JP2005316105A - Polarizer and its manufacturing method and projection type liquid crystal display device having the polarizer - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a polarizer which is easily manufactured and excellent in heat resistance, to provide a method for easily manufacturing the polarizer, and to provide a projection type liquid crystal display device having the polarizer. <P>SOLUTION: The polarizer 1 comprises: a transparent substrate 2; a grid 3 composed of a collection of light-shield needle-like magnetic materials 3a regularly arranged on the substrate 2; and a translucent film 4 for fixing the needle-like magnetic materials 3a on the substrate 2. The regular arrangement of the needle-like magnetic materials 3a on the substrate 2 is carried out by coating one side of the substrate 2 with a material liquid containing the needle-like magnetic materials 3a, and then applying a magnetic field or an electric field to the substrate 2 coated with the material liquid. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a polarizer, a method for manufacturing the same, and a projection type liquid crystal display device including the polarizer, and more particularly, to a means for improving the heat resistance of the polarizer and a means for reducing the manufacturing cost.

  In recent years, as a device for enlarging and projecting an image on a screen, a projection type liquid crystal display device that directly projects electronic data on a screen is becoming popular, instead of a conventional slide projector or overhead projector. Projection-type liquid crystal display devices are characterized by higher projected image illuminance than conventional slide projectors and overhead projectors, and are capable of projecting images even in a bright room. To improve the projection lens, improve the high-intensity lamp, improve the integrator lens to uniformly illuminate the liquid crystal panel, and improve the light utilization efficiency by aligning the polarization direction Improvements to the polarization conversion optical system are ongoing.

  In a projection type liquid crystal display device, since a high-intensity lamp such as an ultra-high pressure mercury lamp is used to project a projection image with high illuminance, it is particularly excellent in heat resistance for optical elements such as lenses and polarizers. Required. Conventionally, as a polarizer having excellent heat resistance, as shown in FIG. 6, a large number of fine metal wires 102 having a line width of about 100 nm are arranged in parallel at intervals of about 100 nm on a translucent substrate 101. Wire grid polarizers have been developed.

  The fine metal wires 102 constituting the wire grid are subjected to an etching process on a metal layer such as aluminum formed on the substrate 101 by a vacuum deposition method or a sputtering method, and a portion of the metal layer corresponding to the space between the wires is selectively removed. (See, for example, Patent Document 1). In addition, a method of filling the concave portions formed between the thin metal wires 102 with a material having the same refractive index as that of the substrate has been proposed (see, for example, Patent Document 2).

The wire grid type polarizer in which the grid is composed of the fine metal wires 102 is excellent in heat resistance because the grid is not deteriorated by the light heat of the high-intensity lamp.
Special table 2003-502708 gazette JP-A-10-153706

  However, the wire grid type polarizer has a problem in that it is not suitable for mass production and the product cost is high because it is necessary to perform an etching process for each individual product when forming the wire grid.

  In addition, a wire grid polarizer described in Patent Document 2 in which a material having a refractive index comparable to that of the substrate is filled between the thin metal wires 102 is used for a long time at a high temperature. There is a problem that the thin metal wire 102 is easily peeled off from the substrate 101 due to thermal stress caused by the difference in thermal expansion coefficient between the fine metal wire 102 and the filler.

  The present invention has been made to solve such deficiencies in the prior art, and the object thereof is to provide a polarizer that is easy to manufacture and excellent in heat resistance, and that a polarizer excellent in heat resistance is easily provided. An object of the present invention is to provide a manufacturing method, and to provide a projection type liquid crystal display device including a polarizer that is easy to manufacture and excellent in heat resistance.

  In order to solve the above-described problems, the present invention provides a polarizer with a light-transmitting substrate, a grid formed of a collection of light-shielding acicular magnetic bodies regularly arranged on the substrate, and the substrate. A translucent film for fixing the needle-like magnetic body is provided.

  A magnetic body is made of a metal, an alloy material, or ceramics, and itself has excellent heat resistance. Therefore, a polarizer formed with a grid using this material has excellent heat resistance equivalent to or higher than a wire grid type polarizer. . In addition, when a magnetic field is applied to a needle-like magnetic body in a dispersed state on a substrate, it can align with the direction of the magnetic field and form a required grid pattern. Formation of the pattern can be facilitated, the mass productivity of the polarizer can be improved, and the manufacturing cost can be reduced.

  Moreover, this invention made the structure that the said board | substrate and a film consist of a heat resistant synthetic resin material or a glass material in the polarizer of the said structure.

  When heat-resistant synthetic resin materials or glass materials are used as the substrate material and coating material, the heat resistance of the polarizer can be further enhanced in combination with the high heat resistance of the grid. However, it is possible to prevent a decrease in the performance of the polarizer.

  In the polarizer having the above-described configuration, the acicular magnetic body has a configuration in which a width or a diameter is ¼ to 波長 of a wavelength of transmitted light.

  The width or diameter of the acicular magnetic body is set to 1/4 to 1/5 of the wavelength of the light passing through, and 1 / wavelength of the light passing through the interval in the width direction of the acicular magnetic body arranged on the substrate. If it is set to 4 to 1/5, the polarization efficiency of the polarizer can be maximized, so that a high-performance polarizer can be obtained.

  In the polarizer of the above configuration, an antireflection film is formed on the surface of the substrate opposite to the surface on which the needle-like magnetic body is fixed.

  This prevents reflection on the surface of the substrate opposite to the surface on which the needle-like magnetic material is fixed, so that the polarization efficiency of incident light can be further increased, and a high-performance polarizer can be obtained. Can do.

  On the other hand, in order to solve the above-described problems, the present invention provides a method for producing a polarizer, the step of dispersing a light-shielding acicular magnetic body on a substrate, and the substrate on which the acicular magnetic body is dispersed. The method includes a step of applying a magnetic field to regularly arrange the acicular magnetic bodies on the substrate and a step of fixing the regularly arranged acicular magnetic bodies to the surface of the substrate.

  The needle-like magnetic material dispersed on the substrate so that it can operate in any direction can be aligned with the direction of the applied magnetic field by applying the magnetic field, so the direction of the applied magnetic field or electric field is adjusted. By doing so, it is possible to form a desired grid pattern composed of a collection of needle-like magnetic bodies on the substrate. Therefore, the formation of the grid pattern can be facilitated by the etching process as compared with the formation of the grid pattern, and the mass productivity of the polarizer can be improved and the manufacturing cost thereof can be reduced.

  Further, in the method of manufacturing a polarizer having the above-described configuration, the step of dispersing the light-shielding acicular magnetic substance on the substrate includes the acicular magnetism in a glass manufactured by an ultraviolet curable resin or a sol-gel method. The raw material liquid in which the body is dispersed is applied onto the substrate.

  When the raw material liquid in which the acicular magnetic body is dispersed is applied on the substrate, the acicular magnetic body can be uniformly dispersed on the substrate as compared with the case where the acicular magnetic body is dispersed on the substrate alone. Formation of a desired grid pattern is facilitated. In addition, when the acicular magnetic material is dispersed in an ultraviolet curable resin or glass produced by a sol-gel method, the fixation of the grid pattern to the substrate is completed simply by solidifying the ultraviolet curable resin or glass after the formation of the desired grid pattern. Therefore, the polarizer can be manufactured more easily.

  Furthermore, in order to solve the above-described problems, the present invention provides a projection-type liquid crystal display device that transmits a light source lamp, a polarizer that separates light from the light source lamp, and light separated by the polarizer. In a projection-type liquid crystal display device comprising a liquid crystal panel and a projection lens that projects light transmitted through the liquid crystal panel onto a screen, a light-transmitting substrate and a light-shielding regularly arranged on the substrate as the polarizer And a needle-shaped magnetic body having a light-transmitting film that fixes the needle-shaped magnetic body on the substrate.

  A polarizer comprising a light-transmitting substrate, a light-shielding needle-like magnetic body regularly arranged on the substrate, and a light-transmitting film that fixes the needle-like magnetic body on the substrate is heat resistant. Therefore, when this polarizer is provided, the durability of the projection type liquid crystal display device can be improved, and a light source lamp with higher brightness can be mounted, and the illuminance of the projected image can be increased. Further, since the polarizer having the above-described configuration can be manufactured at low cost, the manufacturing cost of the projection type liquid crystal display device can be reduced by providing the polarizer.

  In the polarizer of the present invention, the grid is composed of a collection of light-shielding needle-like magnetic bodies regularly arranged on the substrate. Therefore, the polarizer has heat resistance equal to or higher than that of the wire grid polarizer, and on the substrate. Since a desired grid pattern can be formed simply by applying a magnetic field to the dispersed needle-like magnetic material, the grid pattern can be formed more easily than the grid pattern formed by etching. The mass productivity of the child can be improved, and the manufacturing cost can be reduced.

  In the method for producing a polarizer according to the present invention, after a light-shielding acicular magnetic material is dispersed on a substrate, a magnetic field is applied to the substrate on which the acicular magnetic material is dispersed to thereby dispose the acicular magnetic material on the substrate. Since the arrangement is regular, the formation of the grid pattern can be facilitated by the etching process as compared with the formation of the grid pattern, and the mass productivity of the polarizer can be improved and the manufacturing cost thereof can be reduced.

  A projection-type liquid crystal display device according to the present invention includes a light-transmitting substrate, a light-blocking needle-like magnetic body regularly arranged on the substrate, and a light-transmitting surface that fixes the needle-like magnetic body on the substrate. Since it is equipped with a low-cost and heat-resistant polarizer consisting of a coating, not only can the manufacturing cost of the projection-type liquid crystal display device be reduced, but also the durability of the projection-type liquid crystal display device can be improved, and even higher brightness The light source lamp can be mounted, and the illuminance of the projected image can be increased.

  First, an embodiment of a polarizer according to the present invention will be described with reference to FIGS. FIG. 1 is a plan view of a polarizer according to the embodiment, and FIG. 2 is a side view of the polarizer according to the embodiment.

  As shown in FIGS. 1 and 2, the polarizer 1 of this example includes a translucent substrate 2 and a grid 3 composed of a collection of light-shielding acicular magnetic bodies 3 a regularly arranged on the substrate 2. The translucent film 4 for fixing the needle-like magnetic body 3a on the substrate 2 and the antireflection film 5 formed on the surface of the substrate 2 opposite to the surface on which the needle-like magnetic body 3a is fixed. Become.

  The substrate 2 is formed with a translucent hard material. Light-transmitting materials with the required rigidity include polycarbonate resin, acrylic resin, methacrylic resin, polystyrene resin, vinyl chloride resin, epoxy resin, polyester resin, polyimide resin, polyetherimide resin, polyethersulfone resin, phenolic resin Examples thereof include synthetic resin materials such as norbornene-based amorphous polyolefin resin, and glass materials such as blue plate glass, white plate glass, and sapphire glass. Among the resin materials, polycarbonate resin is particularly preferable as the substrate material because it has high heat resistance and is excellent in light transmittance. In addition, a polyimide resin and a norbornene-based amorphous polyolefin resin are also suitable as a substrate material because they have high heat resistance.

  Although the thickness of the board | substrate 2 can be set arbitrarily as needed, it is 0.1 mm-2.0 mm normally, Preferably it is 0.7 mm-1.1 mm. Moreover, the planar shape and planar size of the substrate 2 can be arbitrarily set as necessary, and can be formed into a rectangle or a square having a side of 10 to 100 mm, a circle or an ellipse having a diameter of 5 to 100 mm.

  As shown in FIGS. 1 and 2, the grid 3 is formed by arranging needle-like magnetic bodies 3 a in a stripe shape in the vertical and horizontal directions of the substrate 2. The acicular magnetic body 3a is made of a magnetic material such as iron, an iron alloy, nickel, a nickel alloy, or magnetic ceramics, and in order to obtain high polarization efficiency, the width or diameter is ¼ to ５ of the wavelength of light that is transmitted. It is formed in the shape of a needle. Further, the width of the light transmission part 3b formed between the adjacent needle-like magnetic substance rows is also formed to be ¼ to ５ of the wavelength of the transmitted light in order to obtain high polarization efficiency. The

  The coating 4 is for fixing the grid 3 to the substrate 2 and is formed of a translucent heat-resistant synthetic resin material or glass material. Examples of the synthetic resin material for forming the coating film 4 include an ultraviolet curable resin, and examples of the glass material include glass manufactured by a sol-gel method.

  The antireflection film 5 prevents reflection of light on the surface of the substrate 2 opposite to the surface on which the needle-like magnetic body 3a is fixed, and further increases the polarization efficiency of incident light. Alternatively, it is formed by depositing an antireflection film material made of metal fluoride or the like on the substrate surface according to a conventional method. Examples of the metal antireflection film material include silver. Examples of the metal oxide antireflection film material include silicon oxide, aluminum oxide, titanium oxide, tantalum oxide, yttrium oxide, and zirconium oxide. Furthermore, examples of the metal fluoride antireflection film material include magnesium fluoride. The antireflection film 5 may be a single layer or a multilayer.

  In the polarizer 1 of this example, the grid 3 is composed of a set of light-shielding needle-like magnetic bodies 3 a regularly arranged on the substrate 2, and thus has heat resistance equal to or higher than that of the wire grid polarizer. Since a desired grid pattern can be formed simply by applying a magnetic field to the needle-like magnetic bodies 3a dispersed on the substrate 2, the grid pattern can be formed more easily than the grid pattern formed by etching. It is excellent in mass productivity and low cost.

  Next, the manufacturing method of the polarizer which concerns on the embodiment is demonstrated based on FIG.3 and FIG.4. FIG. 3 is a flowchart showing a manufacturing procedure of a polarizer according to the embodiment, and FIG. 4 is an explanatory diagram showing a method of regularly arranging acicular magnetic bodies.

  As shown in FIG. 3, the polarizer manufacturing method of the present example includes a substrate 2, which is a constituent material of the polarizer 1, a needle-like magnetic body 3a, and a coating material (for example, a glass manufactured by an ultraviolet curable resin or a sol-gel method). And a step of preparing an antireflection film material (for example, metal, metal oxide or metal fluoride) (procedure S1), a step of forming the antireflection film 5 on one surface of the substrate 2 (procedure S2), and a coating material A step of preparing a raw material liquid by dispersing the needle-like magnetic body 3a (step S3), and a step of uniformly applying the prepared raw material liquid to the surface of the substrate 2 on which the antireflection film 5 is not formed (step S4). ), Applying a magnetic field to the substrate 2 coated with the raw material liquid, and arranging the needle-like magnetic bodies 3a regularly on the substrate 2 (step S5), and solidifying the coating material and arranging the needle-like magnetic bodies regularly. A step of fixing 3a to the surface of the substrate 2 (step S6). Constructed.

  As means for uniformly applying the prepared raw material liquid onto the substrate 2, spin coating or spray coating can be used. The coating material is solidified by an appropriate method according to the type of coating material, such as irradiation with ultraviolet rays or heating.

  As shown in FIG. 4, the acicular magnetic body 3a has electromagnets or permanent magnets A and B arranged along opposing sides of the substrate 2 on which the raw material liquid is uniformly applied, and applies a magnetic field in the AB direction. Ordered by

  The antireflection film 5 is formed by sputtering an antireflection film material on the surface of the substrate 2 opposite to the surface on which the acicular magnetic bodies 3a and the coating 4 are formed.

  In the manufacturing method of the polarizer 1 of this example, after the light-shielding acicular magnetic body 3a is dispersed on the substrate 2, a magnetic field is applied to the substrate 2 on which the acicular magnetic body 3a is dispersed. Since the needle-like magnetic bodies 3a are regularly arranged and a required grid pattern is formed, the grid pattern can be easily formed by etching, compared to the grid pattern, and the mass productivity of the polarizer 1 is improved. And the manufacturing cost can be reduced.

  Next, an embodiment of a projection type liquid crystal display device according to the present invention will be described with reference to FIG. FIG. 5 is an optical circuit diagram of the projection type liquid crystal display device according to the embodiment.

  As shown in FIG. 5, the projection type liquid crystal display device of this example is a three-plate type liquid crystal projector, and includes a white light source 11 that emits white light 10a, integrator lenses 12 and 13, and white light 10a as S-polarized light. The polarizer 1 that separates into P-polarized light, the dichroic mirrors 14 and 15 that separate the white light 10a into three lights 10b, 10c, and 10d having different wavelengths, and the three lights 10b, 10c, and 10d are individually transmitted. Three liquid crystal panels 16, 17, 18, a dichroic prism 19 that combines the three lights 10 b, 10 c, 10 d transmitted through the liquid crystal panels 16, 17, 18, a projection lens 20, and mirrors 21, 22 as optical components , 23, 24 and relay lenses 25, 26. The white light source 11 includes a high-intensity lamp 11a such as an ultra-high pressure mercury lamp or a metal halide lamp, and an elliptical mirror 11b that condenses light from the high-intensity lamp 11a. The polarizer 1 is illustrated in FIGS. 1 and 2, and as is clear from these drawings, the light-transmitting substrate 2 and the light-shielding regularly arranged on the substrate 2. A grid 3 formed of a set of uniaxial acicular magnetic bodies 3a, a translucent film 4 for fixing the acicular magnetic bodies 3a on the substrate 2, and a surface of the substrate 2 on which the acicular magnetic bodies 3a are fixed It consists of the antireflection film 5 formed on the opposite surface.

  Since the white light 10a emitted from the white light source 11 is collected by the elliptical mirror 11b, the brightness is uneven. The integrator lenses 12 and 13 divide and combine the light beam of the white light 10a to make the uneven brightness uniform. The white light 10 a that has passed through the integrator lenses 12 and 13 is aligned with linearly polarized light in the same direction by the polarizer 1 in order to reduce loss in the liquid crystal panels 16, 17, and 18, and the dichroic mirror 14, 15 is incident. Thereby, the white light 10a is divided into blue light 10b, green light 10c, and red light 10d. The blue light 10b enters the liquid crystal panel 16 through the relay lens 25, the mirror 22, the relay lens 26, and the mirror 23, the green light 10c enters the liquid crystal panel 17 from the dichroic mirror 15, and the red light 10d passes through the mirror 24. Through the liquid crystal panel 18. The blue light 10b, the green light 10c, and the red light 10d transmitted through the liquid crystal panels 16, 17, and 18 are combined by the dichroic prism 19 and projected onto a screen (not shown) through the projection lens 20.

  The projection type liquid crystal display device of this example includes a translucent substrate 2, a light-shielding acicular magnetic body 3 a regularly arranged on the substrate 2, and the acicular magnetic body 3 a is fixed on the substrate 2. The light-transmitting coating 4 and the polarizer 1 having excellent heat resistance are provided, so that the manufacturing cost of the projection type liquid crystal display device can be reduced and the durability of the projection type liquid crystal display device can be reduced. Furthermore, it becomes possible to mount a light source lamp with higher brightness, and the illuminance of the projected image can be increased.

  Hereinafter, more specific examples of the polarizer according to the present invention will be shown to clarify the effects.

<Example 1>
An antireflection film in which a Ta ₂ O ₅ film and a SiO ₂ film were laminated in two layers was formed on one side of a glass substrate having a thickness of 1.0 mm.

  Next, a grid formed by regularly arranging needle-like magnetic bodies by the following procedure was formed on the surface of the glass substrate where the antireflection film was not formed.

That is, an alcohol solution of H ₂ O and HCl is added to Si (OC ₂ H ₅ ) ₄ , and the alkoxide-water-acid-alcohol solution is stirred under reflux at room temperature to 80 ° C. to hydrolyze the alkoxide. And polycondensation. The solution thus obtained becomes a sol. A needle-like magnetic material having a length of 150 nm and a width of 100 nm was put into the sol and stirred, and applied to the surface of the glass substrate where the antireflection film was not formed. After coating, the glass substrate was heat-treated at 400 ° C. while applying a magnetic field of 5000 (Oe) in the direction of the two opposing sides of the glass substrate, and the required polarizer 1 was obtained.

  The polarizer 1 thus obtained was attached to the three-plate liquid crystal projector shown in FIG. 5, and an experiment was performed in which the white light source 11 was projected for 1000 hours. As a result, no damage was observed in the appearance of the polarizer 1, and no deterioration in display quality was observed in the projected image.

<Example 2>
An antireflection film in which a Ta ₂ O ₅ film and a SiO ₂ film were laminated in two layers was formed on one side of a glass substrate having a thickness of 1.0 mm.

  Next, a grid formed by regularly arranging needle-like magnetic bodies by the following procedure was formed on the surface of the glass substrate where the antireflection film was not formed.

  That is, a needle-like magnetic material having a length of 150 nm and a width of 100 nm was put into an ultraviolet curable resin Dicure Clear SD-2407 (manufactured by Dainippon Ink & Chemicals, Inc.) and stirred, and this was used as an antireflection film on the glass substrate. It applied to the surface which is not formed. After the application, while applying a magnetic field of 5000 (Oe) in the direction of two opposing sides of the glass substrate, the ultraviolet curable resin was irradiated with ultraviolet rays having a wavelength of 365 nm to obtain the required polarizer 1.

  The polarizer 1 thus obtained was attached to the three-plate liquid crystal projector shown in FIG. 5, and an experiment was performed in which the white light source 11 was projected for 1000 hours. As a result, no damage was observed in the appearance of the polarizer 1, and no deterioration in display quality was observed in the projected image.

It is a top view of the polarizer concerning the example of an embodiment. It is a side view of the polarizer which concerns on the example of embodiment. It is a flowchart which shows the manufacture procedure of the polarizer which concerns on the embodiment. It is explanatory drawing which shows the regular arrangement | sequence method of a acicular magnetic body. It is an optical circuit diagram of the projection type liquid crystal display device according to the embodiment. It is a perspective view of the polarizer which concerns on a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Polarizer 2 Substrate 3 Grid 3a Needle-like magnetic body 4 Coating 5 Antireflection film 11 White light source 12, 13 Integrator lens 14, 15 Dichroic mirror 16, 17, 18 Liquid crystal panel 19 Dichroic prism 20 Projection lens 21, 22, 23, 24 mirror 25, 26 relay lens

Claims (7)

  A translucent substrate, a grid made of a collection of light-shielding acicular magnetic bodies regularly arranged on the substrate, and a translucent film for fixing the acicular magnetic bodies on the substrate are provided. A polarizer characterized by that.   The polarizer according to claim 1, wherein the substrate and the coating are made of a heat-resistant synthetic resin material or a glass material.   2. The polarizer according to claim 1, wherein the needle-like magnetic body has a width or a diameter that is ¼ to ５ of a wavelength of light transmitted therethrough.   The polarizer according to claim 1, wherein an antireflection film is formed on a surface of the substrate opposite to a surface on which the acicular magnetic body is fixed.   A step of dispersing a light-shielding acicular magnetic body on the substrate, a step of applying a magnetic field to the substrate on which the acicular magnetic body is dispersed, and regularly arranging the acicular magnetic bodies on the substrate; And a step of fixing the arranged needle-like magnetic bodies to the surface of the substrate.   In the step of dispersing the light-shielding acicular magnetic substance on the substrate, a raw material liquid in which the acicular magnetic substance is dispersed in glass produced by an ultraviolet curable resin or a sol-gel method is applied on the substrate. The method for producing a polarizer according to claim 5, wherein: A light source lamp; a polarizer that separates light from the light source lamp; a liquid crystal panel that transmits the light separated by the polarizer; and a projection lens that projects the light transmitted through the liquid crystal panel onto a screen. In the projection type liquid crystal display device,
The polarizer includes a translucent substrate, a light-shielding acicular magnetic body regularly arranged on the substrate, and a translucent film that fixes the acicular magnetic body on the substrate. What is claimed is: 1. A projection type liquid crystal display device using the same.

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