COMPOSITE QUANTUM-DOT OPTICAL FILM

A composite quantum-dot optical film comprises a quantum-dot layer and a substrate, wherein the substrate comprises a unitary body formed by a first material, wherein a plurality of particles are disposed in the unitary body that encapsulates an outer surface of a first particle with said outer surface of the first particle being located above the top surface of the unitary body, wherein the substrate is disposed over the quantum-dot layer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an optical film, and more particularly to a composite quantum-dot optical film.

2. Description of Related Art

Conventional quantum-dot optical film often has an adhesion problem with other optical layers. Additionally, the surface of quantum-dot optical film can be scratched easily. Additionally, the trend of slimming down optical modules affects the compatibility and assembly yield of optical films within compressed modules. This, in turn, influences customers' willingness to adopt mid-to-high-end mainstream models. Therefore, how quantum-dot optical films respond to the trend of slimming down future display products is crucial.

Accordingly, the present invention proposes a new solution to overcome the disadvantages as mentioned above.

SUMMARY OF THE INVENTION

One objective of the present invention is to develop a substrate that has a roughened surface exhibiting excellent antistatic and scratch resistance between optical film layers.

One objective of the present invention is to develop a substrate that has a roughened surface on one side of the substrate that exhibits excellent antistatic and scratch resistance between optical film layers, on the other side of the substrate, a gas and moisture barrier layer is formed through a subsequent vapor deposition or sputtering process.

One objective of the present invention is to develop a composite quantum-dot optical film comprising a substrate disposed on a quantum-dot optical film, wherein the substrate has a roughened surface on one side of the substrate exhibiting excellent antistatic and scratch resistance between optical film layers, on the other side of the substrate, a gas and moisture barrier layer is formed through a subsequent vapor deposition or sputtering process.

In one embodiment, the present invention discloses an optical film comprising: a first substrate, wherein the first substrate comprises a unitary body formed by a first material, wherein a first plurality of particles are disposed in the unitary body, wherein the unitary body comprises a top surface between a first particle and a second particle of the first plurality of particles, wherein the unitary body encapsulates an outer surface of the first particle with said outer surface of the first particle being located above the top surface of the unitary body.

In one embodiment, the present invention discloses a composite optical film comprising: an optical layer; and a first substrate, wherein the first substrate comprises a unitary body formed by a first material, wherein a first plurality of particles are disposed in the unitary body, wherein the unitary body comprises a top surface between a first particle and a second particle of the first plurality of particles, wherein the unitary body encapsulates an outer surface of the first particle with said outer surface of the first particle being located above the top surface of the unitary body, wherein the first substrate is disposed over a top surface of the optical layer.

In one embodiment, the present invention discloses a composite quantum-dot optical film, wherein the composite quantum-dot optical film comprises: a quantum-dot layer comprising a binder and a plurality of quantum dots dispersed in the binder; and a first substrate, being made of a first material, wherein a first plurality of particles are disposed in the first substrate, wherein the first material forms a unitary body that encapsulates the entire outer surface of a first particle with at least one portion of the first particle protruding on the a top surface of the unitary body of the first substrate, wherein the first substrate is disposed over a top surface of the quantum-dot layer.

In one embodiment, the entire first particle is located above the top surface of the unitary body of the first substrate with no portion of the first particle being located below the top surface of the unitary body of the first substrate.

In one embodiment, a first portion of the first particle is located above the top surface of the unitary body of the first substrate, and a second portion of the first particle is located below the top surface of the unitary body of the first substrate.

In one embodiment, the outer surface of the first particle has a roughed surface.

In one embodiment, a first bottom of the first substrate is laminated on a top surface of the quantum-dot layer.

In one embodiment, a first inorganic compound is evaporated or sputtered on a first bottom of the first substrate, wherein the first bottom of the first substrate is laminated on a top surface of the quantum-dot layer.

The detailed technology and above-preferred embodiments implemented for the present invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The detailed explanation of the present invention is described as follows. The described preferred embodiments are presented for purposes of illustrations and descriptions, and they are not intended to limit the scope of the present invention.

The substrate of this invention not only can address the barrier properties in the optical film industry but also enhance the scratch resistance of the quantum dot film. Simultaneously, when used in conjunction with other optical films, it can prevent interference issues caused by adsorption or sticking, resolving one of the anomalies encountered in the panel industry related to poor image quality.

FIG.1Aillustrates a schematic cross-sectional view of the composite quantum-dot optical film according to one embodiment of the present invention,FIG.1Billustrates an enlarged view of the cross-sectional view of the composite quantum-dot optical film according to one embodiment of the present invention. Please refer toFIG.1AandFIG.1B, wherein the composite quantum-dot optical film comprises: a quantum-dot layer200comprising a binder200B and a plurality of quantum dots200A dispersed in the binder200B; and a first substrate250, wherein the first substrate250is formed by a first material, wherein a first plurality of particles250a,250bare disposed in the first substrate250, wherein the first substrate250comprises a top surface250T between a first particle250aand a second particle250bof the first plurality of particles250a,250b,wherein the first material forms the top surface250T of the first substrate250and encapsulates an outer surface250asof the first particle250awith said outer surface250asof the first particle250abeing located above the top surface250T of the first substrate250, as shown inFIG.1B, wherein the first substrate250is disposed over the quantum-dot layer200as shown inFIG.1A.

FIG.1Aillustrates a schematic cross-sectional view of the composite quantum-dot optical film according to one embodiment of the present invention,FIG.1Billustrates an enlarged view of the cross-sectional view of the composite quantum-dot optical film according to one embodiment of the present invention. Please refer toFIG.1AandFIG.1B, wherein the composite quantum-dot optical film comprises: a quantum-dot layer200comprising a binder200B and a plurality of quantum dots200A dispersed in the binder200B; and a first substrate250, wherein the first substrate250comprises a unitary body250U formed by a first material, wherein a first plurality of particles250a,250bare disposed in the unitary body250U, wherein the unitary body250U comprises a top surface250T between a first particle250aand a second particle250bof the first plurality of particles250a,250b,wherein the unitary body250U encapsulates an outer surface250asof the first particle250awith said outer surface250asof the first particle250abeing located above the top surface250T of the unitary body250U, as shown inFIG.1B, wherein the first substrate250is disposed over the quantum-dot layer200as shown inFIG.1A.

In one embodiment, the first substrate250is a first base film.

In one embodiment, the first particle250acomprises silica.

In one embodiment, the first particle250aconsists of silica.

In one embodiment, the first material comprises a polymer.

In one embodiment, the first material consists of polymer.

In one embodiment, the first material comprises PET.

In one embodiment, the first material consists of PET.

In one embodiment, as shown inFIG.1B, a first portion250ap1of the first particle250ais located above the top surface250T of the unitary body250U, and a second portion250ap2of the first particle250ais located below the top surface250T of the unitary body250U.

In one embodiment, as shown inFIG.1C, the entire first particle250ais located above the top surface250T of the unitary body250U with no portion of the first particle250abeing located below the top surface250T of the unitary body250U of the first substrate250.

In one embodiment, as shown inFIG.1C, the entire outer surface250sof the first particle250ais encapsulated by the unitary body250U.

In one embodiment, the outer surface of the first particle has a roughed surface.

In one embodiment, a first bottom of the first substrate250is laminated on a top surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.1AandFIG.1D, the second substrate260comprises a unitary body260U formed by a second material, wherein a second plurality of particles260a,260bare disposed in the unitary body260U, wherein the unitary body260U comprises a top surface260T between a third particle260aand a fourth particle260bof the second plurality of particles260a,260b,wherein the unitary body260U encapsulates an outer surface260asof the first particle260awith said outer surface260asof the third particle260abeing located above the top surface260T of the unitary body260U, wherein the second substrate260is disposed over the bottom surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.1D, a first portion260ap1of the third particle260ais located above the top surface260T of the unitary body260U, and a second portion260ap2of the third particle260ais located below the top surface260T of the unitary body260U.

In one embodiment, as shown inFIG.1E, the entire third particle260ais located above the top surface260T of the unitary body260U with no portion of the third particle260abeing located below the top surface260T of the unitary body260U.

In one embodiment, the second bottom surface260B is laminated on a bottom surface of the quantum-dot layer200.

In one embodiment, the second substrate260is a second base film.

In one embodiment, the third particle260acomprises silica.

In one embodiment, the third particle260aconsists of silica.

In one embodiment, the second material comprises a polymer.

In one embodiment, the second material consists of polymer.

In one embodiment, the second material comprises PET.

In one embodiment, the second material consists of PET.

In one embodiment, as shown inFIG.2, a first inorganic compound is evaporated or sputtered on a first bottom surface250B of the first substrate250to form a barrier layer270, wherein the barrier layer270is laminated on the top surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.2, a second inorganic compound is evaporated or sputtered on the second bottom surface260B of the second substrate260to form a barrier layer280, wherein the barrier layer280is laminated on a bottom surface of the quantum-dot layer200.

In one embodiment, the first inorganic compound is capable of being water-resistant and oxygen-resistant.

In one embodiment, the second inorganic compound is capable of being water-resistant and oxygen-resistant.

In one embodiment, as shown inFIG.2, a second inorganic compound is evaporated or sputtered on a bottom of the second substrate260to form a barrier layer280, wherein the bottom of the barrier layer280is laminated on the bottom surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.1A, a composite quantum-dot optical film is disclosed, wherein the composite quantum-dot optical film comprises: a quantum-dot layer200comprising a binder and a plurality of quantum dots200A dispersed in the binder200B;

and a first substrate250, wherein the first substrate250is formed by a first material, wherein a first plurality of particles250a,250bare disposed in the first substrate250, wherein the first substrate250comprises a top surface250T between a first particle250aand a second particle250bof the first plurality of particles, wherein the first material encapsulates an outer surface250asof the first particle250awith said outer surface250asof the first particle250abeing located above the top surface250T of the first substrate250, wherein the first substrate250is disposed over a top surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.2, a first inorganic compound is evaporated or sputtered on a bottom of the first substrate to form a first barrier layer270, wherein the first barrier layer270is laminated on a top surface of the quantum-dot layer200.

In one embodiment, as shown inFIG.1B, a first portion250ap1of the first particle250ais located above the top surface250T of the unitary body250U, and a second portion250ap2of the first particle250ais located below the top surface250T of the unitary body250U.

In one embodiment, a thickness of the first substrate is in a range of 12-125 um.

In one embodiment, a thickness of the composite quantum-dot optical film is in a range of 36-350 um.

In one embodiment, the plurality of particles comprise at least one of the organic particles: PMMA, PS, or Melamine.

In one embodiment, the plurality of particles comprise at least one of the inorganic particles: Silicon, SiO2, TiO2, CaCO3, Al2O3, ZrO2.

FIG.1Billustrates an enlarged view of the cross-sectional view of the composite optical film according to one embodiment of the present invention. Please refer toFIG.1B, wherein the composite optical film comprises: a first substrate250, wherein the first substrate250comprises a unitary body250U formed by a first material, wherein a first plurality of particles250a,250bare disposed in the unitary body250U, wherein the unitary body250U comprises a top surface250T between a first particle250aand a second particle250bof the first plurality of particles250a,250b,wherein the unitary body250U encapsulates an outer surface250asof the first particle250awith said outer surface250asof the first particle250abeing located above the top surface250T of the unitary body250U.

FIG.3illustrates a method to form a composite quantum-dot optical film according to one embodiment of the present invention, wherein the method comprises: step301: forming a mixture substrate by disposing a plurality of particles in a polymer; step302: performing a stretching process on the mixture substrate to form a first substrate, wherein the polymer encapsulates an outer surface of a first particle with said outer surface of the first particle being located above a top surface of the first substrate.

In one embodiment, the mixture substrate is formed by performing an injection molding with a mixture formed by adding the plurality of particles into said polymer, and the plurality of particles are caused to protrude on a top surface of the first substrate during the stretching process on the mixture substrate.

In one embodiment, the first particle comprises silica.

In one embodiment, the first particle consists of silica.

In one embodiment, the polymer comprises PET.

In one embodiment, the polymer consists of PET.

In one embodiment, the method further comprises laminating the first bottom of the first substrate on a top surface of a quantum-dot layer.

In one embodiment, the method further comprises forming a barrier layer on a first bottom of the first substrate by evaporating or sputtering an inorganic compound on the first bottom of the first substrate to form the barrier layer.

In one embodiment, the method further comprises laminating the first bottom of the barrier layer on the top surface of the quantum-dot layer.

FIG.4illustrates a chart to compare the present invention with the conventional technology. Under the condition of a weight load of greater than 1 Kg, the QD film (roughened) was tested under high temperature and pressure with a light guide plate. There was no adsorption of the light guide plate on the bottom surface, and there were no adsorption indentations of heavy objects. The adsorption state of QD film (non-roughened) will recover in about 2˜3 seconds when paired with a light guide plate. According to the diaphragm sliding test, the roughened QD film moves more smoothly, while the non-roughened QD film moves more astringently, indicating that the roughening effect still achieves the anti-adsorption effect.