisture or oxygen permeated into the quantum dot resin layers included in the optical sheets of examples 4 to 6, while a large amount of moisture and oxygen permeated into the quantum dot resin layers included in the optical sheet of comparative example 1.
This is a result corresponding to whether the inorganic barrier layer which cuts off moisture and oxygen is damaged or not, and it can be confirmed that the inorganic barrier layer included in the optical sheet of examples 4 to 6 is hardly damaged, whereas the inorganic barrier layer included in the optical sheet of comparative example 1 is damaged. Also, when a quantum dot chip is placed on the BLUE LED panel, unlike embodiments 4 to 6, black speckles occur in the case of comparative example 1, which can be considered as a result of a reduction in the lifetime (Life Time) of the quantum dot particles due to a reduction in barrier performance.
the above results are based on the embossing roll process in the manufacture of the quantum dot sheet, which is a result corresponding to the optical sheet of examples 4 to 6 having a more stable structure than the optical sheet of comparative example 1, and being able to prevent the inorganic barrier layer from being damaged by the pressing of the embossing roll when the lamination is performed, thereby being able to stably protect the quantum dot resin layer from moisture, oxygen, and the like.
[ Experimental example 2]Quantum dot resin and structural stability of barrier laminate
With respect to the quantum dot sheets manufactured in examples 4 to 6, the bonding force between the quantum dot resin layer and the inorganic barrier layer was confirmed, and the stability of the internal structure of each of the optical sheets manufactured in examples 4 to 6 and comparative example 1 was evaluated, and the structural stability of the quantum dot resin and the barrier laminate was shown in table 2 below.
[ TABLE 2 ]
As a result of evaluating the bonding force between the quantum dot resin layer and the barrier layer integrated body, as shown in table 2, it was confirmed that example 6 in which the continuous coating layer and the protective coating layer were laminated exhibited a bonding force of 1000gf/inch or more, example 5 in which only the continuous coating layer was laminated exhibited a bonding force of about 970gf/inch, and the optical sheet of example 4 exhibited a bonding force of about 522 gf/inch.

Claims (16)

1. An optical sheet comprising:
A quantum dot resin layer including a polymer resin and quantum dots dispersed in the polymer resin; and
A first polymer substrate layer, an inorganic barrier layer, and a second polymer substrate layer sequentially formed on at least one side of the quantum dot resin layer,
The distance between the quantum dot resin layer and the inorganic barrier layer is 10 μm or more.
2. The optical sheet according to claim 1,
And sequentially laminating the first polymer substrate layer, the inorganic barrier layer and the second polymer substrate layer on two surfaces of the quantum dot resin layer.
3. The optical sheet according to claim 1,
The thickness of the first polymer substrate layer is 10-150 μm,
The thickness of the second polymer substrate layer is 3-50 μm.
4. The optical sheet according to claim 1, further comprising:
And the bonding layer is positioned between the first high polymer substrate layer and the inorganic barrier layer and has the thickness of 1-10 mu m.
5. The optical sheet according to claim 1, further comprising:
And the continuous coating is formed on at least one surface of the first polymer substrate layer and comprises thermoplastic resin.
6. The optical sheet according to claim 5,
The continuous coating has a thickness of 10nm to 300 nm.
7. The optical sheet according to claim 5,
The thermoplastic resin includes one or more polymer resins selected from the group consisting of polyurethane, polyacrylate, and polyester.
8. The optical sheet of claim 5, further comprising:
And the protective coating is positioned between the quantum dot resin layer and the continuous coating formed on one surface of the first polymer substrate layer.
9. the optical sheet according to claim 8,
The protective coating has a thickness of 0.1 μm to 10 μm.
10. the optical sheet according to claim 8,
The protective coating comprises a polymeric resin selected from the group consisting of epoxy resins, unsaturated polyester resins, polyurethane resins, polycarbonate polyurethanes, polyester polyurethanes, phenolic resins, melamine resins, urea resins, silicone resins, and mixtures thereof.
11. the optical sheet according to claim 1,
The first polymer substrate layer and the second polymer substrate layer each include a polymer resin selected from the group consisting of olefin-based resins, polystyrene-based resins, acrylonitrile-styrene copolymers, acrylonitrile-butadiene-styrene copolymers, polymethacrylic resins, polycarbonate-based resins, polyester-based resins, nylon-containing polyamide-based resins, polyurethane-based resins, acetal-based resins, cellulose-based resins, and mixtures thereof.
12. The optical sheet according to claim 1,
The inorganic barrier layer has a thickness of 10nm to 300 nm.
13. The optical sheet according to claim 1,
The inorganic barrier layer contains one or more metals selected from the group consisting of Si, Al, In, Sn, Zn, Zr, Ti, Cu, Ce, Yt, La, Ba, Mg, F 2, Sb, Sr, and Ta, and oxides, nitrides, carbides, oxynitrides, oxycarbides, and nitrogen or oxynitride carbides thereof.
14. A method for producing an optical sheet, comprising a step of bonding a barrier laminate comprising a first polymer substrate layer, an inorganic barrier layer and a second polymer substrate layer to a quantum dot resin layer comprising a polymer resin and quantum dots dispersed in the polymer resin.
15. The method of manufacturing an optical sheet according to claim 14,
the quantum dot resin layer and the barrier laminate are bonded by a method selected from the group consisting of embossing, non-patterned lamination, and direct coating.
16. A display device comprising the optical sheet according to claim 1.
CN201910462421.9A 2018-05-31 2019-05-30 Optical sheet, method for manufacturing optical sheet, and display device Withdrawn CN110549706A (en)

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Application publication date: 20191210