CN1183746A - 具有低反射色抗反射涂层的柔性塑料基片及其方法 - Google Patents
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Abstract
一种包括折射率为1.55—1.71、具有第一表面(23)和第二表面(24)以及由第一表面(23)的柔性塑料基片(22)和由所述的第一表面承载的抗反射涂层(26)的光学制品(21)。抗反射涂层(26)是由高折射率材料及低折射率材料组成,其中高折射率材料的折射率为2.0或2.0以上,以便使基片与高折射率材料的折射率差为0.29—0.75。低折射率材料是由折射率为1.38或1.38以下的材料所构成,以便使高折射率材料与低折射率材料的折射率差大约于0.59~0.92范围。
Description
本发明涉及一种具有低反射色(low reflective color)抗反射涂层的柔性塑料基片及其方法;特别涉及具有两层抗反射涂层的柔性硬涂层塑料卷材及其方法,该抗反射涂层具有低的倾角反射色。
迄今,在玻璃上提供两层抗反射涂层。在塑料上也提供两层抗反射涂层。例如,Santa Rosa的光学涂层实验室(Optical Coating LaboratoryInc)(California,)生产的一种商标为HEA 2000的产品,就是在硬涂层PET(即聚对苯二甲酸乙二醇酯)或类似塑料的基片上涂有宽频谱多层抗反射涂层。涂层表面为有纹理的或平滑的。无涂层的表面上有一层由剥离衬垫所保护的压敏胶粘剂。该产品采用了一种由四层在涂层表面上下对称的二氧化硅和二氧化钛所组成的抗反射涂层。
Allen的专利4,333,933披露了一种在聚酯上的双层涂层(一层为胶粘剂层,一层为抗反射涂层),在选定的波长下,使反射透光率从约6%降至约1%。而在其它波长下,在大部分可见光谱区,反射率大于1%和在1-3%之间。这样的光学性能清晰地表示于Allen专利的图7中。该图7显示Allen专利图6中所述制品的光谱性能曲线,其中聚酯片两面上涂布了170纳米的氧化铝,再于氧化铝每一面上部涂布四分之一波长的MgF2。换言之,这样的设计包括在约560纳米半波长的氧化铝,再加上四分之一波长的MgF2。Allen指出“目前用辊式涂布设备在柔性塑料基片上形成光学涂层的优选方法,如图10中所述及前述其它的类型,表示于图11中(第9栏59行)”。这样的设计已经在PET上进行了模拟,如申请人的图5中曲线91(其一侧涂敷PET)所示。尽管Allen专利讨论的是一种三层系统(半波长的氧化铝胶粘剂层,再加上一双层的抗反射涂层),但这种设计涉及到氧化铝与另一种折射率约2.1的材料的混合物(第8栏47-50行)。这种设计有两个难点。第一,由氧化铝与折射率约为2.1的材料混合一起构成折射率为1.89的混合物,一般在市场上是买不到的,而且还有蒸发过和中分离的可能。第二,在真空辊式涂布机中使用三种材料也是不实际的。Allen指出,“在大规模的辊式涂布机中应用多层的不同材料沉积更为复杂的光学涂层时,由于各种材料均需单独的冷却滚筒,可能需要使用三种或三种以上的沉积源(第9栏54-48行)”。由于这在工业上不实际,所以,对于沉积双层系统,亦即半波长的氧化铝再加上四分之一波长的MgF2,Allen建议采用如第9栏59-68行和第10栏1-30行中所述的方法来形成光学涂层。
对于HEA 2000及Allen两种设计,都需要有附加层,对于Allen的设计需要有用于三种不同材料的多种物源,而对于四层的HEA 2000设计,还要求辊式涂布机有另外的通路。这就需要有一种可应用于柔性塑料基片的新式的和改良的反射涂层,从而以较低费用得到低的倾角反射色。
一般来说,本发明的目的在于,提供一种有或无硬涂层的柔性塑料基片,以及一种特别适于在工业规模的辊式涂布机上进行经济生产的方法。该塑料基片具有仅用两种材料的抗反射涂层,该抗反射涂层能极大地改进抗反射性能并具有低反射色。
本发明的另一目的在于,提供一种具有上述特征的产品及方法,其中仅需两层形成抗反射涂层。
本发明的另一目的在于,提供一种具有上述特征的产品及方法,其中用一次通过或两次通过辊式涂布机械的方法就能够生产所述的产品。
本发明的另一目的在于,提供一种耐用特性极佳的具有前述特征的产品。
本发明的另一目的在于,提供一种具有前述特征的产品,其中在塑料基片上涂布硬涂料层以赋予抗反射涂层意外好的耐用性。
本发明的另一目的在于,提供一种在可见光波长区反射率非常低的具有前述特征的产品。
结合附图,从下列说明(包括优选实施方案)中,可以清楚地看出本发明的另一些目的及特征。
图1表示具有低反射色抗反射涂层的柔性塑料基片形式的包括本发明制品的截面图。
图2表示图1所示的使用有机硬涂层制品的另一实施方案。
图3表示与图2类似的制品的截面图,不同的是塑料基片两侧面均有抗反射涂层。
图4说明用于制造在图1、2及3中所示制品或产品的辊式涂布机的侧面流程图。
图5表示与按本发明制备的制品相比较,现有技术制品光学性能的曲线。
图6表示本发明制品与现有技术制品倾角光学性能的曲线。
图7表示按照本发明制备的产品的实际光学性能的曲线。
图8表示按照本发明制备的产品的实际光学性能的另一曲线。
图9表示按照本发明制备的产品的光学性能另一曲线。
一般来说,按照本发明制备的制品是由具有第一及第二表面的柔性塑料基片组成。在此两表面的一面上涂布由半波长的折射率为n≥2的高折射率氧化物层和四分之一波长的氟化镁层所组成的双层抗反射涂层,以使抗反射涂层具有低反射色。为使之经久耐用,可先在其表面上涂布一层硬涂层,后再沉积抗反射涂层。
更特别的是,光学制品21包括厚度适宜的,如为1-10密尔(mil),优选3-5密尔的柔性塑料基片22。塑料基片的折射率可以在1.65~1.71范围,而且在可见光区400~700纳米范围内塑料基片应当是透明的。基片22具有一般基本平行的第一表面23及第二表面24。塑料基片22一般是由聚合物构成,如折射率约1.67的聚对苯二甲酸乙二醇酯。也可以利用其它性能理想的材料,如折射率1.55的PEN,即聚萘二甲酸乙二醇酯。但是,利用这种折射率较低的基片时,其光学性能会有所下降。作为这种基片的塑料应当是柔性的、透明的及韧性较好的。
在表面23和24中的一面涂布一层抗反射涂层26,如图1所示是涂布在表面23上的。按照本发明抗反射涂层26是由在设计波长550纳米下半波的氧化锆及在同样设计波长下四分之一波长的氟化镁所组成。正如此后所述,氧化锆及氟化镁可在辊式涂布机的真空室内进行沉积。氧化锆是一种高折射率的材料,折射率在2.0或以上,能使塑料基片与氧化锆的折射率差在0.29至0.75之间。另一方面,可以使用在1995年5月9日提交的共同未决专利申请书No:08/438,198中所述高折射率的混合氧化物涂层材料。它的折射率在2.0或2.0以上。氟化镁是一种低折射率的材料,应当属于一种折射率在1.38或1.38以下的材料,能使高折射率材料与低折射率材料的折射率差在0.59至0.92之间,优选为约0.62。
压敏胶粘剂27是涂布在塑料基片22的表面24上的,并还有一层粘结其上的可为塑料或纸片状的剥离衬垫28。
按照本发明,抗反射涂层26可以称为是一种柔软涂层,以提供一种能用于生产一次性使用或短期使用的产品的制品,诸如外科及牙科面罩等产品的材料。
若需要抗反射涂层使用期更长时,可以利用如图2所示的结构,其中提供类似于塑料基片22的塑料基片31,而且要有第一表面32和第二表面33。在表面32上涂布硬涂层36,而且是诸如丙烯酸酯聚合物型的有机硬涂层。此硬涂层涂布厚度要适当,如1-25微米,优选地是厚度约1-5微米。但是,应当理解,如果需要,可以使用其它的材料,如紫外光固化的环氧树脂(UV-cured epoxy)。已找到的一种特别令人满意的材料是由Tekra(16700 West Lincoln Avenue,St.Albins,Vermont.)公司生产的产品MARNOT XL。硬涂层在真空室外进行涂敷,并可采用适当的方法,诸如湿化学法中的照相凹板式涂布机,进行涂敷。此硬涂层材料可在室温下进行涂布,并允许在真空室外进行干燥。在它干燥之后,再用与图1所示涂布抗反射涂层26的同样方法,将抗反射涂层37沉积于有机硬涂层32上。这样的涂层具有在设计波长下半波的氧化锆及四分之一波长的氟化镁的结构。
在塑料基片31上涂敷抗反射涂层37,其性能比现有技术曾强调的玻璃基片上的抗反射涂层得到明显改善,因为塑料基片折射率为1.65-1.71,而玻璃的折射率约1.45。如下文所述,在抗反射涂层37之下涂布有机硬涂层32,会极大改进使用期限。
采用与如图1所述的涂布压敏胶粘剂27与剥离层28相同的方法,将压敏胶粘剂41涂布于表面33上,再覆盖剥离层42。
另外一种包括本发明的制品示于图3截面图中,其中塑料基片51属于前述类型具有第一表面52和第二表面53。将有机硬涂层54涂布于表面52上,接着再涂布如前述类型的双层抗反射涂层56。再于表面53上涂敷与有机硬涂层54相同的有机硬涂层57,并在其上涂敷与抗反射涂层56类似的一层双层抗反射涂层58。因此,由图3的实施方案可以看出,在塑料基片两侧表面上涂布有硬涂层,硬涂层还覆盖有抗反射涂层。
图1、2及3所示制品的结构本身较为简单,特别有助于在传统的辊式涂布机上低成本地进行生产。这种传统涂布机械71的示意于图4中。对于这种辊式涂布机,在塑料基片送到涂布机上之前,可以在塑料基片22、31及51的一侧表面上涂布一层如前所述类型的硬涂层,还可在其另一侧面涂布一层带剥离衬垫的压敏胶粘剂层。可以在涂布机真空室外对这样一种有涂层的塑料基片进行加工,可以使有涂层的塑料基片从解绕筒72上放卷,如图3所示,并于绕卷筒73上进行绕卷,形成卷材76。塑料基片或卷材76,在从解卷筒退卷时,可将其送进第一和第二真空室77和78内,或者送进一个单真空室内,其内最好在第一真空室77内放置第一转筒81和在第二真空室78内放置第二转筒82,并按图4所示使卷材或膜76通过滚筒81及82之下和通过空转辊83及84之上。在真空室77及78内提供适当的物源86和87。因而,例如物源86可以是一种电子束蒸发源用以蒸发氧化锆,物源87可以是一种电阻蒸发源用以蒸发氟化镁。另一方面,电子束蒸发源也可以用于蒸发氟化镁。因此,按照本发明,可以看出,由氧化锆及氟化镁组成的双层抗反射涂料可以在辊式涂布机中采用基片76一次通过辊式涂布机的方法进行涂敷,而不必隔断真空。按照本发明,应当理解,如果需要,可以用一次通过辊式涂布机的方法将抗反射涂料直接涂敷于基片上,如图1所示,而后如果需要,可以于辊式涂布机71的真空室外再涂敷压敏粘结剂和剥离层。
如果需要在基片的两面都涂敷上抗反射涂层,可以在基片的两侧面都涂敷有机硬涂层,而后在卷材第一次通过辊式涂布机时可以将抗反射涂料涂敷于这一层有机硬涂层之上,而后在使之第二次通过辊式涂布机时再将抗反射涂层涂敷于另一层硬涂层之上。
图5-11说明按照本发明制备的光学制品所能达到的颇不寻常的性能。图5所示的曲线91、92及93,表明三种不同产品的光学性能,曲线表示在350-850纳米范围内,特别是主要关注的400-700纳米范围内的理论光学性能。曲线91代表按照前述Allen专利4,333,983制备的产品。曲线92代表鉴别为Optical Coating Laboratory Inc.生产的HEA 2000TM的一种四层型的产品。曲线93代表按照本发明制备的产品。曲线91代表的是一种用PET基片制备的产品,具有厚度为170纳米的氧化铝胶层,和再加上一种半波的折射率为1.89的混合物的介电材料层以及在设计波长550纳米下四分之一波长的氟化镁层。HEA2000TM的制品有一层PET基片,再加上沉积于其一侧表面上的硬涂层,其上沉积有在设计波长550纳米八分之一波长的二氧化钛、八分之一波长的二氧化硅、半波的二氧化钛以及四分之一波长的二氧化硅。
以理论曲线93表示的本发明产品利用了PET作为基片,并有2微米的硬涂层沉积于其表面之上,再加上二者均在设计波长550纳米下半波的氧化锆和四分之一波长的氟化镁。由图5可以看出,包括本发明的制品的曲线93的镜反射性能明显地优于曲线91及92所代表的其它两种制品所能得到的性能,因为它在整个谱带区内提供反射率基本上降低至1%以下的非常宽的谱带。另一方面,曲线91基本上为V型,在550纳米以上其反射率非常迅速地上升。曲线92也是在620纳米之后相当迅速地上升。另一方面,对于本发明的制品,曲线91在约420纳米至超过700纳米的区域基本上在1%以下。
因此,从本发明可以看出,申请人仅仅应用了在一次通过辊式涂布机时能从两种物源中汽化出来的两种材料就达到了非常明显的效果,而现有技术的Allen制品和HEA2000TM产品,由于需要使用的材料较多和涂层较多,需要在真空室内进行处理的步骤也就更多,因而基本上都太复杂,得到的抗反射性能也较差。
图6表示本发明的制品与HEA2000TM产品相比的倾角镜反射的理论光学性能。曲线101及102、103、104及106表示分别在60°、45°、30°、15°及0°时的反射率;而曲线111、112、113、114及116表示HEA200TM产品分别在倾角60°、45°、30°、15°及0°时的反射率。由这些曲线可以看出,对于本发明的产品倾角反射色的理论曲线比HEA200TM产品的好很多。HEA200TM产品的倾角反射色看起来为浅品红色,而本发明产品,由于对较高波长,如700纳米或700纳米以上的反射极大地减少,所以其颜色较浅。
图7表明按照本发明制备的产品的实际光学性能,其中基片是由PET所构成的,其上涂布有无光泽的硬涂层,再涂敷以抗反射涂层。曲线121表明的是总的镜反射率和扩散反射率,亦即总反射率,其表明在可见光区约425-675纳米范围内反射率约在1%以下。在进行所示测定时,基片背面被涂黑,以减小任何背面的反射。
图8中的曲线126表示,采用PET基片,并在基片两面均按本发明涂敷抗反射涂层而在两面均无硬涂层时,所得的光学性能。此外,还可看出,在400-700纳米区内有极好的抗反射性能,其镜反射率在所关注的整个区域内小于半个百分点,而且一般约为0.3%。还可确定的是,按照本发明在塑料基片上得到的抗反射涂层具有较宽的频带,与HEA200TM产品相比,它对倾角反射色也不太敏感。
图9中表示了两条曲线131及132,其中131代表PET基片本身的光学性能,曲线132代表按照本发明在PET基片的透明硬涂层上沉积抗反射涂层制得的制品。从这些曲线可以看出,反射率从400纳米以下延续至约675纳米,并且双层抗反射涂层将总的反射率由约6%下降至0.75%的实际的总反射率。对于有涂层及无涂层的两种PET基片,其背面均涂上了黑色,以使背面反射减至最小。
除了前述的低反射性及极佳的色特征之外,还发现在抗反射涂层之下提供硬涂层时,该制品的耐用性极好。例如,它可经受住000号钢丝棉材料20次摩擦,在耐湿试验之后可经受同样钢丝棉材料10-20次摩擦。它还可以承受2000次以上粗滤布的摩擦。这至少是与现有技术制品所能得到的一样好,例如,与按照Allen专利的或HEA 2000TM的制品一样好。
由前所述内容可以看出,利用本发明的产品制备的光学制品或产品可以有许多用途。例如,如前所述的,如果该产品属于仅用一次或仅用几次的,则此产品可以有一层抗反射涂层而在抗反射涂层之下无硬涂层。若需要延长使用期,可以在沉积抗反射涂层之前在基片表面上使用硬涂层,很容易地这一目的。此产品的频带宽,总可见光反射率低,对倾角反射色较不敏感。
Claims (15)
1、一种包括一折射率在1.55-1.71、具有第一及第二表面的柔性塑料基片和一层由所述第一表面承载的抗反射涂层的光学制品,所述抗反射涂层是由高折射率材料和低折射率材料所组成,其中高折射率材料折射率在2.0及2.0以上,以使基片与高折射率材料的折射率之差在0.29-0.75之间;并且其中的低折射率材料的折射率在1.38或1.38以下,以使高折射率材料与低折射率材料的折射率之差在约0.59-0.92之间。
2、按照权利要求1所述的制品,其中所述高折射率材料是氧化锆,和其中所述低折射率材料为氟化镁。
3、按照权利要求2所述的制品,其中所述氧化锆在设计波长550纳米具有半波长的光学厚度,和氟化镁在设计波长550纳米具有四分之一波长的光学厚度。
4、按照权利要求1所述制品,还包括一沉积在基片表面上并插在抗反射涂层与基片表面之间的有机硬涂层。
5、按照权利要求4所述制品,其中所述硬涂层厚度在1-25微米范围。
6、按照权利要求5所述制品,其中硬涂层厚度约为2微米。
7、按照权利要求1所述制品,其中基片是选自PET及聚萘二甲酸乙二醇酯(PEN)的一种材料。
8、按照权利要求1所述制品还包括承载于基片上的压敏胶粘剂以及固定于压敏胶粘剂上的剥离层。
9、按照权利要求1所述的制品,还包括在基片第二表面上构成的有机硬涂层以及位于第二表面有机硬涂层上的抗反射涂层。
10、按照权利要求1所述制品,其中由抗反射涂层提供的反射率在400-700纳米区内平均约有半个百分点。
11、按照权利要求1所述制品,其中所述的抗反射涂层在高倾角时构成低反射色。
12、按照权利要求4所述制品,其中所述的抗反射涂层可以承受000号钢丝棉20次摩擦。
13、一种采用辊式涂布机在真空室中由具有第一及第二表面的柔性塑料基片卷材形成光学制品的方法,包括在真空室外在卷材的第一表面上形成有机硬涂层;将具有硬涂层的卷材引入真空室内;在真空室内将一种折射率在2.0或2.0以上的材料沉积在此硬涂层上,其厚度为在设计波长的半波长,此后再于真空室内将一种折射率1.38或1.38以下的材料沉积到折射率为2.0及2.0以上的材料上,其厚度为在设计波长的四分之一波长,和从辊式涂布机上取下卷材。
14、按照权利要求13所述方法,其中的高折射率材料是通过用电子束蒸发来沉积氧化锆的方法而涂敷的,而其中折射率1.38或1.38以下的材料是通过用电子束蒸发来沉积氟化镁的方法而涂敷的。
15、按照权利要求13所述方法,还包括如下步骤:在真空室外将压敏胶粘剂涂敷在卷材的表面上和将剥离层涂敷在压敏胶粘剂上。
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- 1996-05-06 WO PCT/US1996/006371 patent/WO1996035579A1/en active IP Right Grant
- 1996-05-06 EP EP96915536A patent/EP0824398A4/en not_active Withdrawn
- 1996-05-06 CN CN96193729A patent/CN1074985C/zh not_active Expired - Fee Related
- 1996-05-06 KR KR1019970708030A patent/KR19990014689A/ko active IP Right Grant
- 1996-05-06 JP JP8534162A patent/JPH11505036A/ja active Pending
- 1996-05-21 TW TW085105994A patent/TW420636B/zh active
Cited By (5)
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CN1867522B (zh) * | 2003-08-13 | 2011-11-16 | 法国圣戈班玻璃厂 | 包括抗反射涂层的透明基材 |
CN104271509A (zh) * | 2012-05-29 | 2015-01-07 | 斯泰拉化工公司 | 氟化镁颗粒、氟化镁颗粒的制造方法、氟化镁颗粒分散液、氟化镁颗粒分散液的制造方法、低折射率层形成用组合物、低折射率层形成用组合物的制造方法、附有低折射率层的基材以及附有低折射率层的基材的制造方法 |
CN109765646A (zh) * | 2018-12-28 | 2019-05-17 | 张家港康得新光电材料有限公司 | 一种柔性盖板 |
CN112377826A (zh) * | 2020-11-21 | 2021-02-19 | 苏州讯能光电科技有限公司 | 一种发光范围可调节的led灯 |
CN112377826B (zh) * | 2020-11-21 | 2021-11-23 | 苏州讯能光电科技有限公司 | 一种发光范围可调节的led灯 |
Also Published As
Publication number | Publication date |
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KR19990014689A (ko) | 1999-02-25 |
CA2219316C (en) | 2001-07-10 |
TW420636B (en) | 2001-02-01 |
JPH11505036A (ja) | 1999-05-11 |
EP0824398A1 (en) | 1998-02-25 |
EP0824398A4 (en) | 1999-04-07 |
WO1996035579A1 (en) | 1996-11-14 |
CA2219316A1 (en) | 1996-11-14 |
US5939189A (en) | 1999-08-17 |
CN1074985C (zh) | 2001-11-21 |
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