JP2007206720A - Reflector and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To supply a reflector with fine protrusions and recessions formed thereon at low cost. <P>SOLUTION: The reflector 20, having a reflection film 22 with the fine protrusions and recessions 25, formed thereon, is manufactured by pressing a film shaped raw material 80, formed of the reflection film 22 and a supporting film 24 laminated on each other, with a mold 89 having a press face 88 with the fine protrusions and recessions 25 formed thereon. According to this manufacturing method, the reflector 20 is supplied within a short time period and at low cost, because the reflector 20 is continuously manufactured. Furthermore, even a semi-transmissive reflector is manufactured with the same process, and the semi-transmissive reflector can also be supplied at low cost. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a reflector suitable for a display device of a mobile terminal such as a mobile phone or a PDA.

  Mobile terminals such as mobile phones and PDAs are often used, and a display device that can display bright and clear images with low power consumption is demanded. One of them is a reflective liquid crystal panel, which is displayed on the liquid crystal panel using external light by providing a reflective electrode on the back surface of the liquid crystal panel or by attaching a sheet type reflector on the back surface. It illuminates the letters and images. The reflector is smaller than the size of the liquid crystal cell and larger than the wavelength level of visible light, which is several tens of microns to 0. It is known that by providing minute irregularities of several microns, preferably several microns, it is possible to reflect a large amount of external light in the direction of the user's eyes and improve the brightness and visibility.

  On the other hand, in order to display a multi-color image displayed on the color LCD panel clearly, more light is required, and for night use, forcibly illuminating using the front light or backlight. It is desirable to do. And when it is going to display a liquid crystal panel with more uniform illumination intensity, a backlight system is excellent. For this reason, transflective liquid crystal panels that can also use external light have been developed. This transflective liquid crystal panel can be used to forcibly remove a part of the reflective film of the reflector to create a light transmitting part, or to strictly control the thickness of the reflective film such as aluminum. By forming a thin film, a reflector that transmits part of light is employed.

  Conventionally, these reflectors are manufactured by forming fine irregularities on a substrate by a method such as etching or transfer, and then laminating a reflective material such as aluminum on the surface by a method such as vapor deposition. Therefore, the manufacturing process is batch processing, and the manufacturing efficiency is not high. In particular, when a semi-transparent reflector is to be manufactured, a method is adopted in which first, after forming fine irregularities, a part thereof is removed. For this reason, since a removal process is newly required in order to make it semi-permeable, manufacturing cost becomes still higher.

  Furthermore, in order to ensure the reflection efficiency of the reflector, it is required to precisely design fine irregularities and to produce them precisely as designed, but only the reflective film at the predetermined locations of the fine irregularities is removed. It is very difficult to do. Further, since fine irregularities are randomly formed in order to prevent a pattern due to interference light from appearing, it is impossible to remove only the reflection film at those predetermined locations. Therefore, by making it semi-transmissive, the reflection efficiency of the reflector inevitably decreases, and it is impossible to achieve both reflection efficiency and semi-transparency.

  In particular, it has been proved that a structure in which inclined fine mirror surfaces are randomly arranged is effective when the amount of light reflected is precisely controlled to secure the amount of light. If is removed, the reflection efficiency is greatly deteriorated.

  On the other hand, when the entire thickness is made semi-transmissive by controlling the film thickness, it is necessary to precisely manage the thickness of the reflective film, resulting in poor yield and high cost. Further, by making the film thinner, it is difficult to accurately reproduce the reflection shape, and it becomes difficult to maintain the reflection efficiency. Moreover, since the reflectance is reduced by making the whole semi-transparent, the reflection efficiency is inevitably deteriorated. In addition, partially translucent is a more difficult task than partially removing the reflective film described above, and it is impossible to specify the location. Therefore, even with this method, it is not possible to manufacture a reflector having both reflection efficiency and semi-transparency at low cost.

  Accordingly, an object of the present invention is to provide a method capable of manufacturing a reflector having fine irregularities formed at low cost. Furthermore, even if it is a translucent reflector, it aims at providing the manufacturing method which can manufacture a reflector with good reflection efficiency and high transparency at low cost.

  For this reason, in the present invention, unlike a reflector manufacturing method using a conventional substrate, a reflector having fine irregularities on the surface is manufactured using a continuous film-like member. For this purpose, the fine irregularities are press-molded on a film-like member using a mold having fine irregularities formed on the press surface.

  That is, in the reflector manufacturing method of the present invention, at least one surface is pressed with a reflective film material by a first mold having a plurality of fine irregularities formed on the press surface, and the fine irregularities are press-molded. The process to do is adopted. If it is this manufacturing method, it will become possible to continuously shape | mold the reflector which has a fine unevenness | corrugation by pressing a part of continuous film material with a press surface, and repeating it. Therefore, unlike the conventional batch processing, it is possible to efficiently mass-produce and supply at low cost a film-like reflector in which at least one surface is a reflecting surface and a plurality of fine irregularities are press-molded. Also, in the press molding process, a reflector wound in a roll shape is supplied at a low cost by adopting a method in which it is drawn out and transferred to a film material wound up in a roll shape, and then wound again in a roll shape. it can.

  Since the press molding process forms fine irregularities of about several μm to several tens of μm, the film thickness of the film material can also be increased by sandwiching and pressing the film material between the flat base and the first mold. Unevenness can be press-formed with sufficient accuracy by deformation within the range. Alternatively, the base plate may be easily deformed by giving elasticity. In order to further stabilize the fine shape to be press-molded, it is also possible to sandwich the film material between the second mold having the press surface that complements the press surface of the first mold and the first mold. In particular, it is effective when the film material is thinned or intermittently made semi-permeable.

  In the press molding step, it is desirable to sandwich an appropriate protective agent that promotes peeling between the press surface and the film material, instead of bringing the press surface into direct contact with the reflective surface. For example, the protective agent is a mold release agent, and peeling can be promoted by applying the mold release agent to the press surface or the film material side, so that the production efficiency is improved and the yield is also improved. The protective agent may be a film that protects the reflective surface of the film material and reduces the adhesion to the press surface. Furthermore, the protective agent may be a surface protective film on the pressed surface that reduces the adhesion to the film material, and the materials that reduce the adhesion include fluorine-based and silicon-based materials.

  The film material may have a single-layer structure such as a metal thin film or a multilayer film. The multilayer film may be a reflective film formed by laminating a semi-transmissive film, or a reflective film such as a metal thin film and supported in consideration of strength or convenience in handling. The support film to be laminated may be used. In the case of a film material in which a support film and a reflective film are laminated, the reflective film is sandwiched between a protective film and a support film that weaken the adhesive force between the reflective film and the press surface rather than the adhesive force between the support film and the reflective film. It is desirable to have a structure.

  Furthermore, in the manufacturing method of the present invention in which fine irregularities are press-molded on a film material, the shape of the minute irregularities formed on the surface is the first shape in which the reflective surface (reflecting surface) of the reflector is easily molded. The semi-transparent portion can be automatically formed by forming the region and the second region having a shape in which the reflecting surface is intermittent or thin with respect to the first region. Accordingly, at least a part of the unevenness is a reflective region having an inclined mirror surface and a shape that complements the shape of the reflective region, and the reflective surface is intermittent or thinner than the reflective region. The semi-transmissive reflector formed by the non-reflective region provided with the portion can be mass-produced at a low cost in the same process as the totally reflective reflector.

  That is, according to the manufacturing method of the present invention, it is not necessary to make it semi-transparent in the post-process as in the prior art, and the factor of high cost can be eliminated. Furthermore, since a portion that becomes transparent or semi-transmissive can be incorporated into the uneven shape, it is possible to make the shape as designed and semi-transmissive without breaking the uneven shape. Therefore, even if irregularities are randomly created, a desired place is transmitted or semi-transmitted. For this reason, the manufacturing method of the present invention makes it possible to manufacture a high-quality reflector that achieves both reflection efficiency and translucency at low cost.

  In this reflector, it is possible to form a first mirror surface that reflects, condenses, or distributes the first incident light from the surface in a desired direction in the reflection region. The reflection efficiency of light, that is, external light can be improved. On the other hand, from the non-reflective region, the second incident light from the back surface of the reflector, that is, the light beam from the backlight can be guided to the front surface side, and the reflector can be made semi-transmissive. Therefore, it is possible to provide a transflective reflector having both reflection efficiency and transparency. In addition, in order to form a large number of reflection regions having the first mirror surface, a shape that complements the reflection regions is necessarily required. Therefore, even if it is used as a non-reflection region, it does not cause a decrease in the efficiency of the reflection region.

  Therefore, by combining the reflector of the present invention, the transmissive display body disposed on the front surface side of the reflector, and the light source disposed on the back surface side of the reflector, that is, the backlight device, external light is combined. It is possible to provide a display device that can display a bright and clear image using the light and can display a bright image even at night by the light of the backlight device.

  One of the shapes of the non-reflective region that complements the shape of the reflective region is a shape having a reverse gradient with respect to the first mirror surface, and the non-reflective region may be provided with a reverse-gradient transmissive or semi-transmissive transmissive surface. it can. This reverse gradient surface is a portion that is intermittently transmitted because cracks and cracks are likely to occur in the non-reflective region even when pressing by making the gradient steep relative to the gradient of the first mirror surface. , Tends to become a semi-transparent part by thinning. In addition, when the top of the reflection region and the bottom of the adjacent reflection region are arranged so as to overlap each other, a surface or an intermittent structure facing the reflection region is formed by the reflection regions. The space is a non-reflective region.

  In order to press such a shape, the first region of the press surface is provided with a first inclined surface that is inclined so as to reflect incident light from the surface, and the second region is referred to as the first inclined surface. A second slope having a reverse slope is provided. It is desirable that the slope or slope of the second slope is steeper than the slope of the first slope. Further, in the first step, by forming irregularities so that the top of the first region and the bottom of the adjacent first region overlap, a non-reflective region can be formed between them.

  The reflective region of the reflector may further include a second mirror surface that reflects the second incident light that has entered from the back side of the reflector and transmitted through the non-reflective region, that is, the light flux from the backlight, to the surface side. it can. As a result, it is possible to provide a reflector that can further control the emission direction of the light flux of the backlight. When the second mirror surface is provided, the external light reflected by the second mirror surface escapes from the non-reflective region, but the light from the backlight reflected by the second mirror surface is output toward the user's eyes. Therefore, there is basically no external light incident from the direction of the eyes as a reverse ray, and it does not cause a deterioration in the reflection characteristics of the reflector.

  Furthermore, by forming a back-surface reflection area that reflects the light from the backlight toward the non-reflection area, it is possible to efficiently guide the light flux output from the backlight to the surface of the reflector. Efficiency can also be improved. This back surface reflection region can be arranged using the back surface of the reflection region.

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an outline of a mobile phone 1 equipped with a display device 2 according to the present invention. The display device 2 includes a transmissive liquid crystal panel 10 disposed on the front side of the mobile phone 1, a translucent reflector 20 disposed on the back surface thereof, and a backlight device 3 disposed on the back surface thereof. It has. Therefore, when there is sunlight or the illumination device 70 that illuminates the display device 2, light (external light or first incident light) 71 therefrom is reflected by the reflector 20 toward the user 79 as display light 73, and the liquid crystal The image displayed on the panel 10 is displayed to the user 79. On the other hand, when there is no external light 71 or when the external light 71 is insufficient, light (backlight light or second incident light) 72 from the backlight 3 is transmitted via the semi-transmissive reflector 20. The liquid crystal panel 10 is illuminated by. Therefore, a bright and clear image can be displayed with low power consumption using the external light 71 in an environment where the external light 71 is present, and the backlight light 72 is bright and clear even in an environment where the external light 71 is absent or insufficient. Simple images can be displayed.

  FIG. 2 is an enlarged schematic view of the display device 2 using a cross section. The liquid crystal panel 10 has a configuration in which a liquid crystal layer 12 is sandwiched between a pair of glass substrates 11a and 11b, and a pair of alignment films 13a and 13b between the glass substrates 11a and 11b and the liquid crystal layer 12, and 1 A pair of transparent electrodes 14a and 14b are disposed. A pair of polarizing plates 15a and 15b are arranged outside the glass substrates 11a and 11b. When the upper side of FIG. 2 is the front side, the reflective film 22 is formed on the lower side (back side) of the lower polarizing plate 15b, that is, on the back side 10b of the liquid crystal panel 10 on the side (front side) facing the liquid crystal panel 10. A transmissive reflector 20 is attached, and the backlight 3 is attached to the back side thereof. Therefore, the light beam 71 incident from the front surface 10a side of the liquid crystal panel 10 is reflected toward the front surface 10a by the reflector 20 attached to the back surface 10b, and is output as display light 73 from the front surface 10a. The light beam 72 from the backlight 3 passes through the reflector 20 and is output as display light 73 from the surface 10a of the liquid crystal panel.

  FIG. 3 shows an enlarged cross section of the reflector 20. The reflector 20 is a sheet-like member in which a reflective film 22 is formed by vapor-depositing aluminum as a reflective material on the surface 21 of a transmissive plastic sheet 24. The unevenness 25 formed on the surface 21 of the reflector 20 of the present example is formed as a unit or pattern 27, as shown in FIG. Is formed. The pattern 27 includes a reflective region 31 having an inclined mirror surface, and a non-reflective region 32 inclined in a reverse gradient to complement the inclined reflective region 31. The reflective region 31 is covered with the reflective film 22, while the non-reflective region 32 is not attached with a reflective film, and a transparent plastic sheet 24 appears. Therefore, the incident light beam 72 from the backlight device 3 installed on the back surface 23 of the reflector 20 can be used as a light beam 73 that illuminates the liquid crystal panel 10 from the surface of the reflector 20 through the non-reflective region 32.

  On the other hand, the reflection region 31 is provided with a portion of the first mirror surface 35 that is inclined at an angle suitable for reflecting the external light 71 that has passed through the liquid crystal panel 10 in the direction of the liquid crystal panel 10. Therefore, when there is external light 71, it can be used as a light beam 73 that illuminates the liquid crystal panel 10 by reflecting the external light 71 by the reflection region 31.

  5A and 5B show a method for manufacturing the reflector 20. As shown in FIG. 5A, the raw material 80 of the reflector 20 is a film-like member and is supplied in a state of being wound around a roll 82. The film-like raw material 80 drawn from the state of the roll 82 is continuously fed into the vacuum device 86. Inside the vacuum device 86, while the back surface 80b of the raw material 80 is heated by a heater 87 that also serves as a base plate having a flat surface, it is sandwiched between the mold 89 and the base plate 87 under vacuum to continuously press-mold fine irregularities. Is done. The product in which the fine irregularities are press-formed, that is, the reflector 20 is taken out from the vacuum device 86 and wound up as a product roll 83.

  The reflector 20 provided in the form of a roll is cut into an appropriate size according to the size of the liquid crystal panel 10, and is bonded to the back surface of the liquid crystal panel 10 with an adhesive or the like, thereby manufacturing the display device 2 described above. it can.

  The raw film material 80 has a three-layer structure. A transparent plastic film 24 such as a PET film serving as a substrate or a support film, and a reflective material such as aluminum is deposited on the surface 21 in advance to form a reflective thin film (reflective film). Film) 22 and a protective layer 81 for protecting the reflective film 22. The protective layer 81 promotes the peeling between the mold 89 and the reflective film 22, and has a mold release agent layer or a mold release property, that is, the adhesive layer is more adhesive than the plastic film 24 and the reflective film 22. 89 is a layer formed of a member having low adhesion to 89. As the release agent, there are silicon-based or fluorine-based materials. In the silicon system, TSM6851 or TSM6822 manufactured by Toshiba Silicone Co., Ltd., Pericoat A or Pericoat BX-2 manufactured by Chukyo Kasei Co., Ltd., Metaform CL manufactured by Composite Materials Co., etc. can be used. In the case of fluorine, Daikin Industries, Ltd.'s Die Free, Gunze Industry's McClub, etc. can be used.

  It is also possible to promote peeling by applying these release agents to the mold 89 on the press surface 88. However, a mechanism for applying to the press surface 88 is required each time the mold 89 is pressed. Further, when the coating amount becomes unstable, the mold 89 is not completely peeled off, which causes the quality of the reflector 20 to deteriorate. On the other hand, if the protective layer 81 is provided on the raw film material 80, a mechanism for applying a release agent to the press surface 88 is not required, and the uniform protective layer 81 is provided on the film material. The mold 89 can be reliably peeled off.

  Further, instead of applying a release agent as the protective layer 81, a film made of a silicon-based or fluorine-based material can be formed in advance, and the same effect can be obtained. And when sticking the reflector 20 in which the micro unevenness | corrugation was shape | molded on the back surface of the liquid crystal panel 10, it sticks after peeling off the protective film 81. FIG. Therefore, since it can be attached to the liquid crystal panel 10 simply by peeling off the film, it is not necessary to attach the reflector 20 more than removing the applied release agent by a chemical method or the like. Further, since the protective film 81 itself is formed of a material that is easily peeled off such as silicon or fluorine, it can be easily peeled off from the reflecting film 22 and damages the surface of the reflecting film 22 on which minute irregularities are formed. Can be removed without

  FIG. 6 shows an enlarged cross section of the press surface 88 of the press die 89. A plurality of fine irregularities 95 are formed on the press surface 88, and among the irregularities 95, the surface with a gentle inclination becomes the first region 91 that forms the reflection region 31, and the surface has a steep inclination. Becomes the second region 92 forming the non-reflective region 32. If the inclination of the second region 92 is steep, the shape of the press surface 88 is pressed onto the film-like raw material 80, whereby the reflective film 22 of the raw material 80 is broken at the level difference of the second region 92 and cracked. A crack occurs and becomes a transparent part. Alternatively, the reflective film 22 is extended and thinned by the step of the second region 92, thereby becoming semi-transmissive.

  Therefore, in the manufacturing method shown in FIG. 5A, the external light 71 is reflected on the surface 21 by pressurizing the mold 89 on the film-like raw material 80 that is continuously supplied and repeating the process. The film-like reflector 20 having a large number of reflecting regions 31 having the first mirror surface 35 suitable for the above can be mass-produced continuously and efficiently. For this reason, it is possible to manufacture the reflector 20 in a short time and supply it at a low cost.

  Furthermore, in the reflector 20 of this example, in order to make a large number of inclined reflection regions 31, it is necessary to complement the shape to form fine irregularities 25. A semi-transparent reflector is formed as a non-reflective region 32 with an inclined or reverse gradient structure. Since the non-reflective region 32 can be molded simultaneously with the reflective region 31 with the same mold (press) 89, a semi-transmissive reflector is continuously manufactured with the same man-hour as the totally reflective reflector and supplied at low cost. can do.

  Furthermore, the portion of the structure inclined to the opposite side with respect to the reflective region 31 that becomes the non-reflective region 32 has a different surface orientation, and therefore does not become a surface that effectively reflects the external light 71. Therefore, in the reflector 20 of this example, since the area | region for complementing the reflective area | region 31 is used as the non-reflective area | region 32, it can have transmissivity, without reducing the reflective efficiency of the reflector 20. FIG.

  Furthermore, since the part which complements the reflective area 31 and forms unevenness becomes the non-reflective area 32, the reflective area 31 is not eroded by the non-reflective area 32, and the reflection efficiency of the reflector 20 also decreases in this respect. Can be prevented. Since the non-reflective region 32 is structurally formed, the ratio and shape of the non-reflective region 32 can be incorporated into the design of the reflector 20 at the same level as the reflective region 31. In addition to the reflection performance, the transmission performance can be controlled by the reflection pattern 27, that is, the pattern of the unevenness 95 formed on the press surface 88 of the die 89.

  In FIG. 7, the outline | summary of the different reflector 20 of this invention is shown with sectional drawing. The reflector 20 is manufactured by the same manufacturing method as described above. The reflection pattern 28 of the reflector 20 also includes an inclined reflection region 31, and includes a first mirror surface 35 that reflects the external light 71 in a desired direction. In the reflection pattern 28 of this example, the reflection region 31 is formed in a sawtooth shape intermittently, and the top portion 31a of the reflection region 31 is formed so as to overlap the bottom portion 31b of the adjacent reflection region 31. . Therefore, the intermittent portion between the reflective regions 31 has a complementary structure for forming a large number of reflective regions 31, and the portion is a transmissive non-reflective region 32.

  Further, in the reflector 20 of this example, a reflection region (back surface reflection region) 33 is also formed on the back surface 23 of the reflection region 32. Then, the second incident light 72 irradiated from the backlight device 3 disposed on the back surface 23 is reflected by the back surface reflection region 33 and reaches the surface 21 of the reflector 20 through the transmissive non-reflection region 32. To do. Further, a second mirror surface 36 that reflects the light beam 72 in a desired direction is formed in the reflection region 32 at a position where the light beam 72 reflected by the back surface reflection region 33 hits. Therefore, the incident light 72 irradiated from the backlight device 3 is reflected in substantially the same direction as the light reflected from the external light 71 through the back surface reflection region 33, the non-reflection region 32, and the second mirror surface 36, and the liquid crystal panel 10 to illuminate 10.

  Therefore, in the reflector 20 of this example, it is possible to control not only the direction in which the external light 71 is reflected but also the direction in which the light 72 from the backlight 3 is reflected by the reflective region 31. The light 72 can also be output so as to illuminate the liquid crystal panel 10 more efficiently. On the contrary, the external light 71 reflected by the second mirror surface 36 is discharged to the back surface 23 through the non-reflective region 32. However, such external light 71 is emitted from the direction of illuminating the liquid crystal panel 10, that is, the direction of the eyes of the user viewing the liquid crystal display device 2, and when the user views the liquid crystal display device 2, it is a reflector. The light 20 does not enter. Therefore, the reflector 20 of this example can also be transmissive without affecting the reflection efficiency of the external light 71. And since the emission direction of the light beam 72 from the backlight 3 is easy to control, the light from the backlight 3 can be used more effectively.

  FIG. 8 is a sectional view showing a configuration of a different reflector 20 according to the present invention. In the reflector 20, fine irregularities 25 are press-formed on the surface 21 of the support film 24 by a plurality of types of reflection patterns 29 a to 29 d having different optical characteristics, and illuminate the liquid crystal panel 10 such as viewing angle and brightness. Even when the conditions for the luminous flux 73 to be performed are complicated, it is possible to cope with it. For example, the reflective pattern 29 a is a reflective pattern convex on the surface 21 constituted by the reflective region 31 and the non-reflective region 32. The reflective pattern 29 c is a reflective pattern that is concave on the surface 21 constituted by the reflective region 31 and the non-reflective region 32. As described above, the reflective region 31 and the non-reflective region 32 can be configured to have any uneven pattern, and a portion of the reflective pattern to which the function of reflecting the external light 71 is not given is provided. The non-reflective region 32 can be formed to be transmissive or semi-transmissive.

  As described above, in this example, the film is formed by the mold 89 having the first region in which the shape of the reflecting surface is easily formed and the second region in which the reflecting surface is not formed or difficult to be formed. The semi-transmissive reflector 20 including the reflective region 31 and the non-reflective region 32 can be continuously manufactured by continuously press-molding the reflective raw material. For this reason, mass productivity becomes very high, and it becomes possible to supply a semi-transmissive reflector with good performance at a very low cost. Of course, not only the transflective reflector, but also a reflector having fine irregularities formed only with the first region can be press-molded in the same manner as described above, and the total reflection type reflector is also low. Can be supplied at a cost.

  In the above description, the raw material in which the protective layer, the reflective film, and the support film are multilayered is described as an example. However, a multilayer film having four or more layers may be used as the raw material. Furthermore, as a raw material, it is also possible to use a reflective thin film having a multilayer structure using a polyester resin such as Vikuiti-ESR manufactured by 3M. Moreover, it is also possible to peel the reflective film 22 on which fine irregularities are formed by press molding from the support film 24 and use it as the reflector 20.

  Further, in the manufacturing method described above, the reflector is manufactured by sandwiching it between the flat base 87 and the mold 89, but also includes the support film 24 that gives elasticity to the base and the film-like raw material becomes the substrate. It may be deformed. Further, a second die having a press surface that complements the press surface 88 of the first die 89 is provided, and a fine unevenness is formed by sandwiching the raw material film 80 between the second die and the first die. It is also possible to form the fine shape more stably. In particular, it is effective when the entire film-like raw material is thinned or intermittently made semi-permeable.

  Thus, since the reflector 20 can be supplied at low cost by the manufacturing method of the present invention, the reflector 20, the transmissive liquid crystal display 10, and the light source disposed on the back side 23 of the reflector 20, that is, By combining with the backlight device 3, a bright and clear image can be displayed using the external light 71, and further, a display device 2 that can display a bright image even at night by the light 72 of the backlight device is provided at low cost. be able to. Further, by combining the reflector 20 and the transmissive liquid crystal display 10, it is possible to provide the reflective display device 2 in which a clear image can be seen at low cost. Moreover, the display device 2 that employs the reflector 20 of the present invention is not limited to the mobile phone 1 but is also suitable for other portable information terminals such as a palmtop PC.

  As described above, in the present invention, it is possible to continuously manufacture a reflector with fine irregularities formed by press-molding fine irregularities on a reflective film in which a reflective film is continuously formed. , Can be supplied at low cost in a short time. In particular, in the production method of the present invention, even a semi-transmissive reflector can be produced in the same process, and a semi-transmissive reflector can be supplied at low cost.

It is a figure which shows the example of the mobile telephone using the display apparatus of this invention. It is a figure which shows schematic structure of the display apparatus of this invention. It is sectional drawing which shows an example of the reflector of this invention. It is a figure which shows the surface of the reflector shown in FIG. It is a figure which shows a mode that a reflector is manufactured by press. It is a figure which expands and shows a press die. It is sectional drawing which shows the example from which the reflector of this invention differs. It is sectional drawing which shows the further different example of the reflector of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 2 ... Display apparatus (liquid crystal display device), 3 ... Backlight, 10 ... Liquid crystal panel (display body), 20 ... Reflector, 21 ... Reflective surface, 22 ... Reflective film, 23 ... Back surface, 24 ... Support film, 25 ... Unevenness, 26 ... opening shape, 27, 28, 29 ... reflective pattern, 80 ... raw material in film form, 81 ... protective film, 89 ... mold (mold).

Claims (31)

  A method of manufacturing a reflector, comprising: a step of pressing a reflective film material having at least one surface by press forming a fine unevenness by a first mold having a plurality of fine unevenness formed on a press surface.   2. The method of manufacturing a reflector according to claim 1, wherein, in the press molding step, a part of the continuous film material is pressurized by the press surface and is repeated.   3. The method of manufacturing a reflector according to claim 2, wherein, in the step of press molding, the film material wound up in a roll shape is drawn and transferred, and is wound up in a roll shape again.   2. The method of manufacturing a reflector according to claim 1, wherein, in the press molding step, the film material is sandwiched between a second mold having a press surface that complements the press surface of the first mold and the first mold. .   2. The method of manufacturing a reflector according to claim 1, wherein in the press molding step, a protective agent that promotes peeling is sandwiched between the press surface and the film material.   6. The method for manufacturing a reflector according to claim 5, wherein the protective agent is a mold release agent.   6. The method of manufacturing a reflector according to claim 5, wherein the protective agent is a protective film that covers the reflective surface of the film material.   6. The method of manufacturing a reflector according to claim 5, wherein the protective agent is a surface protective film for the press surface.   2. The method of manufacturing a reflector according to claim 1, wherein the film material is a multilayer film.   The method of manufacturing a reflector according to claim 9, wherein the film material includes a reflective film and a support film that supports the reflective film.   The method of manufacturing a reflector according to claim 10, wherein the reflective film is sandwiched between the support film and a protective film having a weak adhesion to the press surface.   2. The at least one part of the unevenness of the press surface according to claim 1, wherein the reflective region of the reflector is easily formed with the first region and the reflective surface of the reflector is intermittently or intermittently formed. A method for manufacturing a reflector, comprising: a second region having a shape thinner than the first region.   The method for manufacturing a reflector according to claim 12, wherein the second region has a shape that complements the shape of the first region.   13. The first region according to claim 12, wherein the first region includes a first inclined surface that is inclined so as to reflect the first incident light from the surface, and the second region is opposite to the first inclined surface. A method for manufacturing a reflector, comprising a sloped second slope.   15. The method of manufacturing a reflector according to claim 14, wherein the slope of the second slope is steep with respect to the slope of the first slope.   The method of manufacturing a reflector according to claim 12, wherein a top portion of the first region and a bottom portion of the adjacent first region overlap each other.   A film-like reflector in which at least one surface is a reflecting surface and a plurality of fine irregularities are press-molded.   In Claim 17, the reflector wound by roll shape.   The reflector according to claim 17, wherein the reflector has a multilayer structure.   18. The reflector according to claim 17, wherein the reflective film and a support film that supports the reflective film are laminated.   21. The reflector according to claim 20, wherein the reflective film is sandwiched between the support film and a protective film having a weak adhesion to the press surface.   In Claim 17, at least one part of the said unevenness | corrugation is a reflective area | region provided with the inclined mirror surface, and the shape which complements the shape of this reflective area | region, The reflective surface of the said reflector became intermittent or thinner than the said reflective area | region. A reflector formed of a non-reflective region having a transmissive or semi-transmissive transmissive portion.   23. The reflector according to claim 22, wherein the reflection region includes a first mirror surface that reflects the first incident light from the surface.   24. The reflector according to claim 23, wherein the non-reflective area includes a transmissive or semi-transmissive transmissive surface having a reverse gradient to the first mirror surface.   25. The reflector according to claim 24, wherein a gradient of the transmission surface is steep with respect to a gradient of the first mirror surface.   The reflector according to claim 22, wherein a top portion of the reflection region and a bottom portion of the adjacent reflection region overlap each other.   23. The reflector according to claim 22, wherein the reflection region includes a second mirror surface that reflects the second incident light incident from the back side of the reflector and transmitted through the non-reflection region to the surface side.   23. The reflector according to claim 22, wherein a back surface reflection region is formed that reflects the second incident light incident from the back surface side of the reflector toward the non-reflection region.   29. The reflector according to claim 28, wherein at least a part of the back surface of the reflection region becomes the back surface reflection region.   29. The reflector according to claim 28, wherein the reflective region includes a second mirror surface that reflects the second incident light transmitted through the non-reflective region to the surface side. A reflector according to claim 17;
And a transmissive display disposed on the surface side of the reflector.

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