JP2006154185A - Method of manufacturing light guide plate formed of fine rugged pattern and its light guide plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a light guide plate by which the duplicate plate that a plurality of rugged patterns are formed by obliquely arranging an original plate onto a transparent substrate highly precisely, and to provide its light guide plate. <P>SOLUTION: The method of manufacturing the light guide plate comprises: a process of disposing a photocuring resin on the surface of the planar transparent substrate; a process of sticking a planar original plate having fine rugged patterns closely to the photocuring resin and proximately arranging the transparent substrate and the original plate; a curing process of photocuring resin for curing the photocuring resin by irradiating the transparent substrate with light ray from the opposite side to the original plate; and a process of peeling the original plate from the transparent substrate. In the process of proximately arranging the transparent substrate and the original plate, the original plate is obliquely arranged onto the transparent substrate. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a manufacturing method for mass-producing and replicating a light guide plate having a fine concavo-convex pattern on the surface, and particularly used when replicating a light guide plate having a diffraction grating pattern. The present invention relates to a method for transferring a fine concavo-convex pattern in which a shape is transferred by using a photocurable resin, and a method for manufacturing a light guide plate using the same.

  Conventionally, as a light guide plate arranged on the back of the liquid crystal display as illumination for liquid crystal display, a structure in which light incident from the end face is repeatedly reflected inside, and a structure in which light guided to the surface of the light guide plate is emitted to the outside A method of providing an object and emitting surface light to a liquid crystal surface is generally used.

  In addition, when the concave / convex pattern of the diffraction grating is used as a structure that emits to the outside, the shape of the light guide plate is not an equal plate thickness, but a wedge shape whose thickness differs from the light incident optical axis direction of the light guide plate. By doing so, incident light can be guided efficiently.

  FIG. 1 shows a conventional configuration example of a light guide plate using a diffraction grating.

  The light emitting diodes 12 are arranged on the end face of the light guide plate 11. The light guide plate 11 has a wedge shape so that the thickness is reduced in the direction of the incident optical axis. The light propagating through the light guide plate 11 is transmitted to the outside by the diffraction grating 13. It is extracted as the emitted light 14.

  By the way, in order to efficiently manufacture a light guide plate having a diffraction grating pattern, a method of manufacturing using a replica (stamper) in which a plurality of concave / convex patterns of the diffraction grating of the original plate are provided has been used.

  Here, as a method of imposing a plurality of sheets, there is a method of connecting a plurality of plates to produce a duplicate plate. However, in this method, it is necessary to incline the surface of the concavo-convex pattern of the diffraction grating, and the accuracy There is a problem that it is difficult to connect the plates by tilting well.

  Moreover, as a method of producing a large-area replica by transferring the concavo-convex shape of the original plate, the resin is cured by ultraviolet irradiation while the resin is in close contact with the original plate using a photocurable resin or an ultraviolet curable resin. There is a method of transferring an uneven shape of an original plate (for example, see Patent Document 1).

  In addition, as a method for producing a large-area replica by transferring the uneven shape of the original, a specific range is scanned with a beam of light while the resin is in close contact with the original using a photo-curing resin. There is a method of transferring the concavo-convex shape of the original plate by curing the resin in a specific range on the substrate by irradiating with ultraviolet rays.

  However, in this method, when the original is larger than a specific range to be cured, if the substrate and the original are inclined and arranged close to each other, the original interferes with an adjacent cured portion, and thus it is difficult to incline the original. is there.

The patent documents are shown below.
Japanese Patent No. 027989597

  As described above, as a conventional method, in a method for producing a duplicate plate by connecting a plurality of plates, it is necessary to incline the surface of the concavo-convex pattern of the diffraction grating, and it is necessary to incline with high accuracy. There is a problem that it is difficult to connect the plates, and it is difficult to place the substrate and the original plate in an inclined manner in the method of transferring the concave / convex pattern of the original plate by curing a specific range of resin on the substrate. There is a problem.

  The present invention solves the problems of the prior art, and the problem is that a step of providing a photo-curing resin on the surface of a planar transparent substrate and a planar master having a fine concavo-convex pattern are provided. A step of closely adhering the transparent substrate and the original plate, and a step of curing the photocurable resin by irradiating the transparent substrate with light from the opposite side of the original plate; A method for producing a light guide plate comprising a step of peeling an original from a transparent substrate, and a method for producing a light guide plate for producing a plurality of duplicated plates so that the original is inclined with respect to the transparent substrate with high accuracy, and the light guide plate. Is to provide.

  In order to achieve the above object in the present invention, first, in the invention of claim 1, a step of providing a photocurable resin on the surface of a planar transparent substrate, and a planar original having a fine concavo-convex pattern are photocured. A step of placing the transparent substrate and the original plate in close contact with each other; a step of curing the photocurable resin by irradiating the transparent substrate with a light beam from the side opposite to the original plate; and the transparent of the original plate In a method of manufacturing a light guide plate comprising a step of peeling from a substrate, a guide having a fine concavo-convex pattern, characterized in that the original is inclined with respect to the transparent substrate in the step of arranging the transparent substrate and the original in proximity. This is a method for manufacturing an optical plate.

  According to a second aspect of the present invention, the fine uneven pattern according to the first aspect is characterized in that the inclination angle of the light guide plate with respect to the light incident optical axis direction when the original is inclined is not more than 1 degree. This is a method for producing a light guide plate.

  According to a third aspect of the present invention, in the planar master having the fine concavo-convex pattern, a range substantially equal to a range in which the photo-curing resin is cured is a convex shape. This is a method for producing a light guide plate having a fine uneven pattern.

  According to a fourth aspect of the present invention, when the light beam is irradiated, the beam-shaped light beam is scanned and moved to sequentially cure the photocurable resin. This is a method for producing a light guide plate having a fine uneven pattern.

  The invention according to claim 5 is the method for producing a light guide plate comprising the fine uneven pattern according to any one of claims 1 to 4, wherein the fine uneven pattern is a diffraction grating pattern. .

  In the invention of claim 6, the diffraction grating pattern is a blazed diffraction grating shape, and the method for producing a light guide plate having a fine concavo-convex pattern according to claim 5 is provided.

  Furthermore, in the invention of claim 7, a conductive treatment is applied to the fine concavo-convex pattern of the light guide plate made of the fine concavo-convex pattern obtained by the method for producing a light guide plate according to any one of claims 1 to 6. A light guide plate having a fine concavo-convex pattern produced using a replica plate obtained by performing electroforming plating or chemical plating after application.

  Since this invention is the above structure, there exist the following effects.

  That is, according to the first aspect of the invention, since the original plate is inclined with respect to the transparent substrate in the step of arranging the transparent substrate and the original plate close to each other, the original plate is accurately inclined with respect to the transparent substrate. It is possible to provide a method for producing a light guide plate having a fine concavo-convex pattern for producing a plurality of imprinted replica plates.

  Further, according to the invention according to claim 2, the inclination angle of the light guide plate with respect to the light incident optical axis direction when the original is inclined is 1 degree or less. With the light guide plate manufacturing method, it is possible to obtain a light guide plate having a fine concavo-convex pattern capable of efficiently guiding incident light.

  According to the invention of claim 3, the planar master having the fine concavo-convex pattern has a convex shape in a range substantially equal to the range in which the photocurable resin is cured. Since the method for producing a light guide plate having a fine uneven pattern described in 1 to 2 above, even if the substrate and the original plate are inclined and arranged close to each other, the original plate does not interfere with the adjacent cured portion. It is possible to obtain a duplicate plate with a plurality of impositions arranged with high accuracy.

  Further, according to the invention of claim 4, when the light beam is irradiated, the beam-like light beam is scanned and moved to sequentially cure the photo-curing resin. 3 is a method for producing a light guide plate having a fine concavo-convex pattern, whereby an amount of uncured resin cured and shrunk to a beam-shaped cured part is supplied from the uncured part, and distortion due to curing shrinkage is suppressed. A light guide plate with higher accuracy can be obtained.

  According to the invention of claim 5, the fine uneven pattern is a diffraction grating pattern, and the method for producing a light guide plate comprising the fine uneven pattern according to claim 1, As a result, a light guide plate capable of efficiently guiding incident light can be obtained.

  According to the invention of claim 6, the method for producing a light guide plate having a fine concavo-convex pattern according to claim 5, wherein the diffraction grating pattern has a blazed diffraction grating shape. Thus, a light guide plate capable of guiding light with higher efficiency can be obtained.

  Furthermore, in the invention of the seventh aspect, the light-curing resin light guide plate obtained by the method for producing a light guide plate having the fine uneven pattern according to any one of the first to sixth aspects is subjected to a conductive treatment. And a light guide plate produced using a duplicated plate obtained by electroforming plating or chemical plating. Obtainable.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment as the best example for carrying out the present invention will be described in detail with reference to the drawings.

  FIG. 2 is a perspective view showing components in an embodiment of a method for producing a light guide plate having a fine uneven pattern.

  In FIG. 2, an elevating head 24 that moves in the vertical direction with respect to the surface of the glass substrate 21 is disposed. On the surface of the elevating head 24 facing the glass substrate 21, a Ni original plate 23 having a fine concavo-convex pattern as a diffraction grating is attached to the surface.

  The molding surface of the glass substrate 21 is subjected to non-glare treatment that dissolves the glass surface with a chemical solution to make the surface finely roughened, and further silane coupling treatment is performed to strengthen the adhesion between the cured resin and the glass. is there.

  Next, the ultraviolet curable resin 22 is applied (dropped) on the surface of the glass substrate 21, and the elevating stage 24 to which the Ni original plate 23 is attached is gradually lowered to be placed close to the glass substrate 21. The glass substrate 21 is inclined and arranged at a desired angle.

  Next, the laser light oscillated from the ultraviolet laser 25 whose wavelength of the oscillating light is ultraviolet light having a wavelength of 325 nm (He—Cd laser) is reflected by the mirror 26 and incident on the mirror of the X scanner 28 through the shutter 27.

  Further, the laser beam scanned by the X scanner 28 enters the mirror of the Y scanner 29 and scans in a direction orthogonal to the scanning direction of the X scanner 28.

  By the way, the fine unevenness | corrugation by the non-glare process of the surface of the glass substrate 21 is filled with the ultraviolet curable resin 22 apply | coated to the surface, and it becomes a transparent substrate apparently.

  Here, in FIG. 2, the ultraviolet curable resin 22 applied to the surface of the glass substrate 21 and the Ni original plate 23 are illustrated as being separated from each other, but when actually irradiating laser light, the ultraviolet curable resin 22 and The Ni original plate 23 is disposed in close contact with each other.

  FIG. 3 is a diagram showing components in a first step which is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  The elevating stage 31 is a stage that moves in a direction perpendicular to the glass substrate 34, and the original plate 33 can be inclined with respect to the glass substrate 34 by an inclination angle θ by an inclined stage 32.

  Here, the ultraviolet curable resin 35 is applied to the glass substrate 34, and the elevating stage 31 is lowered while being inclined at an inclination angle θ to gradually approach the glass substrate 34, and the ultraviolet curable resin 35 and the original 33 are brought into contact with each other. Let

  FIG. 4 is a diagram showing components in a second step which is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  While the ultraviolet curable resin 35 and the original plate 33 are in contact with each other, the glass substrate 34 is moved from the side opposite to the original plate while irradiating the ultraviolet laser 41 to cure the ultraviolet curable resin 35.

  Here, as a portion for irradiating the ultraviolet laser 41 to cure the ultraviolet curable resin 35, a range substantially equal to the original plate 33 is cured.

  FIG. 5 is a diagram showing components in a third step which is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  The resin cured portion 51 can be formed on the surface of the glass substrate 34 by gradually raising the elevating stage 31 and separating the resin cured portion 51 and the original plate 33.

  A fine uneven pattern on the surface of the original plate 33 is transferred to the surface of the cured resin portion 51 and is inclined at an inclination angle θ set when the resin is cured.

  Next, the glass substrate 34 is moved, an ultraviolet curable resin is applied to a place other than the resin cured portion 51, and the elevating stage 31 is lowered in the same manner as in the first step, and the resin is cured by an ultraviolet laser. The imposition is performed by repeating the third process from the above process.

  FIG. 6 is a diagram showing components of an imposition resin plate which is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  By repeating the steps described above, the imposition resin 61 is formed on the surface of the glass substrate 34, each imposition is inclined by the inclination angle θ, and a fine uneven pattern which is a diffraction grating is formed on the surface. Yes.

  Next, a conductive film is deposited on the surface of the imposition resin 61 and subjected to a conductive treatment, and a Ni electroforming process is further performed thereon.

  FIG. 7 is a diagram showing components of a Ni electroformed replica that is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  In FIG. 6, the Ni electroforming replica plate 71 can be produced by peeling the glass original plate 34 after the Ni electroforming process has a sufficient thickness.

  FIG. 8 is a diagram showing components of a duplication method which is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  Next, an ultraviolet curable resin 82 is applied to the resin substrate 81, the produced Ni electroformed replica plate 71 is brought into close contact, and ultraviolet rays are irradiated from the resin substrate 81 side to cure the ultraviolet curable resin 82.

  Here, the resin substrate 81 and the ultraviolet curable resin 82 are used in combination with good adhesion after curing.

  Next, after the ultraviolet curable resin 82 is cured, the imposition light guide plate can be produced by peeling the resin substrate 81 from the Ni electroformed replica plate 71.

  FIG. 9 is a diagram showing components of a resin substrate cutting method that is an embodiment of a method for producing a light guide plate having a fine uneven pattern according to the present invention.

  The resin substrate 81 and the ultraviolet curable resin 82 are cut by irradiating the imposition light guide plate produced in FIG. 8 while moving a processing laser 91 such as a carbon dioxide laser.

  Here, by cutting with a size equal to that of the original, the fine uneven pattern, which is the diffraction grating of the original, is replicated, and a light guide plate inclined by a desired inclination angle can be produced.

  As described above, it is possible to produce a duplicate plate in which the original plate is accurately inclined and arranged on the transparent substrate by the method described above, and further, a light guide plate inclined by a desired inclination angle is produced from the duplicate plate. A method can be provided.

The conventional structural example of the light-guide plate using a diffraction grating is shown. It is a perspective view which shows the component in one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component in the 1st process which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component in the 2nd process which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component in the 3rd process which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component of the imposition resin plate which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component of the Ni electroforming replication plate which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component of the replication method which is one Embodiment of the preparation methods of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention. It is a figure which shows the component of the cutting method of the resin substrate which is one Embodiment of the manufacturing method of the light-guide plate which consists of a fine uneven | corrugated pattern by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 ... Light guide plate 12 ... Light emitting diode 13 ... Diffraction grating 14 ... Emission light 21, 34 ... Glass substrate 22, 35 ... UV curable resin 23 ... Ni original plate 24, 31 ... Elevating stage 25 ... UV laser 26 ... Mirror 27 ... Shutter 28 ... X scanner 29 ... Y scanner 32 ... Tilt stage 33 ... Original 41 ... UV laser 51... Resin cured portion 61... Imposition resin 71... Ni electroformed replica plate.

Claims (7)

  A step of providing a photocuring resin on the surface of the flat transparent substrate, a step of closely adhering the flat original plate having a fine uneven pattern to the photocuring resin, and arranging the transparent substrate and the original plate close to each other; and In a method for producing a light guide plate comprising a photocuring resin curing step of irradiating light from the opposite side of the original plate to cure the photocurable resin, and a step of peeling the original plate from the transparent substrate, the transparent substrate and the original plate A method for producing a light guide plate comprising a fine concavo-convex pattern, wherein the original is inclined with respect to the transparent substrate in the step of arranging closely.   The method for producing a light guide plate having a fine uneven pattern according to claim 1, wherein an inclination angle of the light guide plate with respect to the light incident optical axis direction when the original plate is inclined is 1 degree or less.   3. A light guide plate comprising a fine concavo-convex pattern according to claim 1 or 2, wherein in the planar master having the fine concavo-convex pattern, a range substantially equal to a range in which the photo-curing resin is cured is a convex shape. Manufacturing method.   4. The light guide plate having a fine uneven pattern according to claim 1, wherein when the light beam is irradiated, the light beam is scanned and moved to sequentially cure the photo-curing resin. 5. Manufacturing method.   5. The method for producing a light guide plate comprising a fine uneven pattern according to claim 1, wherein the fine uneven pattern is a diffraction grating pattern.   6. The method for producing a light guide plate having a fine uneven pattern according to claim 5, wherein the diffraction grating pattern has a blazed diffraction grating shape.   After conducting a conductive treatment on the fine concavo-convex pattern of the light guide plate comprising the fine concavo-convex pattern obtained by the method for producing a light guide plate according to any one of claims 1 to 6, electroforming plating or chemical plating A light guide plate comprising a fine concavo-convex pattern, which is produced by using a duplicate plate obtained by performing the step.

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