JP2007078828A - Optical sheet for display and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a sheet-shaped laminate used for a liquid crystal display element in a step simpler than conventional one at low costs and with high quality. <P>SOLUTION: A manufacturing method of an optical sheet includes a laminating step for disposing and laminating optical sheets 12 and 16 whose surfaces have sizes larger than a product size on the front surface and/or the rear surface of at least one lens sheet 14 whose surface has a size larger than the product size and in which convex lenses formed in one axis direction are adjacently disposed on the nearly entire surface thereof, a cutting step for cutting the peripheral edge of the laminate of the optical sheets and the lens sheet in the product size and a joining step for joining the lens sheet and the optical sheets at least at one part of the peripheral edge. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an optical sheet for a display and a method for manufacturing the same, and in particular, for a display suitable for manufacturing a laminate of sheet-like materials used for a liquid crystal display element and the like with a simpler process than before. The present invention relates to an optical sheet and a method for manufacturing the same.

  In recent years, a film that diffuses light from a light source such as a light guide plate, a lens film that condenses light in the front direction, and the like are used for electronic displays such as liquid crystal display elements and organic EL.

  In this case, there are many examples in which various optical films (sheets) are laminated. For example, in Patent Document 1, a reflective polarizing film, a retardation film, and a semi-transmissive semi-reflective layer are laminated in an arbitrary order, and further, an absorptive polarizing film is laminated outside these three layers. A semi-reflective polarizing film is provided. And as many as five layers of films are interposed between the light source device and the liquid crystal cell. With this configuration, it is said that screen luminance is increased or power consumption is suppressed.

Patent Documents 2 to 4 disclose a film in which the functions of one light diffusion film and a lens film are integrated.
JP 2004-184575 A Japanese Patent Laid-Open No. 7-230001 Japanese Patent No. 3123006 JP-A-5-341132

  However, in the above-described conventional configuration, it is required to go through a number of processes in order to laminate a number of layers of film, which complicates the process and inevitably increases the cost.

  Further, since the surface of a flat lens such as a lenticular lens or a prism sheet is easily damaged or dirty, it is generally delivered in a state where a protective sheet is stuck on the surface.

  However, such a protective sheet is only discarded after being peeled from the flat lens, and is not preferable because it is not only a waste of resources but also increases costs. Moreover, the operation | work which peels a protective sheet from a flat lens is required, and will also reduce productivity by that much. Further, when the protective sheet is peeled off from the flat lens, contamination such as dust is easily attached to the flat lens by peeling charging, and there are many problems in terms of quality.

  Also, when laminating multiple layers of films (sheets), the film tends to be damaged due to rubbing during lamination, rubbing due to thermal expansion / shrinkage, rubbing due to handling, and the like.

  Furthermore, in order to correct defects (distortion, curl, etc.) due to mismatching due to thermal expansion / contraction between multiple films, measures such as increasing the thickness of individual films (such as increasing rigidity) must also be required. There are many demerits such as design restrictions and cost increase.

  The present invention has been made in view of such circumstances, and manufactures a laminate of sheet-like materials used for display applications such as liquid crystal display elements at low cost and high quality by a simpler process than before. It is an object of the present invention to provide an optical sheet for a display and a method for producing the same.

  In order to achieve the above object, the present invention provides an optical sheet for display, in which two or more optical sheets are laminated, and the optical sheets are bonded to each other at at least one position on the periphery. I will provide a.

  To this end, the present invention provides a laminating step of laminating two or more optical sheets having a planar size of the product equal to or larger than the product size, a cutting step of cutting the periphery of the laminated body of optical sheets into a product size, A method of manufacturing an optical sheet for display, comprising: a step of bonding a laminated body of optical sheets at at least one or more locations on the periphery.

  According to the present invention, two or more optical sheets having a planar size equal to or larger than the product size are laminated, the periphery of the laminate is cut into a product size, and the laminate is joined at at least one location on the periphery.

  Therefore, it is possible to omit the step of cutting a number of films (sheets) into product sizes, and it is possible to omit the step of laminating layers of films (sheets) while positioning them. Further, the above-described problem due to the protective sheet does not occur, and it is advantageous in terms of cost and quality. Furthermore, the above-mentioned problems when laminating several layers of films and the above-mentioned problems due to thermal expansion / contraction between a plurality of films do not occur.

  From the above points, according to the present invention, the optical sheet for display can be manufactured at a low cost and with high quality by a simpler process than before.

  The optical sheet (optical film) is a general term for various sheets having an optical function, and is a diffusion sheet, a polarizing plate (polarizing film), various lens sheets (lenticular lens, fly-eye lens). , Prism sheet, etc.), but also includes a protective sheet (protective film) that hardly performs an optical function.

  In order to achieve the above object, the present invention provides an optical sheet on at least one front surface and / or back surface of a lens sheet in which convex lenses formed in one axial direction are adjacently arranged on substantially the entire surface. Provided is an optical sheet for display, which is laminated, and wherein the lens sheet and the optical sheet are joined at at least one or more positions on the periphery.

  For this reason, the present invention is such that the planar size of the sheet is equal to or larger than the product size, and at least one of the lens sheets in which convex lenses formed in one axial direction are adjacently arranged on substantially the entire surface, A laminating step in which an optical sheet having a planar size equal to or larger than the product size is disposed on the front surface and / or back surface of the lens sheet and laminating, and a cutting step in which the periphery of the laminate of the optical sheet and the lens sheet is cut into the product size And a joining step of joining the lens sheet and the optical sheet at at least one or more locations on the periphery.

  According to the present invention, an optical sheet having a planar size equal to or larger than the product size is laminated on the front surface and / or the back surface of the lens sheet having a planar size equal to or larger than the product size. Cutting and joining the lens sheet and the optical sheet at at least one place on the periphery.

  Therefore, it is possible to omit the step of cutting a number of films (sheets) into product sizes, and it is possible to omit the step of laminating layers of films (sheets) while positioning them. Further, the above-described problem due to the protective sheet does not occur, and it is advantageous in terms of cost and quality. Furthermore, the above-mentioned problems when laminating several layers of films and the above-mentioned problems due to thermal expansion / contraction between a plurality of films do not occur.

  From the above points, according to the present invention, the optical sheet for display can be manufactured at a low cost and with high quality by a simpler process than before.

  The “lens sheet in which convex lenses formed in one axis direction are adjacently arranged on substantially the entire surface” is typically a lenticular lens or a prism sheet, and also includes a diffraction grating and the like.

  In addition, since “the planar size of the sheet is equal to or larger than the product size”, the planar size of the lens sheet or the optical sheet is the same as the product size as well as when the planar size of the lens sheet or the optical sheet is larger than the product size. Is also included. In such a case, in the cutting step, one or more sides of the lens sheet or the optical sheet may not be cut.

  In order to achieve the above object, according to the present invention, two lens sheets each having a convex lens formed in one axial direction adjacent to each other and arranged on substantially the entire surface are substantially perpendicular to each other. The optical sheet is laminated on the front surface and / or the back surface of the laminated body of the lens sheets, and the lens sheets and the lens sheet and the optical sheet are at least at one or more peripheral positions. An optical sheet for display is provided, which is bonded in the above.

  To this end, the present invention provides a lens having two sheets of lens sheets in which the planar size of the sheet is equal to or larger than the product size, and convex lenses formed in one axis direction are adjacent to each other and arranged on substantially the entire surface. And laminating the optical sheet having a plane size of the sheet not smaller than the product size on the front surface and / or the back surface of the laminated body of the lens sheet, and the optical sheet, A cutting step of cutting the periphery of the laminated body with the lens sheet into a product size, and a bonding step of bonding the lens sheets to each other and the lens sheet and the optical sheet at at least one place on the periphery. Provided is a method for producing an optical sheet for display.

  According to the present invention, the above-described various effects can be obtained in a configuration in which two lens sheets are laminated in a direction in which the axes of the convex lenses are substantially orthogonal and the optical sheet is laminated on the front surface and / or the back surface. It is done. Therefore, according to the present invention, the optical sheet for display can be manufactured at a low cost and with high quality by a simpler process than before.

  In addition, although “laminated in a direction in which the lens axes are substantially orthogonal” is described, the angle may be slightly adjusted in order to prevent moire fringes and the like.

  In the present invention, it is preferable that the joining step is performed by fusing the lens sheet and / or the optical sheet. The bonding can be performed by means such as adhesion, but it is preferable to perform the process by fusing the lens sheet and / or the optical sheet in this manner, because the process can be simplified. As a means for fusing the lens sheet and / or the optical sheet, heating by ultrasonic waves, heating by laser light irradiation, or the like can be employed.

  Moreover, in this invention, it is preferable to perform the said joining process by adhesion | attachment. As an adhesive means, not only the use of an adhesive but also the use of a double-sided adhesive tape can be employed.

  Moreover, in this invention, it is preferable to perform the said cutting process and a joining process substantially simultaneously by irradiation of a laser beam. Cutting can be performed by machining (for example, shearing or pressing), but laser light (particularly carbon dioxide laser) is suitable for cutting a resin sheet and is advantageous in terms of layout. Further, it is preferable to use a laser beam because the cutting process and the bonding process can be performed simultaneously, and the process can be simplified.

  Moreover, in this invention, it is preferable to join the said optical sheet in at least 1 side of a periphery in the said joining process. Moreover, in this invention, it is preferable to join the said lens sheet and the said optical sheet in at least 1 side of a periphery in the said joining process. Moreover, in this invention, it is preferable to join the said lens sheets and the said lens sheet and the said optical sheet in at least 1 side of a periphery in the said joining process. As described above, when bonding is performed on at least one side of the periphery of the stacked body, the stacked body is more firmly fixed.

  Moreover, in this invention, it is preferable to join the said optical sheet in 4 sides of a periphery in the said joining process. Moreover, in this invention, it is preferable to join the said lens sheet and the said optical sheet in 4 sides of a periphery in the said joining process. In the joining step, it is preferable that the lens sheets are joined to each other and the lens sheet and the optical sheet are joined at the four peripheral edges. Thus, if bonding is performed on the four sides of the periphery of the laminate, the laminate is more firmly fixed, and contamination such as dust can be more effectively prevented.

  In the present invention, it is preferable that the thermal expansion coefficients of the lens sheet and the optical sheet are substantially matched. If it is such a structure, the said problem by the thermal expansion and thermal contraction between films will not arise.

  Specifically, the difference Δα in the thermal expansion coefficient between the lens sheet and the optical sheet is preferably 2% or less, more preferably 1% or less, and most preferably 0.05% or less.

  As described above, according to the present invention, an optical sheet for display can be manufactured at a low cost and with high quality by a simpler process than before.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. First, the configuration of examples (first to fifth embodiments) of optical sheets for display manufactured by the method for manufacturing optical sheets for display according to the present invention will be described, and then the method for manufacturing optical sheets for display (first) 1 to 6 manufacturing methods) will be described.

  FIG. 1 is a cross-sectional view showing a configuration of an example (first embodiment) of a display optical sheet manufactured by the method for manufacturing a display optical sheet according to the present invention.

  The optical sheet for display 10 is an optical sheet module in which a first optical sheet 12, a prism sheet 14, and a second optical sheet 16 are laminated in order from the bottom. As the first optical sheet 12 and the second optical sheet 16, for example, a reflective polarizing sheet, a diffusion sheet, a transparent optical sheet (PET, TAC, etc.) and the like can be used.

  The prism sheet 14 is a lens sheet in which convex lenses formed in one axial direction are adjacent to each other and arranged on substantially the entire surface. For example, the pitch is 50 μm, the uneven height is 25 μm, and the apex angle of the convex portion is set. It can be 90 degrees (right angle).

  The prism sheet 14 is arranged in a direction in which the axes of the convex lenses (prisms) are substantially orthogonal. That is, in FIG. 1, the axis of the convex lens of the prism sheet 14 is arranged in a direction perpendicular to the paper surface.

  The material and manufacturing method of the prism sheet 14 can take various known modes. For example, a sheet-shaped resin material extruded from a die is placed opposite to the transfer roller that rotates at approximately the same speed as the resin material extrusion speed (a prism sheet reverse type is formed on the surface). A method for producing a resin sheet can be employed in which the pressure is sandwiched between nip roller plates rotating at the same speed and the uneven shape on the surface of the transfer roller is transferred to the resin material.

  In addition, a method of manufacturing a resin sheet in which a transfer mold plate (stamper) on which a reversal type of a prism sheet is formed and a resin plate are laminated by hot pressing and press molding by thermal transfer can be employed.

  As a resin material used in such a manufacturing method, a thermoplastic resin can be used, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, MS resin, AS resin, polypropylene resin, polyethylene resin. , Polyethylene terephthalate resin, polyvinyl chloride resin (PVC), thermoplastic elastomer, or a copolymer thereof, cycloolefin polymer, and the like.

  As another manufacturing method, an uneven roller (inverted prism sheet) is formed on the surface of a transparent film (polyester, cellulose acylate, acrylic, polycarbonate, polyolefin, etc.) similar to that used for the diffusion sheet 18 described later. A method for producing a resin sheet in which surface irregularities are transferred and formed) can be employed.

  More specifically, a transparent film in which an adhesive layer and a resin layer (for example, UV curable resin) are formed in two or more layers is continuously run by sequentially applying an adhesive and a resin to the surface. The transparent film is wound around a rotating concavo-convex roller, the concavo-convex surface of the concavo-convex roller is transferred to the resin layer, and the resin layer is cured in a state where the transparent film is wound around the concavo-convex roller (for example, UV irradiation). The manufacturing method of a concavo-convex sheet can be adopted. Note that no adhesive is required.

  In addition, the manufacturing method of the prism sheet 14 is not necessarily limited to said example, Other manufacturing methods can also be employ | adopted if it is a method which can form desired uneven | corrugated shape on the surface.

  As shown in FIG. 1, the left and right end portions of the display optical sheet 10 are integrated with each other by a joint portion 10 </ b> A. The joining portion 10A is formed by carbon dioxide laser processing or the like in the joining process.

  The display optical sheet 10 described above is disposed, for example, between a light source device and a liquid crystal cell, and is used so as to form a liquid crystal display element as a whole. In this case, in addition to the various merits already described (the optical sheet for display can be manufactured at a low cost and high quality with a simpler process than before), the assemble work of the liquid crystal display element is also very easy. can get.

  Next, another example (second embodiment) of the optical sheet for display manufactured by the method for manufacturing an optical sheet for display according to the present invention will be described. FIG. 2 is a cross-sectional view showing the configuration of the display optical sheet 20. In addition, the same code | symbol is attached | subjected about the same and similar member as FIG. 1 (1st Embodiment), and the detailed description is abbreviate | omitted.

  The display optical sheet 20 is an optical sheet in which a second prism sheet 15 and a first prism sheet 14 are laminated in order from the bottom. The second prism sheet 15 is provided when a wide diffusion performance is required not only in the uniaxial (X axis) direction but also in the biaxial (Y axis) direction as in the display optical sheet 10 described above. The first and second prism sheets 14 and 15 are laminated with their flat surfaces back to back.

  The first and second prism sheets 14 and 15 are arranged so that the axes of the convex lenses (prisms) are substantially orthogonal to each other. That is, in FIG. 2, the axis of the convex lens of the first prism sheet 14 is arranged in a direction perpendicular to the paper surface, and the axis of the convex lens of the second prism sheet 15 is arranged in a direction parallel to the paper surface. Yes. In FIG. 2, the second prism sheet 15 is shown in a direction different from the actual direction so that it can be understood that the section of the second prism sheet 15 is a convex lens.

  The display optical sheet 20 described above is disposed, for example, between the light source device and the liquid crystal cell, and is used so as to form a liquid crystal display element as a whole, as in the first embodiment.

  Next, still another example (third embodiment) of the optical sheet for display manufactured by the method for manufacturing an optical sheet for display according to the present invention will be described. FIG. 3 is a cross-sectional view showing a configuration of the display optical sheet 30.

  The optical sheet for display 30 is an optical sheet in which a first diffusion sheet 13 and a second diffusion sheet 17 are laminated in order from the bottom.

  The optical sheet for display 30 is used when the directional diffusion performance is not required and the isotropic diffusion performance is required as in the optical sheet for display 10 and the optical sheet for display 20 described above. Is.

  The first diffusion sheet 13 and the second diffusion sheet 17 are sheets in which beads are fixed to the surface (one side) of a transparent film (support) with a binder, and have a predetermined light diffusion performance. The first diffusion sheet 13 and the second diffusion sheet 17 have different bead diameters (average particle diameters) and light diffusion performance.

  A resin film can be used for the transparent film (support) used for the first diffusion sheet 13 and the second diffusion sheet 17. As the material of the resin fill, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyester, polyolefin, acrylic, polystyrene, polycarbonate, polyamide, PET (polyethylene terephthalate), biaxially stretched polyethylene terephthalate, Known materials such as polyethylene naphthalate, polyamideimide, polyimide, aromatic polyamide, cellulose acylate, cellulose triacetate, cellulose acetate propionate, and cellulose diacetate can be used. Of these, polyester, cellulose acylate, acrylic, polycarbonate, and polyolefin can be preferably used.

  The bead diameters of the first diffusion sheet 13 and the second diffusion sheet 17 are required to be 100 μm or less, and preferably 25 μm or less. For example, the average particle size can be 17 μm within a predetermined distribution range of 7 to 38 μm.

  The display optical sheet 30 described above is disposed, for example, between the light source device and the liquid crystal cell, and used to form a liquid crystal display element as a whole, as in the first embodiment.

  Next, still another example (fourth embodiment) of the display optical sheet manufactured by the method for manufacturing a display optical sheet according to the present invention will be described. FIG. 4 is a cross-sectional view showing a configuration of the display optical sheet 40.

  The display optical sheet 30 is an optical sheet in which a diffusion sheet 17 and an optical sheet 16 are laminated in order from the bottom. As the optical sheet 16, for example, a polarizing plate can be adopted.

  The display optical sheet 40 described above is arranged, for example, between the light source device and the liquid crystal cell and used to form a liquid crystal display element as a whole, as in the first embodiment.

  Next, still another example (fifth embodiment) of the optical sheet for display manufactured by the method for manufacturing an optical sheet for display according to the present invention will be described. FIG. 5 is a cross-sectional view showing the configuration of the display optical sheet 50.

  The display optical sheet 50 is an optical sheet in which the prism sheet 14 and the optical sheet 16 are laminated in order from the bottom. As the optical sheet 16, for example, a polarizing plate can be adopted.

  The display optical sheet 50 described above is disposed between the light source device and the liquid crystal cell, for example, as in the first embodiment, and used to form a liquid crystal display element as a whole.

  Next, the manufacturing method (1st-6th manufacturing method) of the optical sheet for displays is demonstrated. This manufacturing method can be applied in common to the above-described display optical sheets 10 to 50, but a case where it is applied to a four-layer display optical sheet will be described for convenience of explanation. As such a four-layer optical sheet for display, for example, a sheet in which a protective sheet 18 is laminated on the surface (upper surface) of the optical sheet for display 10 of the first embodiment can be applied.

  FIG. 6 is a configuration diagram of a display optical sheet production line 11 applied to the first production method. The rolls 12B, 14B, 16B, and 18B provided at the left end of the figure are respectively the first optical sheet 12, the prism sheet 14, the second optical sheet 16, and the protection shown in FIG. A roll around which the sheet 18 is wound.

  The rolls 12B, 14B, 16B, and 18B are respectively supported by the rotation shafts of the feeding means (not shown). The optical sheet 16 and the protective sheet 18 can be fed at substantially the same speed.

  The fed first optical sheet 12, prism sheet 14, second optical sheet 16, and protective sheet 18 are supported by guide rollers G, G, respectively, and finally, upstream of a laser head 24 described later. Lamination is performed on the side (lamination process).

  As a laser beam irradiation apparatus including the laser head 24, a YAG laser irradiation apparatus having a wavelength of 355 to 1064 nm, a semiconductor laser irradiation apparatus, a carbon dioxide laser irradiation apparatus having a wavelength of 9 to 11 μm, and the like can be employed. The oscillation method may be continuous oscillation or pulse oscillation. However, in order to perform welding at approximately the same time as cutting, doting by pulse oscillation is preferable because the appearance is good.

  The output and frequency required for welding (joining process) almost simultaneously with the cutting (cutting process) vary depending on the material feed speed, laser beam scanning speed, material thickness, etc. Good welding results can be obtained under the conditions of 50 W and a frequency of 100 kHz or less.

  The laser head 24 is attached to an X drive robot axis or an XY drive robot axis that can move in the X direction (sheet width direction) or the XY direction, and can perform positioning to an arbitrary position and arbitrary trajectory movement. The entire laser head 24 may be moved according to the irradiation pattern of the laser beam, but the laser head 24 is separately placed (fixed), and only the laser beam is guided by the optical fiber to simplify the moving mechanism in the XY directions. You can also

  It is also possible to provide a known mechanism (suction device or the like) that sucks smoke generated during cutting by the laser head 24 and during welding.

  Laser light is irradiated from the laser head 24 to the cut and bonded portions on the periphery of the laminate, and the periphery of the laminate is cut into a product size and melted and joined while moving the irradiation spot at a constant speed.

The optical sheet for display 10 ′ is formed through the above steps. The cut and joined display optical sheet 10 ′ is conveyed onto the conveyor 26 and stopped. The display optical sheet 10 ′ on the conveyor 26 is sequentially stacked on the stacking device 32 by the suction lateral transfer device 28.

  On the other hand, the sheet laminate 34 from which the display optical sheet 10 ′ has been punched out by the laser head 24 is wound around a winding roll 36 of a winding device (not shown in detail).

  According to the above-described optical sheet manufacturing method (first manufacturing method), the following effects 1) to 3) can be obtained.

1) Scratch failure reduction effect When the upper and lower surfaces of the lens sheet (prism sheet 14) are scratched, the scratches are conspicuous because of the lens effect. On the other hand, when the bottom surface of the diffusion sheet (the first diffusion sheet 13 and the second diffusion sheet 17) is scratched, the scratches are not noticeable because the light is diffused. For this reason, preventing damage to the lens sheet leads to reduction of scratch failure. Although scratches are often attached during handling after sheet processing, since the diffusion sheet serves as a protective sheet by combining the lens sheet with the diffusion sheet, failure due to scratches can be reduced. In particular, the effect is great in the optical sheet for display 10 (see FIG. 1) of the first embodiment in which the lens sheet does not appear on the surface.

2) Effect of reducing assembly man-hour For example, when the display optical sheet 10 '(see FIG. 6) of the first embodiment is used in the assembly of the liquid crystal display element, the assembly man-hour incorporates the display optical sheet 10'. In contrast to the process, when the conventional product is used, the first optical sheet is assembled ⇒ The lens sheet is peeled off from the back surface protective sheet ⇒ The lens sheet is peeled off from the surface protective sheet ⇒ The lens sheet is assembled ⇒ The back surface of the second optical sheet Protective sheet peeling ⇒ peeling of surface protective sheet of second optical sheet ⇒ incorporation of second optical sheet ⇒ incorporation of protective sheet 8 steps are required. Thus, according to the first manufacturing method, a significant reduction in assembly man-hours can be achieved, and the product cost can be reduced.

3) Reduction effect of protective sheet In many cases, a protective sheet is attached to the front and back of a lens sheet to prevent scratches. This protective sheet is discarded after the lens sheet is assembled, and is very wasteful. The product of the present invention can save the protective sheet by using the optical sheet as a protective sheet.

  Specifically, the protective sheet for the prism sheet 14 can be reduced by one in the display optical sheet 50 (see FIG. 5) of the fifth embodiment, and the prism in the display optical sheet 10 (see FIG. 1) of the first embodiment. Two protective sheets of the sheet 14 can be reduced, and two protective sheets of the prism sheets 14 and 15 can be reduced in the display optical sheet 20 (see FIG. 2) of the second embodiment.

  Next, another manufacturing method (second manufacturing method) of the optical sheet for display will be described. FIG. 7 is a configuration diagram of a display optical sheet manufacturing line 21 applied to the second manufacturing method. In addition, the same code | symbol is attached | subjected about the member similar to the optical sheet manufacturing line 11 for a display of FIG. 6 (1st manufacturing method), and the detailed description is abbreviate | omitted.

  In the display optical sheet production line 21, dispensers 42, 44, 46 and a punching press device 48 are employed instead of the laser head 24 of the display optical sheet production line 11.

  The dispensers 42, 44, and 46 are supply devices that discharge the adhesive from the tip. The dispenser 42 supplies an adhesive to the surface of the first optical sheet 12 in order to bond the first optical sheet 12 and the prism sheet 14, and the dispenser 44 includes the prism sheet 14 and the second optical sheet 12. In order to bond the optical sheet 16, an adhesive is supplied to the surface of the prism sheet 14, and the dispenser 46 uses the second optical sheet 16 to bond the second optical sheet 16 and the protective sheet 18. An adhesive is supplied to the surface of the sheet 16.

  The adhesive supplied from the dispensers 42, 44 and 46 is preferably an adhesive that is bonded with the aid of heat or a catalyst. Specifically, general adhesives such as silicon adhesives, polyurethane adhesives, polyester adhesives, epoxy adhesives, cyanoacrylate adhesives, and acrylic adhesives can be used.

  Since the display optical sheets 10 to 50 may be used at high temperatures, an adhesive that is stable even at room temperature to 120 ° C. is preferable. Among these, epoxy adhesives are excellent in strength and heat resistance, and can be suitably used. Since the cyanoacrylate adhesive is excellent in immediate effect and strength, it can be used for the production of an efficient optical sheet for display. Polyester adhesives are particularly suitable because they are excellent in strength and processability.

  These adhesives are roughly classified into a thermosetting type, a hot melt type, and a two-component mixed type depending on the bonding method, and a thermosetting type or a hot melt type capable of continuous production is preferably used. Whatever adhesive is used, the coating thickness is preferably 0.5 μm to 50 μm.

  Moreover, it is preferable to provide a drying means for drying the adhesive between the downstream press roller (guide roller G). The drying means is not particularly limited, and examples include known drying methods such as drying with warm air or hot air, drying with dehumidified air, and the like.

  The dispensers 42, 44, and 46 are attached to an X drive robot shaft or an XY drive robot shaft that can move in the X direction (sheet width direction) or XY direction, and can perform positioning to an arbitrary position and arbitrary trajectory movement. It has become.

  An adhesive is supplied from these dispensers 42, 44, and 46 to the joining portion at the periphery of the laminate, and the periphery of the laminate is joined by a downstream press roller (guide roller G) while the laminate is conveyed.

  A punching press device 48 downstream of the dispensers 42, 44, and 46 is a device that cuts the periphery of the laminate into a product size. In this punching press device 48, the blade is inserted into the center portion of the bonded portion, so that all the pieces of the punched sheet (display optical sheets 10 to 30) or only the end portions of the arbitrary pieces are bonded. The obtained composite sheet can be obtained.

  Next, still another manufacturing method (third manufacturing method) of the optical sheet for display will be described. FIG. 8 is a configuration diagram of a display optical sheet manufacturing line 31 applied to the third manufacturing method. In addition, the same code | symbol is attached about the same or similar member as the optical sheet manufacturing line 11 for display of FIG. 6 (1st manufacturing method) and the optical sheet manufacturing line 21 for display of FIG. 7 (2nd manufacturing method). A detailed description thereof will be omitted.

  In this display optical sheet production line 21, tape feeders 52, 54 and 56 are employed in place of the dispensers 42, 44 and 46 of the display optical sheet production line 21. Each of the tape supply devices 52, 54 and 56 is a supply device for supplying a double-sided tape from the tip.

  The tape supply device 52 supplies a double-sided tape to the surface of the first optical sheet 12 in order to bond the first optical sheet 12 and the prism sheet 14, and the tape supply device 54 includes the prism sheet 14. In order to bond the second optical sheet 16 and the second optical sheet 16, a double-sided tape is supplied to the surface of the prism sheet 14, and the tape supply device 56 is used to bond the second optical sheet 16 and the protective sheet 18. In addition, a double-sided tape is supplied to the surface of the second optical sheet 16.

  The double-sided tape supplied from the tape supply devices 52, 54 and 56 is one in which an adhesive is applied to both sides. As the adhesive for this double-sided tape, a highly adhesive acrylic copolymer resin can be used, but other adhesives such as silicone, natural rubber and synthetic rubber can be used. It is preferable to use an acrylic pressure-sensitive adhesive in consideration of physical strength such as property, price and the like.

  The tape supply devices 52, 54 and 56 for supplying the double-sided tape can be used by using a commercially available general-purpose tape dispenser. The tape supply devices 52, 54, and 56 are attached to a single-axis moving mechanism that can move to an arbitrary position in the X direction (sheet width direction), and the position of applying the double-sided tape can be changed according to the punching pattern. it can.

  Further, the fixed portion of the tape supply devices 52, 54 and 56 has a pivot mechanism, and the tape supply pattern in an oblique direction is obtained by changing the position of the tape supply devices 52, 54 and 56 in synchronization with the sheet feeding speed. It is a mechanism that can cope with.

  In the punching press device 48 downstream of the tape supply devices 52, 54 and 56, the blade (display optical sheets 10 to 50) is punched by allowing the blade to enter the central portion of the bonded tape width portion. It is possible to obtain a composite sheet in which all pieces or only end portions of arbitrary pieces are bonded.

  Next, still another manufacturing method (fourth manufacturing method) of the display optical sheet will be described. FIG. 9 is a configuration diagram of a display optical sheet production line 41 applied to the fourth production method. In addition, the optical sheet manufacturing line 11 for display of FIG. 6 (1st manufacturing method), the optical sheet manufacturing line 21 for display of FIG. 7 (2nd manufacturing method), and the display of FIG. 8 (3rd manufacturing method). The same or similar members as those in the optical sheet manufacturing line 31 are denoted by the same reference numerals, and detailed description thereof is omitted.

  In this display optical sheet production line 41, ultrasonic horns 62, 64, 66 are employed instead of the dispensers 42, 44, 46 of the display optical sheet production line 21. The ultrasonic horns 62, 64 and 66 are respectively arranged on the downstream side of the press roller (guide roller G).

  The ultrasonic horns 62, 64 and 66 are devices for fusing two or more laminated sheets. That is, the ultrasonic horn 62 is for fusing the first optical sheet 12 and the prism sheet 14, and the ultrasonic horn 64 is for fusing the prism sheet 14 and the second optical sheet 16. The ultrasonic horn 66 fuses the second optical sheet 16 and the protective sheet 18 together.

  Ultrasonic horns 62, 64, and 66 (ultrasonic welding devices) are conventionally known, and a type that raises and lowers the horn with an air cylinder and a type that raises and lowers the horn with a servo motor are known. However, any type of ultrasonic welding apparatus can be applied as long as the sheets can be welded together by applying ultrasonic vibration while applying a load to the sheets.

  The position control of the ultrasonic horns 62, 64 and 66 is only required to switch the position in the width direction of the sheet when the punching pattern is horizontal with respect to the sheet feeding direction. In such a case, a swing mechanism that can change the traveling direction of the ultrasonic horns 62, 64, and 66 to an arbitrary direction is provided, and it can be handled by moving in the width direction in synchronization with the movement amount of the seat. .

  The setting conditions of the ultrasonic horns 62, 64 and 66 may be determined within a range in which the fused portion is not melted by heat. If necessary, the bonded portion is bonded by an air cooling mechanism such as air blowing after bonding (fusion). It may be cooled.

  In the punching press device 48 downstream of the ultrasonic horns 62, 64 and 66, the blade (display optical sheets 10 to 50) is punched by allowing the blade to enter the center portion of the bonded fused portion. It is possible to obtain a composite sheet in which all pieces or only end portions of arbitrary pieces are bonded.

  Next, still another manufacturing method (fifth manufacturing method) of the optical sheet for display will be described. FIG. 10 is a configuration diagram of a display optical sheet manufacturing line 51 applied to the fifth manufacturing method. In addition, the optical sheet manufacturing line 11 for display of FIG. 6 (1st manufacturing method), the optical sheet manufacturing line 21 for display of FIG. 7 (2nd manufacturing method), and the display of FIG. 8 (3rd manufacturing method). Members that are the same as or similar to the optical sheet manufacturing line 31 and the like are assigned the same reference numerals, and detailed descriptions thereof are omitted.

  In this display optical sheet production line 21, laser heads 72, 74 and 76 are employed instead of the ultrasonic horns 62, 64 and 66 of the display optical sheet production line 41. The laser heads 72, 74, and 76 are disposed on the downstream side of the press roller (guide roller G), similarly to the ultrasonic horns 62, 64, and 66.

  The laser heads 72, 74, and 76 are devices for fusing two or more stacked sheets, similarly to the ultrasonic horns 62, 64, and 66. That is, the laser head 72 is for fusing the first optical sheet 12 and the prism sheet 14, and the laser head 74 is for fusing the prism sheet 14 and the second optical sheet 16. The laser head 76 is for fusing the second optical sheet 16 and the protective sheet 18 together.

  The laser heads 72, 74, and 76 are used only for the joining process, unlike the laser head 24 in the optical sheet production line 11 for display shown in FIG. 9 (first manufacturing method), and the cutting process is performed by a punching press device 48. Done. However, the basic specifications and peripheral configuration of the laser heads 72, 74, and 76 are substantially the same as those in the first manufacturing method.

  The setting conditions of the laser heads 72, 74, and 76 may be determined within a range in which the fused portion is not melted by heat. If necessary, the bonded portion is cooled by an air cooling mechanism such as air blowing after bonding (fusion). May be.

  In the punching press device 48 downstream of the laser heads 72, 74 and 76, all the punched sheets (optical sheets for display 10 to 50) are punched by allowing the blade to enter the central portion of the bonded and bonded part. It is possible to obtain a composite sheet in which only one piece or an end portion of any piece is bonded.

  Next, still another manufacturing method (sixth manufacturing method) of the optical sheet for display will be described. FIG. 11 is a configuration diagram of a display optical sheet production line 61 applied to the sixth production method. In addition, the optical sheet manufacturing line 11 for display of FIG. 6 (1st manufacturing method), the optical sheet manufacturing line 21 for display of FIG. 7 (2nd manufacturing method), and the display of FIG. 8 (3rd manufacturing method). Members that are the same as or similar to the optical sheet manufacturing line 31 and the like are assigned the same reference numerals, and detailed descriptions thereof are omitted.

  In this display optical sheet production line 21, one laser head 78 is employed in place of the three laser heads 72, 74 and 76 of the display optical sheet production line 51. The laser head 78 is disposed on the downstream side of the press roller (guide roller G).

  The laser head 78 is a device that fuses two or more stacked sheets. That is, the laser head 78 fuses the laminated body of the first optical sheet 12, the prism sheet 14, the second optical sheet 16, and the protective sheet 18.

  Note that, unlike the laser head 24 in the display optical sheet manufacturing line 11 of FIG. 9 (first manufacturing method), the laser head 78 is used only for the joining process, and the cutting process is performed by the punching press device 48. However, the basic specifications and peripheral configuration of the laser head 78 are substantially the same as those in the first manufacturing method.

  The setting condition of the laser head 78 may be determined within a range in which the fused portion is not melted by heat. If necessary, the bonded portion may be cooled by an air cooling mechanism such as air blowing after bonding (fusion). .

  In the punching press device 48 downstream of the laser head 78, the blade is inserted into the central portion of the bonded fused portion, so that the entire punched sheet (display optical sheets 10 to 50) or an arbitrary piece A composite sheet in which only the end portions of the pieces are bonded can be obtained.

  Next, a planar arrangement of a sheet (display optical sheet 10 ′) punched out from the laminate of the first optical sheet 12, the prism sheet 14, the second optical sheet 16, and the protective sheet 18 will be described.

  FIG. 12 is a diagram for explaining a planar arrangement of a sheet (display optical sheet 10 ′) punched from the laminate in the first manufacturing method, and FIG. 13 is a diagram illustrating the second to sixth manufacturing methods. It is a figure explaining planar arrangement | positioning of the sheet | seat (optical sheet | seat 10 'for displays) punched out from a laminated body.

  In FIG. 12, (A) shows a state in which fusion (joining process) and punching (cutting process) are performed in a direction parallel and orthogonal to the transport direction of the laminate, and (B) shows transport of the laminate. A state in which fusion (joining process) and punching (cutting process) are performed obliquely with respect to the direction is shown. In the figure, the point on the peripheral edge of the sheet punched out from the laminate indicates the fused part.

  In FIG. 13, (A) shows a state in which fusion or adhesion (joining process) is performed in a direction parallel to and orthogonal to the transport direction of the laminate, and (B) shows the transport direction of the laminate. A state where fusion or adhesion (joining process) is performed in an oblique direction is shown. In the figure, the point on the peripheral edge of the sheet punched out from the laminate indicates a fusion point or an adhesion point.

  As described above, according to the present invention, an optical sheet for display can be manufactured at a low cost and with high quality by a simpler process than before.

  Moreover, according to this invention, the following effects are also acquired.

1) Improvement of Product Value by Cost Reduction and Thinning Optical sheets used for large liquid crystal televisions need rigidity, and therefore, the thickness of the support is about twice that of the conventional one. However, since the optical sheet according to the present invention is a composite of the sheets, it can have sufficient rigidity without increasing the thickness of each sheet, and the thickness of each layer can be reduced.

2) Improved performance by preventing reduction of light collection effect Some products have a matte backside to prevent scratches on the lens sheet (to make the scratches less noticeable). The optical sheet according to the present invention is not necessary, and not only the production cost can be reduced, but also the light collection effect can be prevented from being reduced by the mat treatment, and the performance is improved.

  As mentioned above, although each example of embodiment of the manufacturing method of the optical sheet for a display which concerns on this invention was demonstrated, this invention is not limited to the example of the said embodiment, Various aspects can be taken.

  For example, the layer configuration of the optical sheet for display is not limited to the example of the embodiment, and for example, protective sheets can be laminated on the upper and lower surfaces.

  Even if it is the above structures, it acts similarly to this embodiment and the same effect is acquired.

Sectional drawing of embodiment of the optical sheet for a display manufactured by the manufacturing method of the optical sheet for a display which concerns on this invention Sectional drawing of other embodiment of the optical sheet for displays Sectional drawing of other embodiment of the optical sheet for a display. Sectional drawing of other embodiment of the optical sheet for a display. Sectional drawing of other embodiment of the optical sheet for a display. Configuration diagram of optical sheet manufacturing line for display applied to first manufacturing method Configuration diagram of optical sheet production line for display applied to second production method Configuration diagram of optical sheet manufacturing line for display applied to third manufacturing method Configuration diagram of optical sheet manufacturing line for display applied to fourth manufacturing method Configuration diagram of optical sheet manufacturing line for display applied to fifth manufacturing method Configuration diagram of optical sheet manufacturing line for display applied to sixth manufacturing method The figure explaining the plane arrangement | positioning of the sheet | seat punched out from a laminated body in a 1st manufacturing method. The figure explaining the planar arrangement | positioning of the sheet | seat punched from a laminated body in the 2nd-6th manufacturing method.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10, 20, 30 ... Optical sheet for display, 12 ... 1st optical sheet, 14 ... Prism sheet, 16 ... 2nd optical sheet, 18 ... Protection sheet

Claims (16)

A laminating step of laminating two or more optical sheets having a planar size of the sheet equal to or larger than the product size;
A cutting step of cutting the periphery of the laminate of the optical sheets into a product size;
A bonding step of bonding the laminated body of the optical sheets at at least one place on the periphery;
A method for producing an optical sheet for display. The planar size of the sheet is equal to or larger than the product size, and the planar size of the sheet is equal to or larger than the product size for at least one lens sheet in which convex lenses formed in one axial direction are adjacently arranged on substantially the entire surface. A laminating step of laminating an optical sheet on the front surface and / or back surface of the lens sheet; and
A cutting step of cutting the periphery of the laminate of the optical sheet and the lens sheet into a product size;
A bonding step of bonding the lens sheet and the optical sheet at at least one location on the periphery;
A method for producing an optical sheet for display. The plane size of the sheet is equal to or larger than the product size, and two lens sheets in which convex lenses formed in one axial direction are adjacently arranged on substantially the entire surface are oriented so that the axes of the convex lenses are substantially orthogonal to each other. Laminating and laminating an optical sheet having a planar size of the sheet equal to or larger than the product size on the front and / or back of the lens sheet laminate; and
A cutting step of cutting the periphery of the laminate of the optical sheet and the lens sheet into a product size;
A bonding step of bonding the lens sheets to each other and the lens sheet and the optical sheet at at least one place on the periphery;
A method for producing an optical sheet for display.   The manufacturing method of the optical sheet for a display of any one of Claims 1-3 which perform the said joining process by fusing the said lens sheet and / or the said optical sheet.   The manufacturing method of the optical sheet for a display of any one of Claims 1-3 which perform the said joining process by adhesion | attachment.   The manufacturing method of the optical sheet for a display of any one of Claims 1-3 which perform the said cutting process and a joining process substantially simultaneously by irradiation of a laser beam.   The method for manufacturing an optical sheet for display according to any one of claims 1, 4, 5, and 6, wherein the optical sheet is bonded to at least one side of a peripheral edge in the bonding step.   The method for manufacturing an optical sheet for display according to any one of claims 1, 4, 5, and 6, wherein the optical sheet is bonded at four peripheral edges in the bonding step.   The method for manufacturing an optical sheet for display according to any one of claims 2, 4, 5, and 6, wherein the lens sheet and the optical sheet are bonded to each other at at least one side of a peripheral edge in the bonding step.   The method for manufacturing an optical sheet for display according to any one of claims 2, 4, 5, and 6, wherein the lens sheet and the optical sheet are bonded at four peripheral edges in the bonding step.   The method for manufacturing an optical sheet for display according to any one of claims 3 to 6, wherein in the joining step, the lens sheets and the lens sheet and the optical sheet are joined at at least one side of a peripheral edge.   The manufacturing method of the optical sheet for a display of any one of Claims 3-6 which joins the said lens sheets and the said lens sheet and the said optical sheet in 4 sides of a periphery in the said joining process.   The manufacturing method of the optical sheet for a display of any one of Claims 1-12 which makes the thermal expansion coefficient of the said lens sheet and the said optical sheet substantially correspond.   2. An optical sheet for display, wherein two or more optical sheets are laminated, and the optical sheets are bonded to each other at at least one location on the periphery.   An optical sheet is laminated on at least one front surface and / or back surface of a lens sheet in which convex lenses formed in one axial direction are adjacently arranged on substantially the entire surface, and the lens sheet and the optical sheet are An optical sheet for display, which is bonded to at least one of the peripheral edges. Two lens sheets, in which convex lenses formed in one axial direction are adjacent and arranged on substantially the entire surface, are laminated so that the axes of the convex lenses are substantially orthogonal to each other, and the optical sheet is the lens sheet. An optical sheet for a display which is laminated on the front surface and / or the back surface of the laminated body, and wherein the lens sheets and the lens sheet and the optical sheet are bonded to each other at at least one place on the periphery. .

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