阅读说明：本技术 一种高抗刮扩散膜制造方法 (Method for manufacturing high-scratch-resistance diffusion film ) 是由 丁利明 王嫣红 翟才金 于 2020-07-01 设计创作，主要内容包括：本发明公开了一种高抗刮扩散膜制造方法,包括以下步骤：先制备第一扩散层涂布液、第二扩散层涂布液、抗刮层涂布液,然后将第一扩散层涂布液涂布在基材层上,得到第一扩散层,第一扩散层表面通过第一涂布辊表面凹凸不平的花纹形成凸起与凹槽,接着将第二扩散层涂布液涂布在第一扩散层上得到第二扩散层并通过烘箱加热,再将抗刮层涂布液涂布在基材层的下表面得到抗刮层,最后进行熟化,得到一种高抗刮扩散膜。本发明通过设置抗刮层增加抗刮性能解决了摩擦易导致薄膜受到损坏的问题,通过设置凹槽为第二扩散粒子提供回弹空间解决了薄膜受到外力作用时易产生脱落或者刮伤的问题。(The invention discloses a method for manufacturing a high scratch-resistant diffusion film, which comprises the following steps: preparing a first diffusion layer coating liquid, a second diffusion layer coating liquid and an anti-scraping layer coating liquid, coating the first diffusion layer coating liquid on a base material layer to obtain a first diffusion layer, forming protrusions and grooves on the surface of the first diffusion layer through uneven patterns on the surface of a first coating roller, coating the second diffusion layer coating liquid on the first diffusion layer to obtain a second diffusion layer, heating the second diffusion layer by an oven, coating the anti-scraping layer coating liquid on the lower surface of the base material layer to obtain an anti-scraping layer, and finally curing to obtain the high-scratch-resistant diffusion film. The invention solves the problem that the film is easily damaged due to friction by arranging the scratch-resistant layer to increase the scratch resistance, and solves the problem that the film is easily dropped or scratched when the film is subjected to external force by arranging the groove to provide a rebound space for the second diffusion particles.)

1. A method for manufacturing a high scratch-resistant diffusion film is characterized by comprising the following steps: the method comprises the following steps:

a. adding first diffusion particles (21) into polyacrylic resin by a high-speed dispersion machine, wherein the mass ratio of the polyacrylic resin to the first diffusion particles (21) is 1: 3-1: 2, the particle size of the first diffusion particles (21) is 5-10 um, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating for 10-20 min by the high-speed dispersion machine to obtain a first diffusion layer coating liquid;

b. adding second diffusion particles (11), ethyl acetate A and butyl acetate A into the bi-component hydroxyl acrylic resin A through a high-speed dispersion machine, wherein the mass ratio of the bi-component hydroxyl acrylic resin A to the second diffusion particles (11) to the ethyl acetate A to the butyl acetate A is 1:2:3:1, the particle size of the second diffusion particles (11) is 25-30 um, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating for 40-60 min through the high-speed dispersion machine to obtain a second diffusion layer coating liquid;

c. adding the anti-adhesion particles, ethyl acetate B and butyl acetate B into the bi-component hydroxyl acrylic resin B through a high-speed dispersion machine, wherein the mass ratio of the bi-component hydroxyl acrylic resin B to the anti-adhesion particles to the ethyl acetate B to the butyl acetate B is 1:0.1:2:1, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating the mixture for 5-10 min through the high-speed dispersion machine to obtain an anti-scratch layer coating liquid, wherein the viscosity of the anti-scratch layer coating liquid is 5-10 cps;

d. taking a substrate layer (3), coating the first diffusion layer coating liquid obtained in the step a on the substrate layer (3) through a first coating roller to obtain a first diffusion layer (2), wherein the first coating roller is provided with an uneven pattern, the surface of the first diffusion layer (2) forms protrusions (22) and grooves (23) through the uneven pattern, and then carrying out UV curing on the obtained product;

e. b, coating the second diffusion layer coating liquid obtained in the step b on the first diffusion layer (2) through a second coating roller to obtain a second diffusion layer (1), and then heating for 2-5 min through a 120 ℃ drying oven;

f. c, coating the scratch-resistant layer coating liquid obtained in the step c on the lower surface of the base material layer (3) to obtain a scratch-resistant layer (4), heating in a drying oven at 120 ℃ for 3-5 min, and cooling and rolling;

g. and f, curing the product obtained in the step f at the temperature of 50-60 ℃ for 12-24 hours to obtain the high scratch-resistant diffusion film.

2. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the step e is specifically as follows:

e1. coating the second diffusion layer coating liquid obtained in the step b on the first diffusion layer (2) through a second coating roller to obtain a second diffusion layer (1);

e2. forming a first circular bump (12) on the surface of the second diffusion layer (1) through a first adsorption roller;

e3. and (3) heating the product obtained in the step e2 in an oven at 120 ℃ for 2-5 min.

3. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the step f is specifically as follows:

f1. c, coating the scratch-resistant layer coating liquid obtained in the step c on the lower surface of the base material layer (3) to obtain a scratch-resistant layer (4);

f2. forming a second circular bump (41) on the surface of the scratch-resistant layer (4) through a second adsorption roller;

f3. and (4) heating the product obtained from f2 in an oven at 120 ℃ for 3-5 min, and then cooling and rolling.

4. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the bulges (22) are one of round and square.

5. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the groove (23) is one of a round groove and a square groove.

6. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the material of the second diffusion particles (11) is PMMA or PS.

7. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the first diffusion particles (21) are made of PBMA.

8. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the material of the substrate layer (3) is polycarbonate or polyethylene terephthalate or polymethyl methacrylate.

9. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the refractive index of the first diffusion layer (2) is 1.45-1.5, and the refractive index of the second diffusion layer (1) is 1.55-1.6.

10. The method for manufacturing a high scratch resistant diffusion film according to claim 1, wherein: the anti-adhesion particles are made of impact-resistant polystyrene.

Technical Field

The invention relates to a method for manufacturing a film, in particular to a method for manufacturing a high scratch-resistant diffusion film.

Background

The optical diffusion film is rubbed by a conveyor belt in the cutting process, is easy to scrape manually in the packaging process, is easy to rub among films in the transportation process, and is damaged due to various frictions, so that the qualification rate of the films at a client is reduced, and the diffusion film needs to have stronger scratch resistance. Traditional optics diffusion barrier top layer is the plane coating, and most diffusion particle expose diffusion coating, and use the diffusion particle of single particle diameter or narrow dispersion particle diameter in the current diffusion coating mostly, and the particle is more salient, easily makes the film when receiving the exogenic action, produces and drops or the scratch. The above problems may degrade the quality of the film and need to be solved.

Disclosure of Invention

The invention provides a novel method for manufacturing a high scratch-resistant diffusion film, aiming at the defects that the film is easily damaged due to friction, and diffusion particles are more protruded and easily fall off or scratch when being subjected to external force in the prior art.

In order to solve the technical problems, the invention is realized by the following technical scheme:

a method for manufacturing a high scratch-resistant diffusion film comprises the following steps:

a. adding first diffusion particles into polyacrylic resin by a high-speed dispersion machine, wherein the mass ratio of the polyacrylic resin to the first diffusion particles is 1: 3-1: 2, the particle size of the first diffusion particles is 5-10 um, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating for 10-20 min by the high-speed dispersion machine to obtain a first diffusion layer coating liquid;

b. adding second diffusion particles, ethyl acetate A and butyl acetate A into the bi-component hydroxyl acrylic resin A through a high-speed dispersion machine, wherein the mass ratio of the bi-component hydroxyl acrylic resin A to the second diffusion particles to the ethyl acetate A to the butyl acetate A is 1:2:3:1, the particle size of the second diffusion particles is 25-30 um, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating for 40-60 min through the high-speed dispersion machine to obtain a second diffusion layer coating liquid;

c. adding the anti-adhesion particles, ethyl acetate B and butyl acetate B into the bi-component hydroxyl acrylic resin B through a high-speed dispersion machine, wherein the mass ratio of the bi-component hydroxyl acrylic resin B to the anti-adhesion particles to the ethyl acetate B to the butyl acetate B is 1:0.1:2:1, the rotating speed of the high-speed dispersion machine is 2000-3000 rpm/min, and treating the mixture for 5-10 min through the high-speed dispersion machine to obtain an anti-scratch layer coating liquid, wherein the viscosity of the anti-scratch layer coating liquid is 5-10 cps;

d. b, taking a substrate layer, coating the first diffusion layer coating liquid obtained in the step a on the substrate layer through a first coating roller to obtain a first diffusion layer, wherein the first coating roller is provided with uneven patterns, protrusions and grooves are formed on the surface of the first diffusion layer through the uneven patterns, and then carrying out UV curing on the obtained product;

e. b, coating the second diffusion layer coating liquid obtained in the step b on the first diffusion layer through a second coating roller to obtain a second diffusion layer, and then heating for 2-5 min through a drying oven at 120 ℃;

f. coating the scratch-resistant layer coating liquid obtained in the step c on the lower surface of the base material layer to obtain a scratch-resistant layer, heating the scratch-resistant layer in a drying oven at the temperature of 120 ℃ for 3-5 min, and cooling and rolling;

g. and f, curing the product obtained in the step f at the temperature of 50-60 ℃ for 12-24 hours to obtain the high scratch-resistant diffusion film.

When the mass ratio of the polyacrylic resin to the first diffusion particles in the step a is 1: 3-1: 2, the polyacrylic resin can enable the first diffusion particles to be uniformly distributed in the first diffusion particles, and meanwhile, the effect of rapid curing is achieved. The components in the second diffusion layer coating liquid in the step b are selected according to the proportion, so that the second diffusion particles can be uniformly suspended in the bi-component hydroxyl acrylic resin A, and meanwhile, the ethyl acetate A and the butyl acetate A in the proportion of 3:1 have higher volatilization speed, so that the second diffusion layer can be quickly dried after coating. The anti-scratch layer coating liquid in the step c is prepared from the components according to the proportion, so that the anti-adhesion particles can be uniformly suspended in the two-component hydroxy acrylic resin B, the viscosity is kept at 5-10 cps, the liquid on the film surface can be quickly leveled when the anti-scratch layer is coated, and the generation of vertical lines and horizontal lines is reduced. The substrate layer in the step d has good anti-deformation capacity and bearing capacity, the first diffusion layer formed by coating can correct light rays into an even surface light source so as to achieve the effect of optical diffusion, glare is reduced, the visual angle is increased, the protrusion of the first diffusion layer can play a role of light condensation, the brightness of the film is improved, the groove of the first diffusion layer provides a containing space for the second diffusion particles, and the resilience space of the second diffusion particles is increased. And e, enabling the second diffusion layer generated in the step e to scatter light rays to enable the overall brightness of the light rays to be more uniform, heating the light rays by using an oven to quickly volatilize the ethyl acetate A and the butyl acetate A, controlling the temperature to be 120 ℃, and not causing the coated layers to deform when the temperature is higher than the boiling points of the ethyl acetate A and the butyl acetate A. And f, the scratch-resistant layer generated in the step f plays a scratch-resistant role, the ethyl acetate B and the butyl acetate B can be quickly volatilized by heating in an oven, the temperature is controlled to be 120 ℃, the temperature is higher than the boiling points of the ethyl acetate B and the butyl acetate B, and simultaneously, the coated layers cannot be excessively high to deform. The curing operation in step g may completely volatilize the residual solvent.

The invention solves the problem that the film is easily damaged due to friction by arranging the scratch-resistant layer to increase the scratch resistance, and solves the problem that the film is easily dropped or scratched when the film is subjected to external force by arranging the groove to provide a rebound space for the second diffusion particles.

Preferably, in the method for manufacturing a high scratch resistance diffusion film, step e specifically includes:

e1. coating the second diffusion layer coating liquid obtained in the step b on the first diffusion layer by a second coating roller to obtain a second diffusion layer;

e2. forming a first circular bump on the surface of the second diffusion layer through a first adsorption roller;

e3. and (3) heating the product obtained in the step e2 in an oven at 120 ℃ for 2-5 min.

The first circular protrusion is arranged, so that the surface roughness of the film is increased, the scratch resistance can be effectively improved, a certain light condensation effect can be achieved, and the brightness is improved.

Preferably, in the method for manufacturing a high scratch resistance diffusion film, the step f specifically includes:

f1. c, coating the scratch-resistant layer coating liquid obtained in the step c on the lower surface of the base material layer to obtain a scratch-resistant layer;

f2. forming a second circular bulge on the surface of the scratch-resistant layer through a second adsorption roller;

f3. and (4) heating the product obtained from f2 in an oven at 120 ℃ for 3-5 min, and then cooling and rolling.

The second circular bulge formed on the surface of the scratch-resistant layer increases the surface roughness of the diffusion film, can effectively increase the scratch resistance, and is mainly an anti-adhesion layer, so that the structure increases the light source atomization performance, and the light rays are homogenized.

Preferably, in the above method for manufacturing a high scratch resistance diffusion film, the protrusions are in one of a circular shape and a square shape.

The circular bulge can increase the light gathering effect, and when the first diffusion layer is damaged due to strong damage, the second diffusion layer still has the recovery performance, and the scraping-resistant and pressure-resistant effects are achieved. The square bulges can ensure that the light rays are atomized more uniformly and the interference of the light rays is reduced.

Preferably, in the above method for manufacturing a high scratch resistant diffusion film, the groove is one of a circular groove and a square groove.

When the upper layer of the circular groove is stressed, the resilience space of the second diffusion particles is increased, and the force can be dispersed during stress, so that the circular groove is more resistant to compression and scraping. The square groove plays a role in fixing the second diffusion particles, so that the second diffusion particles are not deviated, and the light ray atomization effect is better.

Preferably, in the method for manufacturing a high scratch resistant diffusion film, the second diffusion particles are made of PMMA or PS.

The PMMA is named as polymethyl methacrylate in Chinese, the PS is named as polystyrene in Chinese, and the second diffusion particles made of the materials are uniform in particle, good in light transmittance and haze effect, high in scratch resistance and high in hardness index.

Preferably, in the method for manufacturing a high scratch resistance diffusion film, the first diffusion particles are made of PBMA.

The PBMA is named as polybutylmethacrylate in Chinese, the PBMA particles have a recovery performance, have a buffering function when being used as first diffusion particles, play a role in resisting pressure and scraping, and are uniform in particles and good in light transmittance and haze effect.

Preferably, in the above method for manufacturing a high scratch resistant diffuser film, the material of the substrate layer is polycarbonate, polyethylene terephthalate or polymethyl methacrylate.

The base material made of the material has high light transmittance and low optical haze, so that the superior performance is ensured, and meanwhile, the material has the advantages of high temperature resistance, convenience in production and the like.

Preferably, in the method for manufacturing a high scratch resistance diffusion film, the refractive index of the first diffusion layer is 1.45 to 1.5, and the refractive index of the second diffusion layer is 1.55 to 1.6.

The refractive index of the second diffusion layer is higher than 1.5, so that the refraction light path in the second diffusion layer is reduced, the scattering loss light is reduced, and the brightness of the high scratch-resistant diffusion film is improved.

Preferably, in the method for manufacturing a high scratch resistant diffusion film, the anti-blocking particles are made of impact resistant polystyrene.

The impact-resistant polystyrene is selected as the anti-adhesion particles, and has the advantages of good elasticity, good diffusion property, good dispersibility, difficult adhesion and the like.

Drawings

Fig. 1 is a schematic structural view of embodiments 1 to 3 of the present invention;

fig. 2 is a schematic structural diagram of embodiments 4 to 6 of the present invention;

fig. 3 is a schematic structural diagram of embodiments 7 to 9 of the present invention.

Detailed Description

The invention will be described in further detail below with reference to the accompanying figures 1-3 and the detailed description, but they are not intended to limit the invention: