Antiglare Layer Formation on Polycarbonate Sheet Using UV-Curable Resin-induced Crystallization and Subsequent CO2 Gas Foaming

A low-reflectance film was used to reduce the reflection of light from the displays of electronic devices (personal computers, televisions, smartphones, etc.). In this study, an ultraviolet (UV)-curable resin was used to form a nano/microstructure by organic-solvent-induced crystallization and to fill the cracks in the polycarbonate plate. Two different processes were examined: Process 1: the surface of the polycarbonate plate was crystallized at 40, 60, 80, or 100 oC for 10 min and thoroughly rinsed with isopropyl alcohol; and Process 2: the surface of the polycarbonate plate was crystallized at 40 oC for a desired time. The excess UV-curable resin was removed by UV-induced curing and CO2 foaming during UV exposure using high-pressure CO2 equipment. CO2 pressures of 4.5, 5.5, and 6.5 MPa and CO2 impregnation times of 80, 160, 240 s were investigated to optimize the microstructure. It was clarified that spherulites of polycarbonate existed on the surface by differential scanning calorimetry and scanning electron microscopy. The surface prepared with Process 2 had a relative reflectance that was about 600 and 30 times lower than those of the untreated polycarbonate plate and a commercially available low-reflectance film, respectively.