US20080096006A1 - Optical film and fabrication method thereof - Google Patents
Optical film and fabrication method thereof Download PDFInfo
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- US20080096006A1 US20080096006A1 US11/964,625 US96462507A US2008096006A1 US 20080096006 A1 US20080096006 A1 US 20080096006A1 US 96462507 A US96462507 A US 96462507A US 2008096006 A1 US2008096006 A1 US 2008096006A1
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- 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
- G02B1/16—Optical coatings produced by application to, or surface treatment of, optical elements having an anti-static effect, e.g. electrically conducting coatings
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/006—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character
- C03C17/007—Surface treatment of glass, not in the form of fibres or filaments, by coating with materials of composite character containing a dispersed phase, e.g. particles, fibres or flakes, in a continuous phase
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/0427—Coating with only one layer of a composition containing a polymer binder
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/044—Forming conductive coatings; Forming coatings having anti-static properties
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/046—Forming abrasion-resistant coatings; Forming surface-hardening coatings
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- 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
-
- 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
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2217/00—Coatings on glass
- C03C2217/40—Coatings comprising at least one inhomogeneous layer
- C03C2217/43—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase
- C03C2217/46—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase
- C03C2217/47—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase consisting of a specific material
- C03C2217/475—Inorganic materials
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C2217/00—Coatings on glass
- C03C2217/40—Coatings comprising at least one inhomogeneous layer
- C03C2217/43—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase
- C03C2217/46—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase
- C03C2217/47—Coatings comprising at least one inhomogeneous layer consisting of a dispersed phase in a continuous phase characterized by the dispersed phase consisting of a specific material
- C03C2217/475—Inorganic materials
- C03C2217/476—Tin oxide or doped tin oxide
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- 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
- G02F2202/00—Materials and properties
- G02F2202/22—Antistatic materials or arrangements
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/256—Heavy metal or aluminum or compound thereof
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/256—Heavy metal or aluminum or compound thereof
- Y10T428/257—Iron oxide or aluminum oxide
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31507—Of polycarbonate
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31938—Polymer of monoethylenically unsaturated hydrocarbon
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
Definitions
- the invention relates to a thin film and fabrication method thereof and in particular to an optical film and fabrication method thereof.
- Liquid crystal display (LCD) and liquid crystal display television (LCD TV) are currently popular in display technology.
- An optical film having good transmittance is an important component.
- a hard coat layer is usually coated on an optical film, preventing outside damage.
- the hard coat layer is mostly insulation and comprises resin materials. such that static electricity is easily accumulated, producing electrostatic discharge (ESD). and dust is readily attracted to its surface. Therefore, an anti-static layer is usually coated on the hard coat layer surface to prevent the static issues.
- a conventional anti-static hard coat layer can be formed by coating once or twice. Two-step coating is more problematic than one-step coating, since some defects appear as a bottom layer coated on a substrate, and other defects appear as a top layer then coated on the bottom layer, so that the defective fraction of two-step coating is higher.
- Two-step coating involves two types, anti-static layer upon hard coat layer and hard coat layer upon anti-static layer.
- FIG. 1 a shows an anti-static hard coat film 10 a , comprising substrate 12 , hard coat layer 14 and anti-static layer 16 respectively disposed on the substrate 12 , and anti-static particles 18 dispersed in the anti-static layer 16 .
- electric conductivity is increased due to the anti-static layer 16 disposed as the surface layer of the anti-static hard coat film 10 a but anti-scratch properties are reduced because the hardness and abrasion of the anti-static layer 16 is usually poorer than that of the hard coat layer 14 .
- FIG. 1 b shows an anti-static hard coat film 10 b , comprising substrate 12 , hard coat layer 14 and anti-static layer 16 respectively disposed on the substrate 12 , and anti-static particles 18 dispersed in the anti-static layer 16 .
- anti-scratch properties are increased due to the hard coat layer 14 disposed as the surface layer of tile anti-static hard coat film 10 b , but electric conductivity is reduced.
- the anti-static layer 16 as shown in FIGS. 1 a and 1 b will results in interference and high reflection, especially the anti-static particles 18 are collected in a thin layer (the anti-static layer 16 ).
- an anti-static hard coat film 10 c is provided, comprising a substrate 12 and an anti-static layer 15 disposed thereon.
- the anti-static layer 15 comprises a resin layer 19 and dispersed anti-static particles 18 .
- the process of one-step coating is simpler than two-step coating, but the anti-static effects of the anti-static hard coat film 10 c are less than the anti-static hard coat film 10 a and 10 b due to more separated particles.
- an optical film comprising a substrate and an anti-static layer disposed thereon.
- the anti-static layer comprises a resin layer and a plurality of anti-static particles, wherein the bottom half portion of the anti-static layer contains more than 60 wt % of the anti-static particles.
- a method for fabricating an optical film is also provided.
- a substrate is provided.
- An anti-static solution is coated on the substrate to form an anti-static wet layer thereon.
- the anti-static solution comprises a plurality of anti-static particles and a resin material.
- the anti-static particles are interacted by an external force or an inter-particle force.
- the anti-static wet layer is dried and cured to form an anti-static layer.
- the anti-static layer has a top half portion and a bottom half portion containing more than 60 wt % of the anti-static particles.
- FIGS. 1 a to 1 c are cross-sections of conventional anti-static hard coat films.
- FIG. 2 a is a cross section of an anti-static solution coated on a substrate in an embodiment of the invention.
- FIG. 2 b is a cross section of an optical film in an embodiment of the invention.
- FIGS. 2 c to 2 d are devices for fabricating an optical film according to the invention.
- An optical film and fabrication method thereof are provided, with, when a bottom half portion of an anti-static layer contains more than 60 wt % of anti-static particles. properties including anti-scratch anti-static, low reflection or low interference.
- FIG. 2 a shows anti-static wet layer 206 being coated on a substrate 201 in an embodiment of the invention.
- the anti-static wet layer 206 comprises solvent and anti-static particles 205 dispersed therein.
- FIG. 2 b is a cross-section of an optical film 200 in an embodiment of the invention.
- the optical film 200 comprises a substrate 201 and an anti-static layer 207 disposed thereon.
- the anti-static layer 207 comprises a resin layer 203 and anti-static particles 205 .
- a virtual plane 209 c parallel to the substrate 201 , is in the position of half thickness of the anti-static layer 207 .
- the portions of anti-static layer 207 above and below the virtual plane 209 c are respectively referred to as top half portion 209 a and bottom half portion 209 b .
- the bottom half portion 209 b contains more than 60 wt % of the anti-static particles 205 , and in another, between about 60 and 90 wt %, and yet another, between about 70 and 90 wt %.
- the anti-static wet layer 206 as shown in FIG. 2 a is a wet layer (having solvent), after the process described the following, the anti-static wet layer 206 is dryer and the structure of the anti-static layer 207 as shown in FIG. 2 b is formed.
- electrolyte in tank 211 is added into anti-static solution placed in tank 213 , and the solution is mixed well by stirring: Added amount of electrolyte depends on its charge.
- Substrate 201 is transported by unwinder 217 and winder 223 , anti-static solution is supplied to the surface of the substrate 201 through coater head 215 , and then a structure as shown in FIG. 2 a is formed.
- the coated substrate is transported by the unwinder 217 and winder 223 to the oven 219 and the following curing device 221 , so that solvent is evaporated. resin is hardened, such that the anti-static wet layer 206 (as shown in FIG. 2 a ) is converted into anti-static layer 207 (as shown in FIG. 2 b ). and then the optical film 200 as shown in FIG. 2 b is formed.
- An acceptable added amount of electrolyte depends on its charge, too high or too low electrolyte concentration is not applicable in the invention.
- concentration of monovalent electrolyte in anti-static solution is between about 10 ⁇ 6 to 10 ⁇ 1 M. Aggregation of particles are not obvious when electrolyte concentration is too low, normally lower than 10 ⁇ 6 M. Larger than 1 um particles are dramatically formed such that transmittance of the film is negatively affected when electrolyte concentration is too high, normally higher than 10 ⁇ 1 M.
- electrolyte can be acid electrolyte, alkali electrolyte, salts, or other ionic compound, such as NaCl, KCl, KNO 3 , Na 2 CO 3 . Mg(NO 3 ) 2 . K 2 SO 4 . H 2 CO 3 , CH 3 COOH, or KAl(SO 4 ) 2 .
- electrolyte By addition of electrolyte, anti-static particles become unstable, so that collision probability between particles is increased and sedimentation of the aggregated particles becomes easier.
- Electrolyte is used in an embodiment of the invention causing aggregations, while polymeric flocculant (also referred to as polymeric flocculating agent) can also be used.
- the polymeric flocculent can be inorganic polymeric flocculant such as poly aluminum chloride, or organic polymeric flocculant such as polyacrylamide. While utilizing polymeric flocculant, anti-static particles are bridged by polymer chains, resulting aggregations.
- a stirring apparatus can optionally be used in the tank 213 as shown in FIG. 2 c , so that electrolyte (or polymeric flocculant) is dissolved (or dispersed) well, and sedimentation of anti-static particles in the tank 213 can be prevented.
- the resin layer 203 can be of ultraviolet-cured resin. thermal-cured resin, or electron-beam-cured resin, so that the curing device 221 as shown in FIGS. 2 c and 2 d can be an ultraviolet curing device, a thermal curing device, or a electron beam curing device.
- the coating method for coating a solution on the substrate 201 by coater head 215 can be slot die coating, extrusion coating, gravure coating, co-extrusion coating, slide coating, or curtain coating.
- FIG. 2 d shows another device for fabricating an optical layer in another embodiment of the invention, wherein, as shown, substrate 201 is transported by the unwinder 217 and winder 223 , anti-static solution placed in tank 213 is supplied to the substrate 201 through coating die 215 , and then a structure as shown in FIG. 2 a is formed.
- the coated substrate is transported by the unwinder 217 and winder 223 to an electric field generator 225 , the anti-static particles 205 in anti-static wet layer 206 as shown in FIG. 2 a are attracted and move to the substrate direction by electric force (referred to as electrophoresis) due to tile charged particles, and then the coated substrate is transported to the oven 219 and the curing device 221 , so that solvent is evaporated, resin is hardened, such that the anti-static wet layer 206 (as shown in FIG. 2 a ) is converted to the anti-static layer 207 (as shown in FIG. 2 b ), and then the optical film 200 as shown in FIG. 2 b is formed.
- electrophoresis electric force due to tile charged particles
- An magnetic field generator (not shown) can also be used to replace the electric field generator 225 to attract and aggregate particles if the particles may also be ferromagnetic.
- tile anti-static wet layer 206 is coated from a solution containing photo initiators and at least one of monomers and oligomers dissolved il a solvent.
- Photo initiators can be of benzophenone, 1-hydroxy-cyclohexyl-phenyl-ketone. 2-hydroxy-2-methyl-1-phenyl-1-propanone, or methylbenzoylformate.
- Monomers can be of isobutyl acrylate, 2-ethylhexyl acrylate, 1,6-hexanediol diacrylate, tripropylene glycol diacrylate, trimethylolpropane diacrylate, dipentaerythritol pentaacrylate, pentaerythritol triacrylate, or dipentaerythritol hexaacrylate.
- Oligomers can be of urethane (meth)acrylate oligomer, polyester (meth)acrylate oligomer, or epoxy (meth)acrylate oligomer.
- Solvents can be of Isopropanol (IPA), methyl ethyl ketone (MEK), methyl isobutyl ketone,(MIBK), ethyl acetate(EAC), butyl acetate (BAC), toluene, cyclohexanone.
- IPA Isopropanol
- MEK methyl ethyl ketone
- MIBK methyl isobutyl ketone
- EAC ethyl acetate
- BAC butyl acetate
- toluene cyclohexanone
- methanol or propylene glycol monoethyl esther.
- Inorganic nanoparticles can be added to the anti-static wet layer 206 as shown in FIG. 2 a to reduce the curl level of the anti-static layer 207 as shown in FIG. 2 b due to volume contraction during drying.
- Inorganic nanoparticles can be of silica, alumina, zirconia, titania, zinc oxide, germanium oxide, indium oxide, or tin oxide.
- the anti-static particles 205 as shown in FIG. 2 a and 2 b can be of antimony-doped tin oxide, tin oxide, zinc antimonite, antimony pentoxide, indium tin oxide, or aluminum-doped zinc oxide.
- the radius of the anti-static particles 205 is between about 5 and 100 nm, preferably between about 10 and 40 nm.
- the zeta potential of the anti-static particles 205 in the anti-static wet layer 206 is between about +70 and ⁇ 70 eV, preferably between about ⁇ 10 and ⁇ 50 eV.
- the anti-static particles 205 can stably suspend in the anti-static solution before adding electrolyte or polymeric flocculant, such that the anti-static solution is suitable for storage.
- the anti-static particles 205 are 20 to 80(wt % of the anti-static layer 207 , preferably 30 to 70 wt %.
- Anti-static layer 207 comprises resin layer 203 and anti-static particles 205 .
- Substrate 201 can be of glass, poly(meth)acrylate, polycarbonate, polyethylene (PE), polyethylene terephthalate (PET), or triacetyl cellulose (TAC).
- PE polyethylene
- PET polyethylene terephthalate
- TAC triacetyl cellulose
- comparison 1 and embodiment 1 were respectively coated on 80 um thick triacetyl cellulose (TAC, Fuji corporation) films by RDS no. 5 coating rod, placed in an oven at 70° C. for 3 minutes, radiated by H-type mercury lamp(300 mJ/Cm 2 dose). and anti-static hard coat films were respectively formed.
- anti-scratch properties of the two anti-static hard coat films were tested 10 times by steel wire rope (no. 0000), transmittance was measured by transmittance measuring instrument (type: ND112000. NIPON DESHOKU corporation), and surface resistance was measured at 100 V by surface resistance measuring instrument (type: model 65, Keithley corporation).
- the experimental results are shown in Table 2.
- an optical film according to the invention provides anti-static property and/or anti-scratch property. Its mechanism is described below.
- anti-scratch ability is usually reduced when anti-static particles 205 exist near the surface of the anti-static layer 207 , because the particles 205 and the resin layer 203 are bonded together by weaker physical bonds such as van der Waals force. Therefore, the anti-scratch ability of the anti-static layer 207 is increased while anti-static particles 205 deposited at the bottom, remaining more chemical-bonded resin material on the surface of the anti-static layer 207 .
- the formation of the conductive regions is affected by dispersed particle concentration, zeta potential of the anti-static particles, particle size, and electrolyte concentration.
- the primary particle size of anti-static particles 205 is between about 5 and 100 nm, preferably 10 and 4 nm.
- the anti-static particles 205 are 20 to 80 wt % of the anti-static layer 207 , preferably 30 to 70 wt %.
- Zeta potential of the anti-static particles 205 are between +70 and ⁇ 70 cV, preferably ⁇ 10 and ⁇ 50 eV.
- Added amount of electrolyte depends on its charge, for example, the concentration needed for univalent electrolyte is between about 10 ⁇ 6 and 10 ⁇ 1 M.
- electric field or magnetic field is applied, such that conductive regions are also formed inside the anti-static layer 207 .
- the surface resistance of the anti-static layer 207 thereof is reduced because the number of particles dispersed in bottom half portion 209 b are more than that in top half portion 209 a . This is because collision probability between particles as shown in FIG. 2 a increases resulting from anti-static particles 205 inside anti-static wet layer 206 are attracted and move to bottom portion thereof.
- anti-static 205 particles are not all dispersed in a very narrower area (unlike structures as shown in FIGS. 1 a and 1 b ). Therefore, interference and reflection of the anti-static layer 207 are lower.
Abstract
An optical film and fabrication method thereof are disclosed. The optical film comprises a substrate and an anti-static layer disposed thereon. The anti-static layer comprises a resin layer and a plurality of anti-static particles *wherein the bottom half portion of the anti-static layer contains more than 60 wt % of tile anti-static particles.
Description
- 1. Field of the Invention
- The invention relates to a thin film and fabrication method thereof and in particular to an optical film and fabrication method thereof.
- Liquid crystal display (LCD) and liquid crystal display television (LCD TV) are currently popular in display technology. An optical film having good transmittance is an important component. A hard coat layer is usually coated on an optical film, preventing outside damage. The hard coat layer is mostly insulation and comprises resin materials. such that static electricity is easily accumulated, producing electrostatic discharge (ESD). and dust is readily attracted to its surface. Therefore, an anti-static layer is usually coated on the hard coat layer surface to prevent the static issues.
- A conventional anti-static hard coat layer can be formed by coating once or twice. Two-step coating is more problematic than one-step coating, since some defects appear as a bottom layer coated on a substrate, and other defects appear as a top layer then coated on the bottom layer, so that the defective fraction of two-step coating is higher.
- Two-step coating involves two types, anti-static layer upon hard coat layer and hard coat layer upon anti-static layer.
-
FIG. 1 a shows an anti-statichard coat film 10 a, comprisingsubstrate 12,hard coat layer 14 andanti-static layer 16 respectively disposed on thesubstrate 12, andanti-static particles 18 dispersed in theanti-static layer 16. In this case, electric conductivity is increased due to theanti-static layer 16 disposed as the surface layer of the anti-statichard coat film 10 a but anti-scratch properties are reduced because the hardness and abrasion of theanti-static layer 16 is usually poorer than that of thehard coat layer 14. -
FIG. 1 b shows an anti-statichard coat film 10 b, comprisingsubstrate 12,hard coat layer 14 andanti-static layer 16 respectively disposed on thesubstrate 12, andanti-static particles 18 dispersed in theanti-static layer 16. In this case, anti-scratch properties are increased due to thehard coat layer 14 disposed as the surface layer of tile anti-statichard coat film 10 b, but electric conductivity is reduced. - If the refractive index of the
anti-static particles 18 is high, theanti-static layer 16 as shown inFIGS. 1 a and 1 b will results in interference and high reflection, especially theanti-static particles 18 are collected in a thin layer (the anti-static layer 16). - One-step coating can also be used. Referring to
FIG. 1 c, an anti-statichard coat film 10 c is provided, comprising asubstrate 12 and ananti-static layer 15 disposed thereon. Theanti-static layer 15 comprises aresin layer 19 and dispersedanti-static particles 18. The process of one-step coating is simpler than two-step coating, but the anti-static effects of the anti-statichard coat film 10 c are less than the anti-statichard coat film - A detailed description is given in the following embodiments with reference to the accompanying drawings.
- In an embodiment, an optical film is provided. The optical film comprises a substrate and an anti-static layer disposed thereon. The anti-static layer comprises a resin layer and a plurality of anti-static particles, wherein the bottom half portion of the anti-static layer contains more than 60 wt % of the anti-static particles.
- A method for fabricating an optical film is also provided. A substrate is provided. An anti-static solution is coated on the substrate to form an anti-static wet layer thereon. The anti-static solution comprises a plurality of anti-static particles and a resin material. The anti-static particles are interacted by an external force or an inter-particle force. The anti-static wet layer is dried and cured to form an anti-static layer. Which comprises the anti-static particles and a resin layer. The anti-static layer has a top half portion and a bottom half portion containing more than 60 wt % of the anti-static particles.
- The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
-
FIGS. 1 a to 1 c are cross-sections of conventional anti-static hard coat films. -
FIG. 2 a is a cross section of an anti-static solution coated on a substrate in an embodiment of the invention. -
FIG. 2 b is a cross section of an optical film in an embodiment of the invention. -
FIGS. 2 c to 2 d are devices for fabricating an optical film according to the invention. - The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
- An optical film and fabrication method thereof are provided, with, when a bottom half portion of an anti-static layer contains more than 60 wt % of anti-static particles. properties including anti-scratch anti-static, low reflection or low interference.
-
FIG. 2 a shows anti-staticwet layer 206 being coated on asubstrate 201 in an embodiment of the invention. The anti-staticwet layer 206 comprises solvent andanti-static particles 205 dispersed therein. -
FIG. 2 b is a cross-section of anoptical film 200 in an embodiment of the invention. Theoptical film 200 comprises asubstrate 201 and ananti-static layer 207 disposed thereon. Theanti-static layer 207 comprises aresin layer 203 andanti-static particles 205. Avirtual plane 209 c, parallel to thesubstrate 201, is in the position of half thickness of theanti-static layer 207. The portions ofanti-static layer 207 above and below thevirtual plane 209 c are respectively referred to astop half portion 209 a and bottomhalf portion 209 b. In an embodiment of the invention, thebottom half portion 209 b contains more than 60 wt % of theanti-static particles 205, and in another, between about 60 and 90 wt %, and yet another, between about 70 and 90 wt %. - The anti-static
wet layer 206 as shown inFIG. 2 a is a wet layer (having solvent), after the process described the following, the anti-staticwet layer 206 is dryer and the structure of theanti-static layer 207 as shown inFIG. 2 b is formed. - Referring to
FIG. 2 c, electrolyte intank 211 is added into anti-static solution placed intank 213, and the solution is mixed well by stirring: Added amount of electrolyte depends on its charge.Substrate 201 is transported byunwinder 217 andwinder 223, anti-static solution is supplied to the surface of thesubstrate 201 throughcoater head 215, and then a structure as shown inFIG. 2 a is formed. - After that, the coated substrate is transported by the
unwinder 217 and winder 223 to theoven 219 and the followingcuring device 221, so that solvent is evaporated. resin is hardened, such that the anti-static wet layer 206 (as shown inFIG. 2 a) is converted into anti-static layer 207 (as shown inFIG. 2 b). and then theoptical film 200 as shown inFIG. 2 b is formed. - An acceptable added amount of electrolyte depends on its charge, too high or too low electrolyte concentration is not applicable in the invention. For example. concentration of monovalent electrolyte in anti-static solution is between about 10−6 to 10 −1 M. Aggregation of particles are not obvious when electrolyte concentration is too low, normally lower than 10−6 M. Larger than 1 um particles are dramatically formed such that transmittance of the film is negatively affected when electrolyte concentration is too high, normally higher than 10−1 M.
- In an embodiment of the invention, electrolyte can be acid electrolyte, alkali electrolyte, salts, or other ionic compound, such as NaCl, KCl, KNO3, Na2CO3. Mg(NO3)2. K2SO4. H2CO3, CH3COOH, or KAl(SO4)2. By addition of electrolyte, anti-static particles become unstable, so that collision probability between particles is increased and sedimentation of the aggregated particles becomes easier.
- Electrolyte is used in an embodiment of the invention causing aggregations, while polymeric flocculant (also referred to as polymeric flocculating agent) can also be used. The polymeric flocculent can be inorganic polymeric flocculant such as poly aluminum chloride, or organic polymeric flocculant such as polyacrylamide. While utilizing polymeric flocculant, anti-static particles are bridged by polymer chains, resulting aggregations.
- A stirring apparatus can optionally be used in the
tank 213 as shown inFIG. 2 c, so that electrolyte (or polymeric flocculant) is dissolved (or dispersed) well, and sedimentation of anti-static particles in thetank 213 can be prevented. - Referring to
FIG. 2 b, theresin layer 203 can be of ultraviolet-cured resin. thermal-cured resin, or electron-beam-cured resin, so that thecuring device 221 as shown inFIGS. 2 c and 2 d can be an ultraviolet curing device, a thermal curing device, or a electron beam curing device. - Referring to
FIG. 2 c, the coating method for coating a solution on thesubstrate 201 bycoater head 215 can be slot die coating, extrusion coating, gravure coating, co-extrusion coating, slide coating, or curtain coating. -
FIG. 2 d shows another device for fabricating an optical layer in another embodiment of the invention, wherein, as shown,substrate 201 is transported by theunwinder 217 andwinder 223, anti-static solution placed intank 213 is supplied to thesubstrate 201 through coating die 215, and then a structure as shown inFIG. 2 a is formed. - After that, the coated substrate is transported by the
unwinder 217 andwinder 223 to anelectric field generator 225, theanti-static particles 205 in anti-staticwet layer 206 as shown inFIG. 2 a are attracted and move to the substrate direction by electric force (referred to as electrophoresis) due to tile charged particles, and then the coated substrate is transported to theoven 219 and thecuring device 221, so that solvent is evaporated, resin is hardened, such that the anti-static wet layer 206 (as shown inFIG. 2 a) is converted to the anti-static layer 207 (as shown inFIG. 2 b), and then theoptical film 200 as shown inFIG. 2 b is formed. - An magnetic field generator (not shown) can also be used to replace the
electric field generator 225 to attract and aggregate particles if the particles may also be ferromagnetic. - Referring to
FIG. 2 a, tile anti-staticwet layer 206 is coated from a solution containing photo initiators and at least one of monomers and oligomers dissolved il a solvent. - Photo initiators can be of benzophenone, 1-hydroxy-cyclohexyl-phenyl-ketone. 2-hydroxy-2-methyl-1-phenyl-1-propanone, or methylbenzoylformate.
- Monomers can be of isobutyl acrylate, 2-ethylhexyl acrylate, 1,6-hexanediol diacrylate, tripropylene glycol diacrylate, trimethylolpropane diacrylate, dipentaerythritol pentaacrylate, pentaerythritol triacrylate, or dipentaerythritol hexaacrylate.
- Oligomers can be of urethane (meth)acrylate oligomer, polyester (meth)acrylate oligomer, or epoxy (meth)acrylate oligomer.
- Solvents can be of Isopropanol (IPA), methyl ethyl ketone (MEK), methyl isobutyl ketone,(MIBK), ethyl acetate(EAC), butyl acetate (BAC), toluene, cyclohexanone. methanol, or propylene glycol monoethyl esther.
- Inorganic nanoparticles can be added to the anti-static
wet layer 206 as shown inFIG. 2 a to reduce the curl level of theanti-static layer 207 as shown inFIG. 2 b due to volume contraction during drying. Inorganic nanoparticles can be of silica, alumina, zirconia, titania, zinc oxide, germanium oxide, indium oxide, or tin oxide. - The
anti-static particles 205 as shown inFIG. 2 a and 2 b can be of antimony-doped tin oxide, tin oxide, zinc antimonite, antimony pentoxide, indium tin oxide, or aluminum-doped zinc oxide. The radius of theanti-static particles 205 is between about 5 and 100 nm, preferably between about 10 and 40 nm. - As shown in
FIG. 2 a, the zeta potential of theanti-static particles 205 in the anti-staticwet layer 206 is between about +70 and −70 eV, preferably between about −10 and −50 eV. Theanti-static particles 205 can stably suspend in the anti-static solution before adding electrolyte or polymeric flocculant, such that the anti-static solution is suitable for storage. - As shown in
FIG. 2 b, theanti-static particles 205 are 20 to 80(wt % of theanti-static layer 207, preferably 30 to 70 wt %.Anti-static layer 207 comprisesresin layer 203 andanti-static particles 205. -
Substrate 201 can be of glass, poly(meth)acrylate, polycarbonate, polyethylene (PE), polyethylene terephthalate (PET), or triacetyl cellulose (TAC). - The invention will be better understood by reference to Tables 1 and 3 showing compositions of each comparison and embodiment, and Tables 2 and 4 showing their experimental results.
TABLE 1 compari- embodi- Name composition son 1 ment 1 photo initiator Irgacure 184(Ciba-Geigy) 3 g 3 g monomer pentaerythritol triacrylate 100 g 100 g anti-static CX-Z210IP (Nissan 200 g 200 g particles chemical) solvent methyl ethyl ketone(MEK) 100 g 100 g electrolyte sodium chloride 0 M 0.001 M - The solutions of comparison 1 and embodiment 1 were respectively coated on 80 um thick triacetyl cellulose (TAC, Fuji corporation) films by RDS no. 5 coating rod, placed in an oven at 70° C. for 3 minutes, radiated by H-type mercury lamp(300 mJ/Cm2 dose). and anti-static hard coat films were respectively formed. After that, anti-scratch properties of the two anti-static hard coat films were tested 10 times by steel wire rope (no. 0000), transmittance was measured by transmittance measuring instrument (type: ND112000. NIPON DESHOKU corporation), and surface resistance was measured at 100 V by surface resistance measuring instrument (type: model 65, Keithley corporation). The experimental results are shown in Table 2.
TABLE 2 experimental result comparison 1 embodiment 1 transmittance 89.04% 88.74% surface resistance 2.3*109Ω/cm2 2.5*109Ω/cm2 anti-scratch property with scratch under without scratch under 200 g/cm2 pressure 300 g/cm2 pressure - As shown in Table 2, the anti-static hard coat film of embodiment 1 was not scratched due to sedimentation of anti-static particles result from addition of electrolyte.
TABLE 3 compari- embodi- name composition son 2 ment 2 photo initiator Irgacurc 184(Cita-Geigy) 3 g 3 g monomer dipentaerythritol 50 g 50 g hexaacrylate oligomer CN7295(Sartomer) 50 g 50 g anti-static CX-Z210IP(Nissan 200 g 200 g particles chemical) solvent 1 methyl ethyl ketone(MEK) 50 g 50 g solvent 2 Isopropanol(IPA) 50 g 50 g electrolyte sodium chloride 0M 0.1M - The solutions of comparison 2 and embodiment 2 were respectively coated on 80 um thick triacetyl cellulose (TAC, Fuji corporation) films by RDS no. 5 coating rod, placed in an oven at 70° C. for 3 minutes, radiated by H-type mercury lamp (300 mJ/cm2 dose). and then anti-static hard coat films were respectively formed. After that, anti-scratch properties of the two anti-static hard coat films were tested 10 times by steel wire rope (no. 0000), transmittance was measured by transmittance measuring instrument (type: NDH2000. NIPPON DESHOKU corporation), and surface resistance was measured at 100 V by surface resistance measuring instrument (type: model 65, Keithley corporation). The experimental results were shown in Table 4.
TABLE 4 experimental result comparison 2 embodiment 2 transminance 89.08% 88.01% surface resistance 1.7*1011Ω/cm2 1.2*109Ω/cm2 anti-scratch property without scratch under without scratch under 300 g/cm2 pressure 300 g/cm2 pressure - As shown in table 4. the surface resistance was reduced due to aggregation of anti-static particles result from addition of electrolyte.
- As shown in above experimental result, an optical film according to the invention provides anti-static property and/or anti-scratch property. Its mechanism is described below.
- Referring to
FIGS. 2 a and 2 b, anti-scratch ability is usually reduced whenanti-static particles 205 exist near the surface of theanti-static layer 207, because theparticles 205 and theresin layer 203 are bonded together by weaker physical bonds such as van der Waals force. Therefore, the anti-scratch ability of theanti-static layer 207 is increased whileanti-static particles 205 deposited at the bottom, remaining more chemical-bonded resin material on the surface of theanti-static layer 207. - Since collision probability between particles as shown in
FIG. 2 a is increased resulting from compressed electric double layer (not shown) ofanti-static particles 205 by addition of electrolyte or polymeric flocculant, the number of particles dispersed inbottom half portion 209 b are more than that intop half portion 209 a. Therefore, theanti-static particles 205 are more concentrated and surface resistance thereof is reduced. - The formation of the conductive regions is affected by dispersed particle concentration, zeta potential of the anti-static particles, particle size, and electrolyte concentration. The primary particle size of
anti-static particles 205 is between about 5 and 100 nm, preferably 10 and 4 nm. Theanti-static particles 205 are 20 to 80 wt % of theanti-static layer 207, preferably 30 to 70 wt %. Zeta potential of theanti-static particles 205 are between +70 and −70 cV, preferably −10 and −50 eV. Added amount of electrolyte depends on its charge, for example, the concentration needed for univalent electrolyte is between about 10−6 and 10−1 M. - In another embodiment of the inventions electric field or magnetic field is applied, such that conductive regions are also formed inside the
anti-static layer 207. The surface resistance of theanti-static layer 207 thereof is reduced because the number of particles dispersed inbottom half portion 209 b are more than that intop half portion 209 a. This is because collision probability between particles as shown inFIG. 2 a increases resulting fromanti-static particles 205 inside anti-staticwet layer 206 are attracted and move to bottom portion thereof. - Referring to
FIG. 2 b, although moreanti-static particles 205 are dispersed in thebottom half portion 209 b than tophalf portion 209 a, anti-static 205 particles are not all dispersed in a very narrower area (unlike structures as shown inFIGS. 1 a and 1 b). Therefore, interference and reflection of theanti-static layer 207 are lower. - While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
Claims (9)
1-10. (canceled)
11. A method of fabricating an optical film, comprising:
providing a substrate;
coating an anti-static solution on the substrate to form an anti-static wet layer thereon, wherein the anti-static solution comprises a plurality of anti-static particles and a resin material;
providing the anti-static particles an external force or an inter-particle force;
drying the anti-static wet layer; and
curing the anti-static wet layer to form an anti-static layer, comprising the anti-static particles and a resin layer, and having a top half portion and a bottom half portion containing more than 60 wt % of the anti-static particles.
12. The optical film of claim 11 , wherein the anti-static particles have a primary diameter of 5 to 100 nm.
13. The optical film of claim 11 , wherein the anti-static particles have a primary diameter of 10 to 40 nm.
14. The method of claim 11 , wherein the anti-static particles have a zeta potential of +70 to −70 eV in the anti-static solution.
15. The method of claim 11 , wherein the anti-static particles have a zeta potential of −10 to −50 eV in the anti-static solution.
16. The method of claim 11 , wherein the inter-particle force is provided by adding an electrolyte or a polymeric flocculant to the anti-static solution.
17. The method of claim 16 , wherein the electrolyte has a concentration of 10−6 to 10−1 M in the anti-static solution.
18. The method of claim 11 , wherein the external force is provided by applying an electric field or a magnetic field to the anti-static particles in the anti-static wet layer.
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US11/388,271 US7425365B2 (en) | 2005-11-16 | 2006-03-24 | Optical film and fabrication method thereof |
US11/964,625 US20080096006A1 (en) | 2005-11-16 | 2007-12-26 | Optical film and fabrication method thereof |
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US20090264572A1 (en) * | 2008-04-16 | 2009-10-22 | Liao Chin-Yi | Coating compositions and uses thereof |
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CN101410334B (en) * | 2006-03-30 | 2012-08-29 | 罗迪亚公司 | Modified surfaces and method for modifying a surface |
CN101888905B (en) * | 2007-11-06 | 2013-07-10 | 罗迪亚公司 | Articles having an interface between a polymer surface and a modified glass surface |
JP2010082565A (en) * | 2008-09-30 | 2010-04-15 | Dainippon Printing Co Ltd | Method of producing multilayered coating film using magnetic field |
JP2010110701A (en) * | 2008-11-06 | 2010-05-20 | Taika:Kk | Method of forming metallic luster thin film and metallic luster decorated article using the same |
JP5659494B2 (en) * | 2009-02-17 | 2015-01-28 | 凸版印刷株式会社 | Antireflection film and manufacturing method thereof, polarizing plate, transmissive liquid crystal display |
JP5685074B2 (en) * | 2009-12-28 | 2015-03-18 | 大日本印刷株式会社 | Optical film, optical film manufacturing method, polarizing plate, display panel, and display |
KR101778344B1 (en) * | 2011-03-23 | 2017-09-13 | 다이니폰 인사츠 가부시키가이샤 | Optical laminate, polarising plate, and image display device |
CN103507352A (en) * | 2012-06-20 | 2014-01-15 | 苏州金海薄膜科技发展有限公司 | Static-free screen protection film and its making method |
CN108493196A (en) * | 2018-03-30 | 2018-09-04 | 京东方科技集团股份有限公司 | A kind of underlay substrate and preparation method thereof, equipment, display base plate and display device |
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- 2005-11-16 TW TW94140235A patent/TWI305587B/en active
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TW200720734A (en) | 2007-06-01 |
TWI305587B (en) | 2009-01-21 |
US20070110995A1 (en) | 2007-05-17 |
JP2007140482A (en) | 2007-06-07 |
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