CN112248581A

CN112248581A - Ultrathin glass-organic film composite cover plate based on roll-to-roll process and manufacturing method thereof

Info

Publication number: CN112248581A
Application number: CN202011115525.1A
Authority: CN
Inventors: 韦新颖; 李欢乐; 张磊; 李晟洙
Original assignee: Tuomi Chengdu Applied Technology Research Institute Co ltd
Current assignee: Chengdu Tuomi Shuangdu Photoelectric Co ltd
Priority date: 2020-10-19
Filing date: 2020-10-19
Publication date: 2021-01-22
Anticipated expiration: 2040-10-19
Also published as: CN112248581B

Abstract

The invention discloses an ultrathin glass-organic film composite cover plate based on a roll-to-roll process and a manufacturing method thereof. The manufacturing method solves the problem of UTG stiffness by attaching UTG to the surface of the support, and the support can be used as a part of a product protective film, so that the manufacturing process can be reduced, and the cost can be saved; by adding a thickness balance medium layer around UTG and carrying out surface treatment on UTG, the surface energy of UTG and the balance medium layer can be unified, and the coating film on the whole surface of UTG is ensured to be uniform; the side coating is naturally wrapped, so that the influence of the UTG side microcracks is weakened, and the product performance is improved; the laser cutting ensures that the product edge is neat and has no defects of residual films, burrs and the like, and the roll-to-roll manufacturing mode has larger capacity and higher benefit than the sheet-to-sheet mode.

Description

Ultrathin glass-organic film composite cover plate based on roll-to-roll process and manufacturing method thereof

Technical Field

The invention relates to the technical field of flexible display terminal accessories, in particular to an ultrathin glass-organic film composite cover plate based on a roll-to-roll process and a manufacturing method thereof.

Background

As an interactive interface of the flexible display terminal, the flexible cover plate not only needs to provide necessary protection for the display terminal, but also needs to have the characteristics of high visible light transmittance, comfortable hand feeling, high surface hardness, strong bending resistance and the like. The current technology development mainly focuses on both organic films and ultra-thin glass (UTG <100um), but a single technology cannot meet the requirements of people on flexible cover plates, so that the UTG-organic film composite cover plate becomes the current compromise.

According to the technical characteristics of UTG-organic film composite cover plate preparation, the method can be roughly divided into a film-coated type and a coating type, wherein the film-coated type is a preparation method of attaching an organic film to the surface of UTG by using Optical Clear Adhesive (OCA) as a binder, and has the advantages of simple process and low equipment cost, but the defects are obvious, such as high cost of supplied organic film, and the product thickness is limited by thicker supplied material and complex structure; the coating method is to use the precursor solution of the organic film as the raw material and coat the precursor solution on the surface of UTG to obtain the organic film, which has the advantages of good adhesion, bending resistance, flexible design of film thickness according to the product requirement and thinner overall thickness of the product, and has the disadvantages of high equipment construction cost and incapability of changing the appearance size of the UTG material according to the design size of the product in the subsequent process, so that the whole UTG surface is an effective area of the product, and the macroscopic defects of ' picture frame ' or ' fat edge ', stripe mura ' and ' tear drop ' are not allowed to appear particularly at the edge of UTG.

However, UTG is thin and has low stiffness, so it cannot be processed alone and must be attached to a certain substrate to be processed. Therefore, the height difference between the surface to be coated of UTG and the substrate and the difference between the surface energies of the surface to be coated and the substrate are always the root of fatal defects of products, and the greatest problem is faced in realizing mass production of the coating type UTG-organic film composite cover plate.

Disclosure of Invention

In view of the defects of the prior art, the invention provides a production method of a reel-to-reel UTG/organic film composite cover plate, which is suitable for mass production and can reduce the defects of products caused by the height difference between the surface to be coated of UTG and a base material and the difference of the surface energy of the base material.

To this end, an aspect of the present invention provides an ultra-thin glass-organic film composite cover plate based on a roll-to-roll process, the composite cover plate comprising ultra-thin glass, a first organic film layer formed on at least one side surface of the ultra-thin glass, and a black pattern layer on or below the surface of the first organic film layer, wherein the composite cover plate is manufactured using a roll-to-roll process.

Further, the roll-to-roll process comprises the steps of:

step S1: preparing a first coiled material formed by coating or attaching an adhesive layer on the surface of a support coiled material, uniformly attaching a plurality of pieces of ultrathin glass on the surface of the adhesive layer of the first coiled material, integrally attaching an organic film with the thickness consistent with that of the ultrathin glass on the surfaces of the ultrathin glass and the adhesive layer to form a thickness balance medium layer, cutting and removing the thickness balance medium layer on the surface of the ultrathin glass along the edge of the ultrathin glass, and exposing the surface to be processed of the ultrathin glass;

or preparing a second coiled material comprising a support, and a bonding layer and a thickness balance medium layer which are sequentially formed on the surface of the support from bottom to top, cutting and removing the thickness balance medium layer in a preset shape on the second coiled material according to the preset shape of the ultrathin glass to form a plurality of ultrathin glass accommodating grooves, and respectively attaching a plurality of ultrathin glasses in the plurality of ultrathin glass accommodating grooves and exposing the surfaces of the ultrathin glasses to be processed;

step S2: sequentially carrying out ultraviolet irradiation, cleaning and drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode;

step S3: uniformly coating a layer of first organic film precursor solution on the surface of one side, which is exposed out of the surface to be processed of the ultrathin glass, of the obtained coiled material in a slit coating or atomizing spraying mode, and removing the solvent to form a first organic film layer; carrying out plasma treatment on the first organic film layer, and forming a black pattern layer on the surface of the first organic film layer;

or carrying out plasma treatment on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, and forming a black pattern layer on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass; uniformly coating a layer of first organic film precursor solution on the surface of one side of the obtained coiled material, including the black pattern layer, by using a slit coating or atomizing spraying mode after plasma treatment, and removing the solvent to form a first organic film layer;

step S4: and cutting along the edge of the ultrathin glass on the obtained coiled material to separate the ultrathin glass from surrounding materials, and finally cutting according to a preset product size to obtain the flaky ultrathin glass-organic film composite cover plate.

Further, the support in the first coil or the second coil is glass, polymer or stainless steel, the polymer is polyimide, polyethylene terephthalate, polyethylene naphthalate, polystyrene or polyurethane, wherein when the support is polymer, the first coil or the second coil is subjected to a dimensional stabilization heat treatment.

Further, the adhesive layer is a silica gel material or an acrylic material, and the peeling force of the adhesive layer and the ultrathin glass during peeling is not more than 15g/in and the adhesive layer can resist temperature of at least 120 ℃.

Further, the thickness balance medium layer is a polyethylene terephthalate film, a polyethylene naphthalate film, a polystyrene film or a polyurethane film, and the diameter of the winding drum in the first winding drum or the second winding drum is set to be larger than the stiffness of the ultrathin glass after being bent along the winding drum and smaller than the peeling force between the ultrathin glass and the bonding layer.

Further, when the thickness balance dielectric layer is cut in step S1, a step of cutting an alignment mark for forming the black pattern layer is further included; in step S3, the black pattern layer is formed by coating a black photoresist layer by slit coating or spray coating, and is formed by exposure-development using the alignment mark after pre-curing or by curing after directly printing a black pattern by screen printing.

Further, the composite cover plate further comprises a second organic film layer formed on the other side surface of the ultrathin glass and a hardening layer formed on the second organic film layer, wherein the first organic film layer and the second organic film layer are transparent polyimide layers, polyethylene terephthalate layers, polyethylene naphthalate layers, polystyrene layers or polyurethane layers.

Further, the roll-to-roll process further includes the following steps performed between step S3 and step S4:

step a: attaching another first coiled material to one side of the coiled material obtained in the step S3, wherein the first coiled material is formed on the first organic film layer, removing the original first coiled material on the coiled material obtained in the step S3, transferring the ultrathin glass, the first organic film layer formed on one side surface of the ultrathin glass, and the black pattern layer positioned on the surface of the first organic film layer or below the surface of the first organic film layer to the other first coiled material together, and exposing the surface to be processed of the ultrathin glass on the other side;

step b: sequentially carrying out ultraviolet irradiation, cleaning and drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode;

step c: uniformly coating a layer of second organic film precursor solution on the surface of one side, which is exposed out of the surface to be processed of the ultrathin glass, of the obtained coiled material in a slit coating or atomizing spraying mode, and removing the solvent to form a second organic film layer; and carrying out plasma treatment on the second organic film layer, and forming a hardened layer on the surface of the second organic film layer.

Further, the roll-to-roll process further includes a step of winding up the roll material after the non-adhesive protective film is coated after each step is performed and a step of removing the non-adhesive protective film and unwinding the roll material before each step is performed.

In another aspect, the present invention provides a method for manufacturing an ultra-thin glass-organic film composite cover plate based on a roll-to-roll process, the method comprising the steps of:

Further, the adhesive layer is a silica gel material or an acrylic UV (ultraviolet) debonding material, and the peeling force of the adhesive layer and the ultrathin glass during peeling is not more than 15g/in and can resist the temperature of 120 ℃ at least.

Further, the thickness balance medium layer is a polyethylene terephthalate film, a polyethylene naphthalate film, a polystyrene film or a polyurethane film, and the diameter of the winding drum in the coiled material is set to be larger than the bending stiffness of the ultrathin glass after being bent along the winding drum and smaller than the peeling force between the ultrathin glass and the bonding layer.

Further, when the thickness balance dielectric layer is cut in step S1, a step of cutting an alignment mark for forming the black pattern layer is further included; in step S3, the black pattern layer is formed by coating a black matrix photoresist by slit coating or spray coating, and is formed by exposure-development using the alignment mark after pre-curing or by curing after directly printing a black pattern by screen printing.

Further, the manufacturing method further comprises the following steps performed between the step S3 and the step S4 to form a second organic film layer and a hardened layer on the second organic film layer on the other side surface of the ultra-thin glass:

Further, the first organic film layer and the second organic film layer are a transparent polyimide layer, a polyethylene terephthalate layer, a polyethylene naphthalate layer, a polystyrene layer, or a polyurethane layer.

Further, the peeling force between the adhesive layer of the other first roll and the ultra-thin glass, the first organic film layer formed on one side surface of the ultra-thin glass, and the black pattern layer located at or below the surface of the first organic film layer is not less than the peeling force between the adhesive layer of the first roll and the ultra-thin glass in the step S1.

Further, the transfer mechanism used in the transfer process comprises a support roller, a peeling roller and a static eliminator, wherein the diameter of the peeling roller is set to be in accordance with the separation of the ultrathin glass, the first organic film layer formed on one side surface of the ultrathin glass, the black pattern layer positioned on the surface of the first organic film layer or below the surface of the first organic film layer and the bonding layer of the first coiled material, and the peeling roller and the support roller are both provided with heating functions.

Further, coating a hardening layer material on the surface of the second organic film layer by adopting a spraying or slit coating mode, baking for 2-5 minutes at 90-130 ℃, and then using 800-1000 mj/cm in air or nitrogen²The hardened layer is formed by ultraviolet curing.

Further, the manufacturing method further comprises the steps of winding up the web after the non-adhesive protective film is coated after each step is performed and removing the non-adhesive protective film and unwinding the web before each step is performed.

In another aspect, the invention provides an ultrathin glass-organic film composite cover plate based on a roll-to-roll process, which is manufactured by the manufacturing method of the ultrathin glass-organic film composite cover plate based on the roll-to-roll process.

The manufacturing method of the ultrathin glass-organic film composite cover plate based on the roll-to-roll process solves the problem of UTG stiffness by attaching UTG to the surface of the support, and meanwhile, the support can also be used as a part of a product protective film, so that the manufacturing process can be reduced, and the cost is saved; by adding a thickness balance medium layer around UTG and carrying out surface treatment on UTG, the surface energy of UTG and the balance medium layer can be unified, and the coating film on the whole surface of UTG is ensured to be uniform; the laser cutting ensures that the product edge is neat and has no defects of residual films, burrs and the like, and the roll-to-roll manufacturing mode has larger capacity and higher benefit than the sheet-to-sheet mode.

Drawings

Fig. 1 is a schematic view illustrating an operation principle of a method for manufacturing an ultra-thin glass-organic film composite cover plate based on a roll-to-roll process according to an exemplary embodiment of the present invention.

Fig. 2 is a schematic structural view illustrating an ultra-thin glass-organic film composite cover plate manufactured based on a roll-to-roll process in example 1.

Fig. 3 is a schematic structural view illustrating an ultra-thin glass-organic film composite cover plate manufactured based on a roll-to-roll process in example 2.

Fig. 4 is a schematic view illustrating an operation principle of a transfer mechanism in a method for manufacturing an ultra-thin glass-organic film composite cover plate based on a roll-to-roll process according to an exemplary embodiment of the present invention.

Fig. 5A illustrates a schematic structural view of a product before transfer in a method for manufacturing an ultra-thin glass-organic film composite cover sheet based on a roll-to-roll process according to an exemplary embodiment of the present invention; fig. 5B illustrates a schematic structural view of a product in transfer in a method of manufacturing an ultra-thin glass-organic film composite cover sheet based on a roll-to-roll process according to an exemplary embodiment of the present invention; fig. 5C shows a schematic view of a transferred product structure in a method for manufacturing an ultra-thin glass-organic film composite cover plate based on a roll-to-roll process according to an exemplary embodiment of the present invention.

Detailed Description

All of the features disclosed in this specification, or all of the steps in any method or process so disclosed, may be combined in any combination, except combinations of features and/or steps that are mutually exclusive.

Any feature disclosed in this specification may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.

The ultrathin glass-organic film composite cover plate based on the roll-to-roll process comprises ultrathin glass, a first organic film layer at least formed on one surface of the ultrathin glass, a black pattern layer positioned on the surface of the first organic film layer or below the first organic film layer, a second organic film layer formed on the other surface of the ultrathin glass, a hardening layer HC formed on the second organic film layer, and functional layers such as an anti-fingerprint layer AF, an anti-reflection layer AR and an anti-dazzle layer AG formed on the hardening layer, so that the performances such as the surface hardness, the optical effect and the like of the cover plate are further enhanced. The ultra-thin glass (UTG) used in the present invention is a glass having a thickness of 100 μm or less, preferably 30 to 100 μm, and is commercially available.

The first organic film layer and the second organic film layer of the present invention may be a transparent polyimide layer, a polyethylene terephthalate layer, a polyethylene naphthalate layer, a polystyrene layer, or a polyurethane layer, and preferably may be formed by applying an organic film precursor solution and then curing the organic film precursor solution to form an organic film.

According to the invention, the ultrathin glass-organic film composite cover plate is manufactured based on a roll-to-roll process, but the roll-to-roll process adopted by the invention is different from the prior art, and the process improvement is also carried out based on the root problem of the defects of the product.

According to an exemplary embodiment of the present invention, the above roll-to-roll process includes the following steps.

Step S1:

preparing a first coiled material formed by coating or attaching an adhesive layer on the surface of a support coiled material, uniformly attaching a plurality of pieces of ultrathin glass on the surface of the adhesive layer of the first coiled material, integrally attaching a layer of organic film with the thickness consistent with that of the ultrathin glass on the surfaces of the ultrathin glass and the adhesive layer to form a thickness balance medium layer, cutting and removing the thickness balance medium layer on the surface of the ultrathin glass along the edge of the ultrathin glass, exposing the surface to be processed of the ultrathin glass, and collecting the coiled material;

or preparing a second coiled material which comprises a support, a bonding layer and a thickness balance medium layer, wherein the bonding layer and the thickness balance medium layer are sequentially formed on the surface of the support from bottom to top, cutting and removing the thickness balance medium layer in a preset shape on the second coiled material according to the preset shape of the ultrathin glass to form a plurality of ultrathin glass accommodating grooves, and respectively attaching a plurality of ultrathin glasses in the plurality of ultrathin glass accommodating grooves and exposing the surfaces to be processed of the ultrathin glasses.

UTG is thin and has low stiffness, and therefore, it must be attached to a substrate to be processed. The support in the first web or the second web as substrate in the present invention may be glass, polymer or stainless steel, wherein the polymer may be polyimide, polyethylene terephthalate, polyethylene naphthalate, polystyrene or polyurethane. Particularly, when the support is a polymer, the first coil or the second coil is subjected to a dimensional stabilization heat treatment, such as baking in a furnace at 100 to 160 ℃ for 0.5 to 2 hours. By attaching UTG to the surface of the support, on one hand, the stiffness problem of UTG is solved, and on the other hand, the support can also be used as a part of a product protective film, so that the manufacturing process can be reduced, and the cost can be saved.

Moreover, the height difference between the surface to be coated of UTG and the substrate and the difference between the surface energies of the surface to be coated and the substrate are always the root of fatal defects of products, and the greatest problem is faced in realizing mass production of the coating type UTG-organic film composite cover plate. As shown in fig. 1, the present invention provides an adhesive layer on the support to facilitate the attachment of UTG to the process. The adhesive layer can be made of silica gel materials or acrylic UV (ultraviolet) debonding materials, and the peeling force between the adhesive layer and the ultrathin glass is not more than 15g/in and can resist the temperature of 120 ℃ at least.

In addition, the invention also adds a thickness balancing medium layer to balance the surface energy among materials, and can ensure that the whole surface of UTG is uniformly coated. The thickness balance medium layer can be a polyethylene terephthalate film, a polyethylene naphthalate film, a polystyrene film or a polyurethane film, the diameter of the winding drum in the first winding drum or the second winding drum is set to be greater than the bending stiffness of the ultrathin glass after the winding drum is bent and smaller than the peeling force between the ultrathin glass and the bonding layer, and the situation that the glass after the ultrathin glass is attached affects subsequent processing procedures is avoided.

As one of the two preferred embodiments of the present invention, the bonding layer and the thickness balance medium layer may be separately formed on the support in sequence, wherein after the bonding layer is formed, a plurality of pieces of ultra-thin glass are attached according to the arrangement requirement, then an organic film having a thickness consistent with that of the ultra-thin glass is integrally attached to form the thickness balance medium layer, then the thickness balance medium layer on the surface of the ultra-thin glass is cut and removed along the edge of the ultra-thin glass, and the surface to be processed of the ultra-thin glass is exposed, and at this time, the thickness of the surface to be processed of the ultra-thin glass is consistent with that of the surrounding thickness balance medium layer, thereby overcoming the problems of the difference in height between.

As another preferred embodiment of the present invention, a coiled material that already includes a support, a bonding layer, and a thickness balance medium layer may be directly used, at this time, the thickness balance medium layer with a predetermined shape is cut and removed from the thickness balance medium layer according to the arrangement requirement and the predetermined shape of the ultra-thin glass, so as to form a plurality of ultra-thin glass accommodating grooves that can accommodate the ultra-thin glass, and then the ultra-thin glass is attached to the ultra-thin glass accommodating grooves and the surface to be processed of the ultra-thin glass is exposed, and at this time, the thickness of the surface to be processed of the ultra-thin glass is the same as the thickness of the surrounding thickness balance medium layer, thereby overcoming the problems of the difference in height between the. Preferably, when the ultra-thin glass accommodating groove is formed by cutting, the cutting of the thickness balance medium layer is carried out according to the tolerance of the length and width of the ultra-thin glass shape plus 100 μm.

In both embodiments, when the support is a polymer, the first or second web needs to be dimensionally stabilized by heat treatment prior to the application of the ultra-thin glass.

Further, when the thickness balance medium layer is cut, the method further comprises the step of cutting an alignment mark for forming the black pattern layer so as to facilitate alignment treatment of a subsequent process. In addition, the laser cutting device adopts laser to cut, and can ensure that the edge of a product is neat and has no defects such as residual films, burrs and the like.

Step S2:

and sequentially carrying out ultraviolet irradiation, cleaning, drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode.

The ultraviolet irradiation is used for removing surface microbial contamination, the cleaning and drying can be carried out by firstly cleaning with an alkaline cleaning agent and then cleaning with high-pressure DI water (deionized water industry standard water) and drying, the plasma treatment is used for removing surface organic matters to improve the surface hydrophilicity of the material, and the treatment can obtain a clean and good-wettability surface to be processed.

The surface of the ultrathin glass to be processed is pretreated by adopting the siloxane coupling agent treating solution or sputtering silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof, so that the adhesion force between UTG and a material to be coated is increased, the surface energy difference between UTG and the surrounding material is balanced, and the uniformity of the whole surface coating film of UTG can be ensured.

Step S3:

uniformly coating a layer of first organic film precursor solution on the surface of one side, which is exposed out of the surface to be processed of the ultrathin glass, of the obtained coiled material in a slit coating or atomizing spraying mode, and removing the solvent to form a first organic film layer; and carrying out plasma treatment on the first organic film layer to form a black pattern layer on the surface of the first organic film layer.

Or carrying out plasma treatment on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, and forming a black pattern layer on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass; and then uniformly coating a layer of first organic film precursor solution on the surface of one side of the obtained coiled material, including the black pattern layer, by using a slit coating or atomizing spraying mode after plasma treatment, and removing the solvent to form a first organic film layer.

The steps are to form a first organic film layer and a black pattern layer on the surface of the first organic film layer or below the first organic film layer on the surface to be processed of the ultrathin glass. Wherein, the removal of the solvent to form the first organic film layer can be accomplished by using a chemical or thermal baking method.

The black pattern layer can be formed by coating a layer of black photoresist in a slit coating or atomizing spraying manner, utilizing the cutting processed alignment mark to form in an exposure-development manner after precuring or directly printing the black pattern in a silk screen printing manner and then curing, and the black pattern layer can play a role in blocking light.

The roll-to-roll process may further include the following steps if the functional layer such as the first organic film layer is formed on one side of the ultra-thin glass and the functional layer such as the second organic film layer is formed by processing the other side of UTG.

Step a:

and (3) attaching another first coil to the side of the coil obtained in the step (S3) on which the first organic film layer is formed, removing the original first coil from the coil obtained in the step (S3), transferring the ultrathin glass, the first organic film layer formed on one side surface of the ultrathin glass, and the black pattern layer positioned on the surface of the first organic film layer or below the surface of the first organic film layer to the other first coil together, and exposing the surface to be processed of the ultrathin glass on the other side.

In this step, the other surface of the ultrathin glass to be processed is actually exposed, so that a functional layer such as a second organic film layer can be formed on the other surface to be processed. On one hand, it is necessary to attach another first roll to the side of the roll obtained in step S3, where the first organic film layer is formed, in the manner of step S1, and it is necessary to ensure that the peeling force between the adhesive layer of the another first roll and the ultra-thin glass, the first organic film layer formed on one side surface of the ultra-thin glass, and the black pattern layer located on the surface of the first organic film layer or below the first organic film layer is not less than the peeling force between the adhesive layer of the first roll and the ultra-thin glass in step S1, so as to ensure the adhesion stability; on the other hand, UTG on the web obtained in step S3 and the layers thereon need to be transferred in their entirety to the newly posted first web.

As shown in fig. 4, the transfer mechanism used in the transfer includes a support roller, a peeling roller and a static eliminator, the diameter of the peeling roller is set to be equal to the separation between the ultra-thin glass, the first organic film layer formed on one side surface of the ultra-thin glass, and the black pattern layer located on the surface of the first organic film layer or below the surface of the first organic film layer, and the bonding layer of the first roll, and both the peeling roller and the support roller have a heating function. The support roller is a driving roller, one side of the support roller is driven by a motor, and the diameter of the roller can be 150-300 mm; the stripping roller is a driven roller and is driven by the pressure between the supporting roller and the stripping roller and the power of the supporting roller, the pressure between the two rollers is provided by air cylinders positioned on two sides of the stripping roller, and the diameter of the stripping roller can be 15-60 mm. The two rollers are hollow and are provided with a heating device, and the surfaces of the rollers are coated with rubber coatings. The diameter of the peel roll is small to provide a large bending stress to separate UTG, etc. from the first web adhesive layer. Static eliminators typically use ion bars in order to eliminate static electricity generated by the separation process.

As shown in fig. 5A-5C, the purpose of the transfer is to separate the first web and the adhesive layer from UTG and its surface coating and transfer to another first web so that another surface to be processed of UTG can be exposed and the formation of a second organic film layer can continue.

Step b:

sequentially carrying out ultraviolet irradiation, cleaning and drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode;

step c:

uniformly coating a layer of second organic film precursor solution on the surface of one side, which is exposed out of the surface to be processed of the ultrathin glass, of the obtained coiled material in a slit coating or atomizing spraying mode, and removing the solvent to form a second organic film layer; and carrying out plasma treatment on the second organic film layer to form a hardened layer on the surface of the second organic film layer.

Step b and step c are similar to the step of forming the first organic film layer in step S3, and functional layers such as the second organic film layer are obtained by similar means, and the first organic film layer may be the same as or different from the second organic film layer, which is not described herein again.

Step S4:

and through the alignment mark formed in the step S1, laser cutting is carried out along the edge of the ultrathin glass on the obtained coiled material to separate the ultrathin glass from the surrounding materials, a protective film is coated, and through the alignment mark formed in the step S1 again, laser cutting is carried out according to the preset product size to obtain the flaky ultrathin glass-organic film composite cover plate.

Further, the roll-to-roll process further includes a step of winding up the roll material after the non-adhesive protective film is coated after each step is performed and a step of removing the non-adhesive protective film and unwinding the roll material before each step is performed, and a PE or PET protective film may be used.

The ultrathin glass-organic film composite cover plate based on the roll-to-roll process is obtained by the manufacturing method, the capacity is large and the benefit is high in a sheet-to-sheet mode, the film coating on the whole surface of the ultrathin glass is uniform and consistent (the thickness uniformity within 0.1mm from the edge is less than 5%), the edge of the product is tidy by laser cutting and edge sweeping, the defects of residual films, burrs and the like are avoided, and the product quality is further guaranteed.

The present invention will be further described with reference to the following specific examples.

Example 1:

the ultra-thin glass-organic film composite cover plate prepared in this example is shown in fig. 2, and the preparation steps are as follows.

1) The method comprises the following steps of (1) using a PET silica gel protective film coiled material with a base material of 100um and the diameter of a winding drum of the PET silica gel protective film coiled material is 8 inches (the diameter of the winding drum is based on the condition that the bending stiffness of the winding drum after being bent along the winding drum is greater than UTG and the peeling force of the winding drum and the silica gel), wherein the silica gel protective film comprises a PET supporting layer with the thickness of 100um, a bonding layer with silica gel and a PET thickness balance medium layer with the thickness of 50um are formed on the surface of the PET supporting layer from bottom;

2) cutting the PET thickness balance medium layer with the upper layer thickness of 50um by using a laser cutting machine according to the UTG shape to be coated and the length-width dimensional tolerance +100um to form a plurality of ultrathin glass accommodating grooves, simultaneously cutting the edges and marking the edges for alignment, removing the UTG-shaped PET thickness balance medium layer after cutting, respectively sticking UTG with the thickness of 50um on the formed plurality of ultrathin glass accommodating grooves, and collecting the ultrathin glass accommodating grooves into a coiled material;

3) sequentially washing and drying the coiled material by ultraviolet irradiation, an alkaline cleaning agent and high-pressure DI water, covering a PE (polyethylene) non-adhesive protective film with the width consistent with that of the support coiled material on the surface, and then rolling;

4) removing the surface PE protective film from the coiled material obtained in the step (3), performing air plasma treatment, soaking the coiled material in a siloxane coupling agent treatment liquid pool for 15 seconds, drying the coiled material by using an air knife, baking the coiled material for 5 minutes by using an IR tunnel furnace at 110 ℃, coating a transparent polyimide solution on the upper surface of the coiled material in a slit coating mode, drying the coated transparent polyimide solution to complete the preparation of transparent polyimide (CPI) with the dry film thickness of 10 mu m, obtaining a first organic film layer, and winding the coiled material after coating the surface of the first organic film layer with the non-adhesive PE protective film;

5) removing the PE protective film on the surface of the coiled material obtained in the step (4), performing air plasma treatment, coating BM (BM) photoresist material by using a slit, precuring at 90 ℃ for 2 minutes, and then winding the PE protective film covered with the non-adhesive material;

6) removing the surface PE protective film from the coiled material obtained in the step (5), aligning the mark formed in the step (2) for exposure of the black pattern, and rolling the non-adhesive PE protective film;

7) removing the PE protective film on the surface of the coiled material obtained in the step 6, developing the coiled material by using a TMAH solution with the concentration of 2.38%, cleaning and curing the coiled material at 120 ℃ for 30 minutes to finish the preparation of a black pattern, obtaining a black pattern layer formed on the surface of the first organic film layer, and rolling the non-adhesive PE protective film;

8) after the surface PE protection film is removed from the roll material obtained in step 7, through the alignment mark formed in step S1, a 10um thick CPI layer is cut along the edge UTG by laser so that UTG is separated from its surrounding material, and a non-adhesive PE protection film is coated for winding;

9) and (4) cutting the coiled material obtained in the step (8) into sheet-shaped finished products according to the packaging size of the products.

Similarly, according to the process of this example, the transparent polyimide is replaced with silicone cured resin, polyurethane material, etc. to obtain products with different characteristics, and the characteristic test data of each product is shown in table 1 below, so that the product performance meets the requirements.

Table 1 data for testing properties of each product prepared according to the procedure of example 1

Example 2:

the ultra-thin glass-organic film composite cover plate prepared in this example is shown in fig. 3, and the preparation steps are as follows.

1) Baking a 100-micron-thick PET coiled material serving as a support for 1 hour at 150 ℃ in a tunnel furnace, cleaning, carrying out corona treatment, then carrying out atomization spraying on the surface of the PET coiled material to form an acrylic acid-series UV (ultraviolet) adhesive-removing layer serving as a bonding layer, curing, regularly attaching UTG with the thickness of 50 microns to the surface of the UV adhesive-removing layer, covering a 50-micron-thick PET balance medium layer, and then rolling;

2) cutting off a PET (polyethylene terephthalate) thickness balance medium layer with the thickness of 50um at the upper layer along the edge (with the dimensional tolerance of +50um) of UTG by using laser, cutting out an alignment mark, cleaning by using a cleaning agent, cleaning by using high-pressure DI (DI) water, drying, covering with a non-adhesive PE protective film, and rolling into a coiled material by using an 8-inch roll core;

3) removing the PE protective film on the surface of the coiled material obtained in the step 2, and using N₂After O plasma treatment, depositing a layer of SiOx with the thickness of 150nm by PECVD, covering an inviscid PE protective film, and rolling;

4) removing the PE protective film on the surface of the coiled material obtained in the step (3), coating a layer of black photoresist in a slit mode after air plasma treatment, forming a black pattern by using a contraposition exposure and development mode after precuring, covering the PE protective film after curing, and rolling;

5) and (4) removing the PE protective film on the surface of the coiled material obtained in the step (4), carrying out air plasma treatment, atomizing and spraying a layer of transparent polyimide solution, and drying to obtain the transparent polyimide (CPI) with the dry film thickness of 10 mu m. Separating the coating film from surrounding materials along the edge (with the dimensional tolerance of +20um) of UTG by using laser, coating a layer of 100um PET silica gel protective film on the surface of the coating film, and rolling the PET silica gel protective film, wherein the PET silica gel protective film is baked for 1 hour at 150 ℃ before use;

6) passing the coiled material obtained in the step 5 through 300-²The UV-irradiation is carried out, the UV-debonding film formed in the step 1 and 100um PET are removed, so that UTG/BM/CPI prepared in the previous step are integrally transferred to the surface of the PET silica gel protective film newly coated in the step 5 (the specific transfer process is shown in figures 5A to 5C), and after the PET silica gel protective film is irradiated by ultraviolet light and cleaned by a cleaning agent, cleaned by high-pressure DI water and dried, the non-adhesive PE protective film is coated and wound;

7) removing the PE protective film on the surface of the coiled material obtained in the step 6, soaking the coiled material in a siloxane coupling agent treatment liquid pool for 15 seconds after air plasma treatment, drying the coiled material by using an air knife, baking the coiled material for 5 minutes by using an IR tunnel furnace at 110 ℃, coating a transparent polyimide solution on the upper surface of the coiled material in a slit coating mode, drying the transparent polyimide solution to complete the preparation of transparent polyimide (CPI) with the dry film thickness of 10 mu m, obtaining a second organic film layer, and winding the coiled material after coating the non-adhesive PE protective film on the surface;

8) removing the PE protective film on the surface of the coiled material obtained in the step 7, carrying out air plasma treatment, uniformly atomizing and spraying a UV curing solution of aromatic epoxy resin with the solid content of 15% on the surface of the second organic film layer, baking for 5 minutes at 110 ℃, and then carrying out 1000mj/cm²Curing the UV (365 nm-405 nm) light to form a film, wherein the thickness of the obtained hardened layer is 5um, and the surface of the hardened layer is wound after being coated with an inviscid PE protective film;

9) removing the PE protective film on the surface of the coiled material obtained in the step 8, separating the coated film from surrounding materials along the UTG edge (with the dimensional tolerance of +30um) by using laser through the alignment mark formed in the step 2, and covering and winding the non-adhesive PE protective film;

10) and cutting the coiled material obtained in the step 9 into sheet-shaped finished products according to the packaging size of the products.

Similarly, according to the procedure of this example, the transparent polyimide is replaced by silicone-cured resin, polyurethane material and their combination, so as to obtain products with different characteristics, and the data of the product characteristics test is similar to that of example 1.

The invention is not limited to the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification and any novel method or process steps or any novel combination of features disclosed.

Claims

1. The ultra-thin glass-organic film composite cover plate based on the roll-to-roll process is characterized by comprising ultra-thin glass, a first organic film layer at least formed on one side surface of the ultra-thin glass and a black pattern layer positioned on the surface of the first organic film layer or below the first organic film layer, wherein the composite cover plate is manufactured by the roll-to-roll process.

2. The ultra-thin glass-organic film composite cover sheet based on roll-to-roll process of claim 1, wherein the roll-to-roll process comprises the steps of:

step S2: sequentially carrying out ultraviolet irradiation, cleaning, drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode;

or carrying out plasma treatment on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, and forming a black pattern layer on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass; uniformly coating a layer of first organic film precursor solution on the surface of one side of the obtained coiled material, including the black matrix pattern layer, by using a slit coating or atomizing spraying mode after plasma treatment, and removing the solvent to form a first organic film layer;

3. The ultra-thin glass-organic film composite cover sheet according to claim 2, wherein the support in the first or second web is glass, polymer or stainless steel, and the polymer is polyimide, polyethylene terephthalate, polyethylene naphthalate, polystyrene or polyurethane, wherein when the support is polymer, the first or second web is subjected to a dimensionally stabilizing heat treatment.

4. The ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 2, wherein the bonding layer is a silica gel material or an acrylic UV debonding material, and the peeling force of the bonding layer and the ultra-thin glass is not more than 15g/in and can resist at least 120 ℃.

5. The ultra-thin glass-organic film composite cover plate based on the roll-to-roll process of claim 2, wherein the thickness balancing medium layer is a polyethylene terephthalate film, a polyethylene naphthalate film, a polystyrene film, or a polyurethane film, and a diameter of the roll of the first roll or the second roll is set to be greater than a stiffness of the ultra-thin glass after bending along the roll and less than a peeling force between the ultra-thin glass and the adhesive layer.

6. The ultra-thin glass-organic film composite cover sheet according to claim 2, further comprising a step of cutting an alignment mark for forming a black pattern layer when the thickness-equalizing dielectric layer is cut in the step S1; in step S3, the black pattern layer is formed by coating a black photoresist layer by slit coating or spray coating, and is formed by exposure-development using the alignment mark after pre-curing or by curing after directly printing a black pattern by screen printing.

7. The ultra-thin glass-organic film composite cover sheet based on a roll-to-roll process of claim 2, further comprising a second organic film layer formed on the other side surface of the ultra-thin glass and a hardened layer formed on the second organic film layer, wherein the first and second organic film layers are a transparent polyimide layer, a polyethylene terephthalate layer, a polyethylene naphthalate layer, a polystyrene layer, or a polyurethane layer.

8. The ultra-thin glass-organic film composite cover sheet based on roll-to-roll process of claim 7, further comprising the following steps performed between steps S3 and S4:

step b: sequentially carrying out ultraviolet irradiation, cleaning, drying and plasma treatment on the obtained coiled material, and treating the obtained coiled material by using a siloxane coupling agent treatment solution or depositing a layer of silicon oxide, silicon nitride, amorphous silicon or a composite buffer layer thereof on the surface of one side of the obtained coiled material, which is exposed out of the surface to be processed of the ultrathin glass, in a sputtering mode;

9. The ultra-thin glass-organic film composite cover sheet according to any one of claims 2 to 8, wherein the roll-to-roll process further comprises the steps of winding up the roll after coating the non-adhesive protective film after each step is performed and removing the non-adhesive protective film and unwinding the roll before each step is performed.

10. A manufacturing method of an ultrathin glass-organic film composite cover plate based on a roll-to-roll process is characterized by comprising the following steps:

11. The method of claim 10, wherein the support of the first or second web is glass, polymer or stainless steel, the polymer is polyimide, polyethylene terephthalate, polyethylene naphthalate, polystyrene or polyurethane, and wherein the first or second web is subjected to a dimensional stabilization heat treatment when the support is a polymer.

12. The manufacturing method of the ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 10, wherein the bonding layer is a silica gel material or an acrylic material, and the peeling force between the bonding layer and the ultra-thin glass is not more than 15g/in and can resist at least 120 ℃.

13. The manufacturing method of the ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 10, wherein the thickness balance medium layer is a polyethylene terephthalate film, a polyethylene naphthalate film, a polystyrene film or a polyurethane film, and the diameter of the roll in the first roll or the second roll is set to be greater than the stiffness of the ultra-thin glass after being bent along the roll and less than the peeling force between the ultra-thin glass and the adhesive layer.

14. The method for manufacturing an ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 10, further comprising the step of cutting an alignment mark for forming a black pattern layer when the thickness-equalizing dielectric layer is cut in step S1; in step S3, the black pattern layer is formed by coating a black matrix photoresist by slit coating or spray coating, and is formed by exposure-development using the alignment mark after pre-curing or by curing after directly printing a black matrix pattern by screen printing.

15. The method for manufacturing an ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 10, wherein the manufacturing method further comprises the following steps performed between the steps S3 and S4 to form a second organic film layer and a hardened layer on the second organic film layer on the other side surface of the ultra-thin glass:

16. The method of claim 15, wherein the first and second organic film layers are a transparent polyimide layer, a polyethylene terephthalate layer, a polyethylene naphthalate layer, a polystyrene layer, or a polyurethane layer.

17. The method of manufacturing an ultra-thin glass-organic film composite cover sheet according to claim 15, wherein a peeling force between the adhesive layer of the other first roll and the ultra-thin glass, the first organic film layer formed on one side surface of the ultra-thin glass, and the black pattern layer located at or below the surface of the first organic film layer is not less than a peeling force between the adhesive layer of the first roll and the ultra-thin glass in the step S1.

18. The manufacturing method of an ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 15, wherein a transfer mechanism used in the transfer includes a support roll, a peeling roll and a static electricity eliminator, the peeling roll has a diameter set to cause the ultra-thin glass and the first organic film layer formed on one side surface of the ultra-thin glass and the black pattern layer located on the surface of the first organic film layer or below the surface of the first organic film layer to be separated from the adhesive layer of the first roll, and both the peeling roll and the support roll are provided with a heating function.

19. The method for manufacturing an ultra-thin glass-organic film composite cover plate based on the roll-to-roll process as claimed in claim 15, wherein a hardened layer material is coated on the surface of the second organic film layer by spraying or slit coating to form the hardened layer.

20. The method of fabricating an ultra-thin glass-organic film composite cover sheet based on roll-to-roll process of any one of claims 10 to 19, further comprising the steps of winding up the roll after coating the non-adhesive protective film after each step is performed and removing the non-adhesive protective film and unwinding the roll before each step is performed.

21. An ultra-thin glass-organic film composite cover plate based on a roll-to-roll process, which is manufactured by the method for manufacturing the ultra-thin glass-organic film composite cover plate based on the roll-to-roll process according to any one of claims 10 to 19.