JP2002107502A - Method for manufacturing optical component, optical component and electronic apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an optical component by which the reduction in the manufacturing cost can be realized by enhancing the productivity of optical components such as a surface cover having a functional film, and to provide an optical component manufactured by the method and an electronic instrument using the optical component. SOLUTION: In manufacturing a surface cover 13 with a lens shape having a functional film such as an antireflection layer, film formation is performed by dip coating on a large-sized substrate 150 which can provide multiple surface covers 13. After forming functional films on the front and back surfaces of the substrate 150, a plurality of surface covers 13 are cut out from the substrate 150. In the substrate 150, the functional film is formed on the surface of the surface cover 13 having a lens shape with a uniform film thickness even when the film formation is performed by dip coating, by ensuring liquid reservoir parts 155 to hold surplus liquid objects by dip coating between the areas where the surface covers 13 with a lens shape are cut out.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an optical component having various films formed on the surface of a transparent substrate having a lens shape, an optical component manufactured by the method, and an electronic apparatus using the optical component. Things. More specifically, the present invention relates to a technology for manufacturing an optical component.

[0002]

2. Description of the Related Art In an electronic apparatus such as a portable telephone, a display section is often constituted by an electro-optical unit using a liquid crystal panel or the like. As shown in FIG. 2, the electro-optical unit includes a liquid crystal panel 400 and a lighting device 1 capable of illuminating the liquid crystal panel 400 from the back side.
0. This electro-optical unit 100
In the lighting device 10, the transparent light guide plate 11 for the backlight and the back side 11 of the light guide plate 11 for the backlight are provided.
1 between the reflection sheet 12 and the front surface side 112 of the backlight light guide plate 11 so as to sandwich the liquid crystal panel 400 to be illuminated.
1 transparent front cover 1 arranged opposite to the front side 112
3 and a light source 14 for emitting light toward the inside of the backlight light guide plate 11.
A diffuse reflection pattern 110 is formed on the back surface side 111 of FIG. Here, the front cover 13 is connected to the liquid crystal panel 40.
In addition to protecting 0, an image displayed on the liquid crystal panel 400 is enlarged and displayed. Therefore, the front cover 13 has a convex lens shape in which the back surface 131 is flat and the front surface 132 is swollen.

The electro-optical unit 10 configured as described above
0, the light emitted from the light source 14 enters the inside of the light guide plate 11 for the backlight,
Are emitted toward the back side 402 of the liquid crystal panel 4.
No. 00 can modulate the light incident from the back side 401 in the process of transmitting to the front side 402. Therefore, an image can be displayed on the liquid crystal panel 400 by turning on or off each pixel included in the liquid crystal panel 400, and this image can be viewed through the front cover 13.

The liquid crystal panel 400 may be of a so-called semi-transmissive / semi-reflective type. Such a semi-transmissive / semi-reflective type liquid crystal panel 400 transmits through the front cover 13 and has a front side 402. It is also possible to modulate this light in the process of reflecting external light incident from the surface and exiting from the front side 402.

Therefore, in the transparent cover 13, an antireflection layer (not shown) is conventionally formed on the front side 132 by a sputtering method.
Are formed to prevent reflection on the front side 132.

[0006]

However, when a functional film such as an anti-reflection layer is formed on the front side 132 of the transparent cover 13 by a sputtering method, the film forming speed is low, and
Because it is necessary to form a film in a vacuum device, productivity is low,
There is a problem that the manufacturing cost is high.

In particular, in the case of small electronic devices such as portable telephones, the color display is progressing. Such color display is realized by the colorization of the liquid crystal panel 400. LCD panel 4
Despite the rise in the cost of 00, there is a situation in which such an increase in cost cannot be passed on to the price of a mobile phone or the like.

In addition, when performing color display, a large amount of light is required as compared with when performing monochrome display. Therefore, antireflection layers are required on both the front side 132 and the rear side 131 of the transparent cover 13. , Front side 1 of transparent cover 13
If an anti-reflection layer is formed on both the side 32 and the back side 131 by a sputtering method, it is necessary to perform the sputter deposition on the front side 132 and the sputter deposition on the back side 131, so that the manufacturing cost is significantly increased.

[0009] In view of the above problems, an object of the present invention is to provide:
A method of manufacturing an optical component capable of reducing the manufacturing cost by increasing the productivity of an optical component such as a surface cover on which a functional film is formed, an optical component manufactured by this method, and a method using the optical component It is to provide an electronic device.

[0010]

According to the present invention, there is provided a method for manufacturing an optical component, comprising at least one functional film formed on at least a surface of a transparent substrate having a lens shape. In forming at least one layer of the film, a plurality of the transparent substrates, a large substrate connected in an in-plane direction is immersed in a liquid material, and then the large substrate is pulled up from the liquid material to remove the large substrate. An immersion step of forming a coating film on both the front side and the back side is performed. After the immersion step, a cutting step of cutting out a plurality of the optical components from the large-sized substrate is performed.

According to the present invention, when manufacturing an optical component having a functional film such as an anti-reflection layer, a film is formed on a large substrate from which a large number of optical components can be formed. Cut out parts. Therefore,
Since a plurality of optical components can be formed simultaneously, the productivity is high. Also, in forming the functional film, the film is formed by an immersion method instead of a sputtering method that requires a vacuum apparatus, so that productivity is high, and such an immersion method can be used for a large substrate. A film can be formed efficiently. In addition, even when it is desired to form the film on both the front and the back as in the case of an anti-reflection film, the film can be formed on both the front and the back simultaneously by the immersion method. Therefore, the manufacturing cost of the optical component on which the functional film is formed can be significantly reduced.

In the present invention, the transparent substrate has, for example, a lens shape in which the back surface is flat and the front surface is swollen.

In the present invention, at least a hard coat layer, an anti-reflection layer, and a water repellent layer are formed as the functional film on at least the surface side of the transparent substrate, and the hard coat layer, the anti-reflection layer, Performing a pre-dipping step in forming at least one of the water-repellent layers;
After performing the immersion step, a cutting step of cutting out a plurality of the optical components from the large-sized substrate is performed.

In the present invention, among the hard coat layer, the anti-reflection layer, and the water-repellent layer, it is preferable that at least the anti-reflection layer is formed by the dipping step in the large-sized substrate. In the case of an anti-reflection film, it is preferable to form it on both front and back, and in the case of an anti-reflection film, it is often formed from a plurality of layers.
If the antireflection film is formed by the immersion method, the productivity of the optical component can be remarkably improved, so that the manufacturing cost of the optical component can be greatly reduced.

In the present invention, it is preferable that all of the hard coat layer, the antireflection layer, and the water repellent layer are formed by the dipping step for the large substrate.

In the present invention, in the cutting step, for example, the large substrate is cut by a laser beam. Or,
The large substrate may be cut by die cutting using cutting teeth.

In the present invention, the large-sized substrate is, for example, a plastic molded product from which a plurality of the transparent substrates are cut out.

In this case, the large substrate is provided with a plurality of regions cut out as the transparent substrate for a flat plastic molded product having no holes between the regions cut out as the transparent substrate. Is preferred. If such unnecessary holes are not provided, the accumulation of excess liquid can be prevented, so that the functional film can be formed to have a uniform thickness even by the immersion method.

In the present invention, the large substrate employs a configuration in which regions cut out as the transparent substrate are arranged in a lattice, or a configuration in which the regions cut out as the transparent substrate are arranged in a staggered manner. be able to.

In the present invention, it is preferable that a flat liquid reservoir is formed between the regions cut out as the transparent substrate in the large-sized substrate. With this configuration, even when a film is formed by a dipping method on a large substrate having swelling or the like at a predetermined interval, an excessive liquid material is retained in the liquid reservoir, so that in a region cut out as an optical component, A functional film having a uniform thickness can be formed.

In the present invention, in the immersion step, the large-sized substrate may be pulled up from the liquid in a posture inclined in an in-plane direction or an out-of-plane direction.

In an optical component manufactured by such a method,
At least one functional film is formed on at least the front side of the transparent substrate having a lens shape, and at least one of the functional films has a layer thickness equal to both the front side and the back side of the transparent substrate. It is formed with.

In the present invention, the transparent substrate has a lens shape in which the back surface is flat and the front surface is swollen.

In the present invention, at least the hard coat layer, the antireflection layer, and the water repellent layer are formed as the functional film on at least the surface side of the transparent substrate. , The anti-reflection layer, and at least one of the water-repellent layers,
The transparent substrate is formed with the same layer thickness on both the front side and the back side.

In the present invention, among the hard coat layer, the antireflection layer, and the water repellent layer, it is preferable that at least the antireflection layer is formed on both the front side and the back side of the transparent substrate.

In the present invention, a hard coat layer is formed on at least the front side and the back side of the transparent substrate having a lens shape.
An anti-reflection layer, and a water-repellent layer are formed, and each of the hard coat layer, the anti-reflection layer, and the water-repellent layer is formed on both the front side and the back side of the transparent substrate in the same front-back order Preferably, it is formed.

In an electronic apparatus using an optical component to which the present invention has been applied, for example, the optical component is disposed as a front cover with the front side facing outward, facing the front side of the electro-optical panel constituting the display section. used.

In the present invention, the electro-optical device is a liquid crystal panel that can modulate external light that has passed through the front cover and entered from the front side while the light is reflected toward the front cover. .

The effect of the present invention is remarkable when the liquid crystal panel is for color display.

[0030]

Embodiments of the present invention will be described with reference to the accompanying drawings.

(Overall Configuration of Electronic Apparatus) FIG. 1 is a perspective view showing the appearance of a mobile phone as an example of an electronic apparatus to which the present invention is applied, and FIGS. 2 and 3 are used in this mobile phone. FIG. 3 is a cross-sectional view of an electro-optical unit with a lighting device, and a cross-sectional view of a front cover used in the electro-optical unit.

In FIG. 1, a display unit 2 using a liquid crystal panel 400 as an electro-optical panel is formed in an upper half of a mobile phone 1 (electronic device) of the present embodiment, and a lower half thereof is Operation unit 3 on which a plurality of key buttons 301 are arranged
Is configured. A speaker hole 4 is formed above the display unit 2, and a microphone hole 5 is formed below the operation unit 3.

In configuring the display unit 2 in the mobile phone 1, an electro-optical unit 100 shown in FIG. 2A is used. Electro-optical unit 100
Is the liquid crystal panel 400 (electro-optic panel / illumination target)
And an illuminating device 10 capable of emitting light to the back surface 401 of the liquid crystal panel 400.

The illuminating device 10 includes a light guide plate 11 for backlight made of a transparent plastic molded product, a reflection sheet 12 (reflection surface) formed on the back surface 111 of the light guide plate 11 for backlight, and a backlight light guide plate 11. A transparent front cover 13 disposed opposite to the front side 112 of the backlight light guide plate 11 so as to sandwich the liquid crystal panel 400 between the front surface side 112 of the light guide plate 11 and the light guide plate 11 for backlight;
And a light source 14 such as an LED that emits light inward. The front cover 13 has a rear surface 131.
Are arranged such that an air layer is interposed between the liquid crystal panel 400 and the liquid crystal panel 400. Back side 111 of light guide plate 11 for backlight
Is formed with a diffuse reflection pattern 110. When the light emitted from the light source 14 is made to enter the light guide plate 11 for backlight, one or more light source storage holes 119 are formed on the back surface 111 of the light guide plate 11 for backlight. A light source 14 is arranged in each of the 119.

The electro-optical unit 10 configured as described above
0, the front cover 13 includes a lens-shaped transparent substrate 15 having a flat rear surface 131 and a swelling front surface 132;
And a functional film laminated on the front side 132 of the transparent substrate 15. In this embodiment, the front cover 13
The hard coat layer 171 and the antireflection layer 181, as functional films, are provided on the front side 132 of the transparent substrate 15 via a primer layer 161 formed as a base on the front side 132 of the transparent substrate 15.
And a water-repellent layer 191 are formed in this order. Also,
In this embodiment, the hard coat layer 172 is formed on the back surface 131 of the front cover 13 via the primer layer 162 formed as a base on the back surface 132 of the transparent substrate 15 as a functional film, similarly to the front surface 132. The prevention layer 182 and the water-repellent layer 192 are formed in this order. Here, the primer layers 161, 162, the hard coat layers 171, 1
72, antireflection layers 181, 182, and water repellent layer 19
The thicknesses of the layers 1 and 192 are equal and uniform between the front side 132 and the back side 131 of the front cover 13.

(Structure of Liquid Crystal Panel 400) The structure of the liquid crystal panel 400 used as the electro-optical panel in the portable telephone 1 of the present embodiment will be described with reference to FIGS.

FIGS. 4 and 5 show the liquid crystal panel 4 respectively.
FIG. 9 is a perspective view and an exploded perspective view when 00 is viewed obliquely from below. FIG. 6 is a cross-sectional view of the liquid crystal panel 400.

In FIGS. 4, 5 and 6, a liquid crystal panel 400 is a passive matrix type color liquid crystal panel, and a pair of transparent glass members made of rectangular glass or the like bonded together by a sealing material 430 with a predetermined gap therebetween. A liquid crystal sealing region 435 is defined between the substrates by a sealant 430, and liquid crystal is sealed in the liquid crystal sealing region 435. Here, of the pair of transparent substrates, a substrate on which a plurality of rows of first electrode patterns 440 extending in the vertical direction in the liquid crystal sealing region 435 are formed is referred to as a first transparent substrate 410, and the liquid crystal sealing region The substrate on which a plurality of rows of second electrode patterns 450 extending in the horizontal direction within 435 are formed is referred to as a second transparent substrate 420.

As shown in FIG. 6, red (R) and green (G) regions are provided on the second transparent substrate 420 at regions corresponding to intersections of the first electrode pattern 440 and the second electrode pattern 450. , Blue (B) color filters 407R, 407
G, 407B are formed, and these color filters 40
7R, 407G, and 407B on the surface side, an insulating planarizing film 426, a second electrode pattern 450, and an alignment film 42.
6 are formed in this order. On the other hand, the first electrode pattern 440 and the alignment film 412 are formed on the first transparent substrate 410 in this order.

In the liquid crystal device 400, the second electrode pattern 450 is made of an ITO film (Indium Tin O 2).
xide / transparent conductive film). On the other hand, the first electrode pattern 440 is formed of a thin aluminum film, and a part of the light reaching the first electrode pattern 440 formed of the thin aluminum film is first.
, And a part of the light is reflected by the first electrode pattern 440. Therefore, the liquid crystal panel 400
The transflective liquid crystal panel has both a function as a transmissive liquid crystal panel and a function as a reflective liquid crystal panel. Note that a polarizing plate 461 is attached to an outer surface of the second transparent substrate 420, and a polarizing plate 462 is attached to an outer surface of the first transparent substrate 410.

In configuring such a semi-transmissive / semi-reflective liquid crystal panel 400, a first electrode pattern 440 is formed of an aluminum film or the like having a thickness that completely reflects light, and the first electrode pattern 440 is formed. Of the patterns 440,
A small light transmitting hole may be formed at a portion that intersects with the second electrode pattern 450.

Referring to FIGS. 4 and 5, a liquid crystal panel 40 is shown.
0, both the input / output of signals to / from the outside and the continuity between the substrates are performed. Each of the substrate sides 41 located in the same direction of the first transparent substrate 410 and the second transparent substrate 420 is used.
A first terminal formation region 411 and a second terminal formation region 421 formed on the first transparent substrate 410 and the second transparent substrate 420 near 8, 428 are used. Here, as the second transparent substrate 420,
A substrate larger than the first transparent substrate 410 is used, and when the first transparent substrate 410 and the second transparent substrate 420 are bonded to each other, the second transparent substrate extends from the substrate side 418 of the first transparent substrate 410. The drive I
C490 is COG mounted. The second terminal formation region 421 of the second transparent substrate 420 is
Input / output terminals 481 are formed at a portion located closer to the substrate side 421 than 90, and the flexible substrate 70 is connected to these input / output terminals 481.

In the second terminal formation region 421, a portion located on the side of the liquid crystal sealing region 435 with respect to the driving IC 490 is used for conduction between the first transparent substrate 410 and the first transparent substrate 410. It is formed in a portion overlapping with the transparent substrate 410. In the first transparent substrate 410, the first terminal formation region 411 is
Since it is used for conduction between the substrate and the 0 side, it is formed at the overlapping portion with the second transparent substrate 420.

Therefore, the first transparent substrate 410 and the second transparent substrate 420 are connected to each other by the sealing material 43 containing the inter-substrate conducting agent.
0, and the terminals for inter-substrate conduction are conducted between the substrates, and a signal is input from the input / output terminal 481 of the second transparent substrate 420 to the driving IC 490.
Is supplied to the first electrode pattern 440 and the second electrode pattern 450, so that each of the pixels corresponding to the intersection of the first electrode pattern 440 and the second electrode pattern 450 is driven. be able to.

(Display Operation) The display operation in the electro-optical unit 100 will be described with reference to FIGS. In these figures, the liquid crystal panel 400 is configured as a semi-transmissive / semi-reflective type, so that the light incident from the back side 401 can be modulated in the process of transmitting to the front side 402, and It is also possible to modulate this light in the process of transmitting external light that has passed through the front cover 13 and incident from the front side 402 and exits from the front side 402.

Therefore, in the electro-optical unit 100, the light emitted from the light source 14 enters the backlight light guide plate 11, and then is repeatedly reflected in the backlight light guide plate 11 while being repeatedly reflected in the backlight light guide plate 11. Light plate 1
1 and the liquid crystal panel 400
Are emitted toward the back side 401 of the light emitting element. Therefore, in the liquid crystal panel 400, if the alignment state of the liquid crystal 404 for each pixel is controlled by the electric field applied to the first electrode pattern 440 and the second electrode pattern 450, the liquid crystal panel 4
The light incident from the back side 401 of the liquid crystal panel 400 is transmitted through the first electrode pattern 440 and then modulated by the liquid crystal 404 for each pixel.
02 is emitted. Therefore, an image is displayed on the liquid crystal panel 400, and this image can be viewed through the front cover 13 (transmission mode).

Further, in the electro-optical unit 400 of the present embodiment, external light that has passed through the front cover 13 and entered the front side 402 of the liquid crystal panel 400 receives the first electrode pattern 4.
After being reflected at 40, the light is emitted from the front side 402 of the liquid crystal panel 400. Since such light is also modulated by the liquid crystal 404 for each pixel, an image is displayed on the liquid crystal panel 400, and the image can be viewed through the front cover 13 (reflection mode).

Accordingly, the front cover 13 is required to have a low reflectance at the interface between the front side 132 and the back side 131 in both the transmission mode and the reflection mode. Cover 1
The anti-reflection layers 181 and 182 are formed on both the front side 132 and the back side 131 of No.3.

The front cover 13 has a low hardness because the transparent substrate 15 is a plastic molded product, but has a hard coat layer 171 and a hard coat layer 171 on the back side 131.
Since 72 is formed, the surface is not easily damaged.

Further, the front side 132 of the front cover 13
Is exposed on the outside and is in a state where it can be easily touched by human hands. However, since a water-repellent layer 191 as an antifouling layer is formed on the front side 132 of the front cover 13,
The surface side 132 of 3 is not easily adhered to dirt such as hand marks.

The back side 131 of the front cover 13 is
Since it faces inward, no object or hand touches it after it is assembled as a mobile phone.
Since the hard coat layer 172 and the water-repellent layer 192 are also formed on the base 31, the back side 131 of the front cover 13 is also less likely to be scratched or stained.

(Manufacturing Method of Front Cover 13) A manufacturing method of the front cover 13 used in the electro-optical unit 100 of the embodiment will be described with reference to FIGS.

FIGS. 7A and 7B are a perspective view of a large substrate used to take a large number of front covers 13 in a process of manufacturing the front cover 13 and a cross-sectional view of the large substrate. . FIGS. 8A and 8B respectively show:
FIG. 9 is a process cross-sectional view illustrating an immersion process for forming a functional film on the surface of the front cover 13.

In manufacturing the front cover 13 of this embodiment, first, as shown in FIGS. 7A and 7B, a plurality of single transparent substrates 15 constituting the front cover 13 are formed in the in-plane direction. The connected large substrate 150 is plastic-molded from acrylic resin or the like. In the large substrate 150 shown here, a plurality of regions to be cut out as the transparent substrate 15 are arranged in a grid on a single plastic plate, and extra holes and the like are provided between the regions to be cut out as the transparent substrate 15. Absent. Further, in the large-sized substrate 150, a flat surface is secured with a predetermined width between the regions to be cut out as the transparent substrate 15, and this flat surface is a liquid in which excess liquid material is accumulated when a immersion step described later is performed. It functions as the reservoir 155.

The primer layers 161 and 16 described with reference to FIG.
2. Hard coat layers 171, 172, antireflection layer 18
In order to sequentially form 1, 182 and the water-repellent layers 191 and 192, in this embodiment, an immersion step shown in FIGS. 8A and 8B is performed.

In this dipping step, the primer layer 161,
162, hard coat layers 171, 172, antireflection layer 1
81, 182 and the respective liquids 200 for forming the water-repellent layers 191 and 192 are prepared, and then the large substrate 150 is immersed in the liquids 200 as shown in FIG.
As shown in FIG. 8B, the film is pulled up at a predetermined speed to form a coating film on the surface of the large-sized substrate 150.
A baking process is performed. Such an immersion step is repeated as many times as necessary, and the primer layers 161, 162, the hard coat layers 171, 172, the antireflection layers 181, 182, and the water repellent layers 191, 192 are sequentially formed on the surface of the large substrate 150.
Laminate.

In forming a coating film by such an immersion method, in this embodiment, to form the primer layers 161 and 162, for example, after immersing the large substrate 150 in a solution of a silane coupling agent, The film is pulled up at a speed, and thereafter, the coating film is dried and fired.

Next, in order to form the hard coat layers 171 and 172, a liquid composition such as disclosed in Japanese Patent Application Laid-Open No. 9-96702, for example, an organosilicon compound and a colloidal metal oxide is used. After the large substrate 150 is immersed in the liquid material 200 mixed and diluted with the organic solvent at a predetermined ratio, the large substrate 150 is pulled up at a predetermined speed, and then dried to a coating film.
A baking process is performed.

Next, in order to form the anti-reflection layers 181 and 182, JP-A-9-96702 and JP-A-9-28.
No. 8202, and the like, for example, a metal alkoxide such as aluminum ethoxide, aluminum isopropoxide, titanium methoxide, titanium ethoxide, titanium isopropoxide, etc. is converted to methyl acetoacetate or acetylacetone. A liquid substrate 200 dissolved in an organic solvent, or a liquid substrate 200 obtained by mixing and diluting an organic silicon compound and a colloidal metal oxide in an organic solvent at a predetermined ratio,
After the immersion, the steps of drying and baking the coating film are repeated as many times as necessary.

Next, in order to form the water-repellent layers 191 and 192, the liquid 200 prepared by dissolving a fluorine compound in an organic solvent is used.
After the large substrate 150 is immersed in the film, the film is pulled up at a predetermined speed, and then the coating film is dried and fired.

As described above, when the immersion step is performed, the primer layer 1
61, 162, hard coat layers 171, 172, antireflection layers 181, 182, and water-repellent layers 191, 192 are formed in this order with the same thickness on the front and back.

In the immersion step, the large substrate 150
When the liquid is pulled up from the liquid material 200, excess liquid material drips on the front side 152 and the back side 152 of the large substrate 150. However, since the back side 151 of the large substrate 150 is a flat surface, Since the excess liquid does not accumulate, the back surface 151 of the large substrate 150
The primer layer 162, the hard coat layer 172, the antireflection layer 182, and the water repellent layer 192 are formed with a uniform thickness. The front side 152 of the large-sized substrate 150 is provided with a front cover 1.
The bulges for forming the lens 3 (transparent substrate 15) into a lens shape are formed at predetermined intervals.
Since a flat liquid reservoir 155 is formed with a sufficient width between regions where the bulges are formed (regions cut out as the front cover 13 and the transparent substrate 15), all excess liquid is collected in the liquid reservoir. 155. Therefore, the area where the bulge is formed (the surface cover 13 and the transparent substrate 15)
Region cut out as a), the primer layer 161,
Hard coat layer 171, antireflection layer 181, water repellent layer 19
1 is formed with a uniform layer thickness.

In this way, the primer layers 161, 1
62, hard coat layers 171, 172, antireflection layer 18
1, 182 and the water-repellent layers 191 and 192 are formed on the surface of the large-sized substrate 150, and then the large-sized substrate 150 is subjected to laser cutting.
3 is taken in large numbers (cutting step). The large substrate 150
In cutting the dies, a die cutting using cutting teeth may be performed.

As described above, in this embodiment, all of the functional films conventionally formed by the sputtering method in a vacuum apparatus are formed by the immersion method in the state of the large substrate 150. However, since the film can be formed in a short time, the productivity of the front cover 13 can be improved. Moreover, according to the immersion method performed in this embodiment, the antireflection layers 181 and 182 can be simultaneously formed on both the front and back surfaces. Therefore, when manufacturing the electro-optical unit 100 for color display, the manufacturing cost of the front cover 13 can be significantly reduced.

[Other Embodiments] In the above embodiment, the large-sized substrate 150 in which the single transparent substrates 15 constituting the front cover 13 are arranged in a lattice is used.
As shown in FIGS. 9A and 9B, a large-sized substrate 150 in which single transparent substrates 15 constituting the front cover 13 are arranged in a staggered manner may be used. In this case, the front cover 1
Since the single-piece transparent substrates 15 constituting 3 are arranged side by side with a sufficiently wide flat surface (liquid pool 155), even when a functional film is formed by the immersion method, the surface side 152 thereof has
The flat liquid reservoir 155 angled between the areas where the bulges are formed (areas cut out as the front cover 13 and the transparent substrate 15) functions sufficiently. Therefore, the area where each bulge is formed (the surface cover 13 and the transparent substrate 15)
Area), the primer layer 161, the hard coat layer 171, the antireflection layer 181, the water repellent layer 191
Can be formed with a uniform layer thickness.

In the immersion step, when pulling up the large substrate 150 shown in FIGS. 7A and 9A, the side face thereof is perpendicular to the liquid surface of the liquid material 200. FIG. 7 (A) and FIG.
As shown by the arrow A (in-plane direction) in FIG.
The large substrate 150 may be pulled up in an oblique posture with the corners of 50 facing upward. Further, as shown in FIGS. 7A and 9A, the large-sized substrate 150 may be pulled up in a posture perpendicular to the liquid surface of the liquid material 200. However, as shown in FIGS. As shown by an arrow B (out-of-plane direction) in B), the large substrate 150 may be pulled up in a posture in which the large substrate 150 is tilted in any of the front and rear directions.

Further, in the above embodiment, all of the hard coat layers 171 and 172, the antireflection layers 181 and 182, and the water-repellent layers 191 and 192 formed as the functional films were subjected to the immersion method. The present invention may be applied to forming only a part of the film. However, among these functional films, it is preferable that the anti-reflection films 181 and 182 are formed on both front and back sides.
1 and 182 are often formed of a plurality of layers. Therefore, when the present invention is applied to the formation of the antireflection films 181 and 182, it is compared with the case where the present invention is applied only to the formation of other functional films. As a result, the manufacturing cost is significantly reduced.

In the above-described embodiment, an example in which the present invention is applied to the front cover 13 used for the electro-optical unit 100 of the mobile phone 1 has been described. However, a case where a functional film is formed on other optical components will be described. The present invention may be applied.

[0069]

As described above, according to the present invention, when manufacturing an optical component having a functional film such as an anti-reflection layer, a film is formed on a large substrate from which a large number of optical components can be formed. Then, a plurality of optical components are cut out from the large substrate. Therefore, since a plurality of optical components can be formed at the same time, the productivity is high. Also, in forming the functional film, the film is formed by an immersion method instead of a sputtering method that requires a vacuum apparatus, so that productivity is high, and such an immersion method can be used for a large substrate. A film can be formed efficiently. In addition, even when it is desired to form the film on both the front and the back as in the case of an anti-reflection film, the film can be formed on both the front and the back simultaneously by the immersion method.
Therefore, the manufacturing cost of the optical component on which the functional film is formed can be significantly reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing the appearance of a mobile phone as an example of an electronic apparatus to which the present invention is applied.

FIG. 2 is a sectional view of an electro-optical unit with a lighting device used in the mobile phone shown in FIG.

FIG. 3 is a sectional view of a front cover to which the present invention is applied.

FIG. 4 is a perspective view of the liquid crystal panel used in the mobile phone shown in FIG. 1 as viewed obliquely from below.

5 is an exploded perspective view of the liquid crystal panel used in the mobile phone shown in FIG. 1 as viewed obliquely from below.

FIG. 6 is a sectional view of the liquid crystal panel shown in FIGS. 4 and 5;

FIGS. 7A and 7B are a perspective view of a large substrate used for removing a large number of surface covers and a cross-sectional view of the large substrate in a method of manufacturing a surface cover to which the present invention is applied. It is.

FIGS. 8A and 8B are process cross-sectional views showing a dipping process for forming a functional film on a surface in a method of manufacturing a surface cover to which the present invention is applied.

FIGS. 9A and 9B are perspective views of a large substrate used for removing a large number of front covers in another method of manufacturing a front cover to which the present invention is applied, and FIGS. It is sectional drawing.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Cellular phone 2 Display part 3 Operation part 4 Speaker hole 5 Microphone hole 10 Illumination device 11 Light guide plate for backlight 12 Reflection sheet 13 Surface cover (optical component) 14 Light source 100 Electro-optical unit 110 Diffuse reflection pattern 111 Light guide plate for backlight 112 Back side of light guide plate for backlight 119 Light source storage hole 131 Back side of front cover 132 Front side of front cover 150 Large substrate 151 Back side of large substrate 152 Front side of large substrate 155 Liquid reservoir 161, 162 Primer layer 171, 172 Hard coat layer (functional film) 181, 182 Antireflection layer (functional film) 191, 192 Water repellent layer (functional film) 200 Liquid material 301 Key button 400 Liquid crystal panel (electro-optical panel) 401 Liquid crystal panel Back side 402 Front side of liquid crystal panel

Claims (21)

[Claims] 1. A method of manufacturing an optical component having at least one functional film formed on at least a surface side of a transparent substrate having a lens shape, wherein at least one of the functional films is formed by the transparent film. After immersing a large substrate in which a plurality of substrates are connected in an in-plane direction into a liquid material, the immersion step of lifting the large substrate from the liquid material and forming a coating film on both the front side and the back side of the large substrate And performing a cutting step of cutting out a plurality of the optical components from the large-sized substrate after performing the immersion step. 2. The method for manufacturing an optical component according to claim 1, wherein the transparent substrate has a lens shape with a flat back surface and a swollen front surface. 3. The hard coat layer according to claim 1, wherein at least a hard coat layer, an antireflection layer, and a water repellent layer are formed as the functional film on at least a surface side of the transparent substrate. In forming at least one of the anti-reflection layer and the water-repellent layer, a pre-dipping step is performed, and after the dipping step is performed, a cutting step of cutting out a plurality of the optical components from the large substrate is performed. Manufacturing method of an optical component. 4. The method according to claim 3, wherein at least the anti-reflection layer among the hard coat layer, the anti-reflection layer, and the water-repellent layer is formed by the immersion step on the large-sized substrate. Manufacturing method of optical parts. 5. The method for manufacturing an optical component according to claim 4, wherein all of the hard coat layer, the antireflection layer, and the water repellent layer are formed by the immersion step on the large-sized substrate. . 6. The method according to claim 1, wherein
In the cutting step, the large substrate is cut with a laser beam. 7. The method for manufacturing an optical component according to claim 1, wherein in said cutting step, said large-sized substrate is cut by die cutting using cutting teeth. 8. The method according to claim 1, wherein
The method for manufacturing an optical component, wherein the large-sized substrate is a plastic molded product from which a plurality of the transparent substrates are cut out. 9. The method according to claim 8, wherein:
A method of manufacturing an optical component, wherein a plurality of regions cut out as the transparent substrate are formed in a flat plastic molded product having no hole between the regions cut out as the transparent substrate. 10. The method for manufacturing an optical component according to claim 9, wherein, on the large-sized substrate, regions cut out as the transparent substrate are arranged in a lattice shape. 11. The method for manufacturing an optical component according to claim 9, wherein in the large-sized substrate, regions cut out as the transparent substrate are arranged in a staggered manner. 12. The manufacturing of an optical component according to claim 9, wherein in the large-sized substrate, a flat liquid reservoir is formed between the regions cut out as the transparent substrate. Method. 13. The method for manufacturing an optical component according to claim 12, wherein in the immersion step, the large-sized substrate is pulled up from the liquid in a posture inclined in an in-plane direction or an out-of-plane direction. 14. An optical component having at least one functional film formed on at least a front surface of a transparent substrate having a lens shape, wherein at least one of the functional films is formed on a front surface and a rear surface of the transparent substrate. An optical component characterized by being formed with a layer thickness substantially equal to both of them. 15. The optical component according to claim 14, wherein the transparent substrate has a lens shape in which the back surface is flat and the front surface is swollen. 16. The functional film according to claim 14, wherein at least a surface side of the transparent substrate is provided as the functional film.
At least the hard coat layer, the antireflection layer, and the water repellent layer are formed, and at least one of the hard coat layer, the antireflection layer, and the water repellent layer is a transparent substrate. An optical component characterized in that it is formed with a substantially equal layer thickness on both the front side and the back side. 17. The transparent substrate according to claim 16, wherein at least one of the hard coat layer, the anti-reflection layer, and the water-repellent layer is formed on both the front side and the back side of the transparent substrate. An optical component characterized by the following. 18. A hard coat layer, an anti-reflection layer and a hard coat layer on at least the front and back sides of a transparent substrate having a lens shape.
And the hard coat layer, the antireflection layer, and the water repellent layer are formed on both the front side and the back side of the transparent substrate in the same front and back order. An optical component, characterized in that: 19. An electronic apparatus using the optical component defined in claim 18, wherein the optical component is opposed to a front side of an electro-optical panel forming a display unit as a front cover having a front side facing outward. An electronic device characterized by being arranged. 20. The liquid crystal device according to claim 19, wherein the electro-optical device is capable of modulating external light transmitted through the front cover and entering the front cover from the front cover while the external light is reflected toward the front cover. Electronic equipment characterized by being a panel. 21. The electronic device according to claim 20, wherein the liquid crystal panel is for color display.