JP2012242515A - Manufacturing method of pattern phase difference film, and manufacturing method of metal mold for manufacturing pattern phase difference film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a pattern phase difference film easily in a large amount, which can be applied to a three-dimensional image display employing a passive method.SOLUTION: A pattern phase difference film is manufactured by transferring a convex-concave shape formed on a metal mold 13 for transfer onto a transparent sheet material to form an alignment film. On the premise of the manufacturing, a sheet-like mask is arranged on the surface of a base material to carry out rubbing processing, and the mask is then shifted relative to the base material to repeat the rubbing processing.

Description

  The present invention relates to the manufacture of a pattern retardation film applied to a three-dimensional image display by a passive method.

  Conventionally, flat panel displays have been mainly two-dimensional displays. However, in recent years, flat panel displays capable of three-dimensional display have attracted attention, and some are also commercially available. Further, there is a tendency that future flat panel displays are capable of three-dimensional display, and flat panel displays capable of three-dimensional display are being studied in a wide range of fields.

  In order to perform three-dimensional display on a flat panel display, it is usually necessary to selectively provide a right-eye image and a left-eye image in some manner, respectively, to the viewer's right eye and left eye. As a method for selectively providing a right-eye video and a left-eye video, for example, a passive method is known. This passive three-dimensional display method will be described with reference to the drawings. FIG. 8 is a schematic diagram showing an example of a passive three-dimensional display using a liquid crystal display panel. In the example of FIG. 8, the pixels of the liquid crystal display panel that are continuous in the vertical direction are assigned alternately to the right eye and the left eye, and are driven by the image data for the right eye and the left eye, respectively. And the image for the left eye are displayed simultaneously. In addition, a pattern retardation film is disposed on the panel surface of the liquid crystal display panel, and light emitted by linearly polarized light from the right-eye and left-eye pixels is converted into circularly polarized light having different directions for the right-eye and left-eye. As a result, in the passive method, glasses equipped with corresponding polarizing filters are attached, and a right eye image and a left eye image are selectively provided to the viewer's right eye and left eye, respectively.

  This passive method can also be applied to a liquid crystal display device having a low response speed, and can also perform three-dimensional display with a simple configuration using a pattern retardation film and circularly polarized glasses. For this reason, a passive liquid crystal display device has attracted a great deal of attention as a center for future three-dimensional display devices.

  By the way, the pattern phase difference film which concerns on a passive system requires the pattern phase difference layer which gives a phase difference to transmitted light corresponding to allocation of a pixel. This pattern retardation film has not been widely researched and developed yet, and there is no established standard technology.

  With respect to this pattern retardation film, Patent Document 1 discloses a production method in which a photo-alignment film in which the alignment regulating force is controlled is formed on a glass substrate, and the alignment of liquid crystals is patterned by this photo-alignment film. However, since the method disclosed in Patent Document 1 requires the use of a glass substrate, there is a problem that the pattern retardation film becomes expensive and it is difficult to mass-produce a large area.

  Regarding the pattern retardation film, Patent Document 2 discloses a photo-alignment film in which a fine uneven shape is formed around a roll plate by laser irradiation, and this uneven shape is transferred to control the alignment regulating force in a pattern shape. A method of making is disclosed. In the method disclosed in Patent Document 2, it is necessary to irradiate the entire circumference of the roll plate with laser without being leaked by laser scanning. Therefore, there is a problem that it takes time to create a roll plate. There is also a problem that an expensive laser processing apparatus must be used.

JP 2005-49865 A JP 2010-152296 A

  The present invention has been made in view of such a situation, and a pattern retardation film producing method and a pattern that can be easily and in large quantities can be produced with respect to a pattern retardation film applied to a three-dimensional image display by a passive method. It aims at providing the preparation method of the metal mold | die for phase difference film preparation.

  The present inventor has conducted extensive research to solve the above-mentioned problems, and after placing a sheet-like mask on the surface of the base material and performing a rubbing process, the mask is shifted with respect to the base material to perform the rubbing process. This led to the idea of repeating, and the present invention was completed.

  Specifically, the present invention provides the following.

  (1) In the method for producing a pattern retardation film in which an uneven film formed on a transfer mold is transferred to a transparent sheet material to form an alignment film, the pattern retardation film is formed by patterning the alignment film. A right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are alternately formed in a belt-like manner, and the transfer The metal mold is created by forming the uneven shape on the surface of the base material, and the pattern retardation film is produced by the slit according to the width of the right eye region or the left eye region in the width direction of the slit. A first rubbing process in which a sheet-shaped mask that has been repeatedly created is placed on the surface of the base material and subjected to a rubbing process to create an uneven shape corresponding to the region for the right eye or the left eye on the base material. And a rubbing process in the first rubbing process step in a direction orthogonal to the rubbing process by the shift step of shifting the mask in the width direction of the slit by the width of the slit, and the arrangement by the shift step. A pattern retardation film comprising: a rubbing treatment of a base material; and a second rubbing treatment step of creating an uneven shape corresponding to the left eye region or the right eye region in the base material. Method.

  (2) The mask is repeatedly created in the longitudinal direction of the slit, and the first rubbing treatment step is performed by arranging the mask on the base material and performing a rubbing treatment, and then in the longitudinal direction of the slit. And the second rubbing treatment step is performed by rubbing the base material in a direction orthogonal to the rubbing treatment in the first rubbing treatment step due to the arrangement by the shift step. The method for producing a patterned phase difference film according to (1), wherein the mask is shifted in the longitudinal direction of the slit to perform rubbing treatment.

  (3) A method for producing a mold for creating a pattern phase difference film by creating an alignment film of a pattern phase difference film by transferring to a concavo-convex shaped transparent sheet material formed on the surface, wherein the pattern phase difference film comprises: By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternatingly formed, the pattern retardation film creation mold is created by forming the concavo-convex shape on the surface of a base material, and the method of creating the pattern retardation film creation mold is for the right eye or the left eye A sheet-like mask in which a slit according to the width of the region is repeatedly created in the width direction of the slit is applied to the surface of the base material and rubbed, for the right eye or A first rubbing treatment step of creating an uneven shape corresponding to an eye area in the base material, a shift step of shifting the mask in the width direction of the slit by the width of the slit, and an arrangement by the shift step Thus, the base material is rubbed in a direction orthogonal to the rubbing processing in the first rubbing processing step, and an uneven shape corresponding to the left eye region or the right eye region is created in the base material. And a second rubbing treatment step. A method for producing a mold for producing a pattern retardation film.

  (4) The mask is repeatedly formed in the longitudinal direction of the slit, and the first rubbing treatment step is performed by attaching the mask to the base material and performing a rubbing treatment, and then in the longitudinal direction of the slit. And the second rubbing treatment step is performed by rubbing the base material in a direction orthogonal to the rubbing treatment in the first rubbing treatment step due to the arrangement by the shift step. The method for producing a mold for producing a pattern retardation film according to (3), wherein rubbing treatment is performed by shifting the mask in the longitudinal direction of the slit.

  According to the present invention, it is possible to create a transfer mold in a short time without using an expensive apparatus, which can be applied to the production of a roll plate. Accordingly, it is possible to easily and in large quantities produce a pattern retardation film that is applied to a passive three-dimensional image display.

It is a figure which shows the pattern phase difference film which concerns on the 1st Embodiment of this invention. It is a figure which shows the manufacturing apparatus of the pattern phase difference film of FIG. It is a figure which shows the roll plate in the manufacturing apparatus of FIG. It is a flowchart which shows the preparation method of the roll version of FIG. It is a top view which shows a mask. It is a figure which shows arrangement | positioning of the mask to a base material. It is a figure where it uses for description of the shift of a mask. It is a figure where it uses for description of the three-dimensional image display by a passive system.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
FIG. 1 is a view showing a pattern retardation film according to the first embodiment of the present invention. In the pattern retardation film 1, an alignment film 3 and a retardation layer 4 are sequentially formed on a base material 2 made of a transparent sheet material. In the pattern retardation film 1, the retardation layer 4 is formed of a liquid crystal material, and the alignment of the liquid crystal material is patterned by the alignment regulating force of the alignment film 3. The orientation of the liquid crystal molecules is indicated by a long and narrow ellipse in FIG. By this patterning, the pattern retardation film 1 is formed in a band shape alternately with the right-eye area A and the left-eye area B sequentially with a certain width corresponding to the pixel assignment in the liquid crystal display panel. A phase difference corresponding to each light emitted from the right-eye pixel and the left-eye pixel is given.

  In the pattern retardation film 1, after the ultraviolet curable resin 5 is applied to the surface of the substrate 2, a fine uneven shape is formed on the surface of the ultraviolet curable resin 5, whereby the substrate 2 is interposed via the ultraviolet curable resin. An uneven shape is formed on the surface. In the pattern retardation film 1, the alignment film 3 is formed by the uneven shape on the surface of the ultraviolet curable resin 5. This uneven shape is formed by a streak pattern made up of a number of streaks extending in one direction, and the extending direction of each streak is set to one direction that coincides with the alignment direction of the liquid crystal material in the vicinity of the alignment film 3. Therefore, the uneven shape formed on the surface of the ultraviolet curable resin 5 is such that the extension direction of the stripes is 90 degrees different between the right eye area and the left eye area A and B, and the extension direction of each area. It is formed so as to be inclined by 45 degrees with respect to the angle. In addition, in the inclination with respect to the extension direction of each area | region, when the retardation of the base material 2 is so large that it cannot disregard, it is increased / decreased suitably according to the retardation value.

  FIG. 2 is a schematic diagram showing an apparatus for manufacturing the pattern retardation film 1. In the manufacturing apparatus 10, the base material 2 is provided by a roll, and the base material 2 is supplied from a supply reel 11. The manufacturing apparatus 10 applies an ultraviolet curable resin to the substrate 2 with the die 12. In this manufacturing apparatus 10, the roll plate 13 is a cylindrical mold in which the uneven shape related to the alignment film 3 of the pattern retardation film 1 is formed around. The manufacturing apparatus 10 presses the base material 2 to which the ultraviolet curable resin is applied against the roll plate 13 by the pressure roller 14, and cures the ultraviolet curable resin by irradiation with ultraviolet rays from the ultraviolet irradiation device 15. Thus, the manufacturing apparatus 10 transfers the uneven shape formed on the roll plate 13 to the base material 2. Thereafter, the substrate 2 is peeled from the roll plate 13 by the peeling roller 16, and the liquid crystal material is applied by the die 19. Thereafter, the liquid crystal material is cured by ultraviolet irradiation by the ultraviolet irradiation device 17, and then wound around the take-up reel 18. The pattern retardation film 1 is formed by forming an adhesive layer, an antireflection layer, and the like on a sheet material wound around the take-up reel 18 as necessary, and then cutting it to a desired size. Thereby, in the pattern phase difference film 1, the base material 2 provided by the roll is continuously processed by the transfer of the concavo-convex shape using the roll plate 13, and is efficiently produced.

  FIG. 3 is a perspective view showing the roll plate 13. In the roll plate 13, ring-shaped regions WA and WB corresponding to the right-eye region A and the left-eye region B of the pattern retardation film 1 are alternately formed in the central axis direction. Corresponding uneven shapes are formed in each of the areas WA and WB.

  FIG. 4 is a flowchart for explaining the manufacturing process of the roll plate 13. The roll plate 13 is produced by winding a sheet-like mask around the base material and repeating rubbing. For this reason, in this manufacturing process, first, a mask is set on the base material of the roll plate 13 (steps SP1-SP2).

  Here, in the roll plate 13, a base material 21 is formed by forming a nickel film on a cylindrical base material made of copper whose periphery is polished. In addition, after making a nickel film contain phosphorus and making uneven | corrugated shape, you may make it improve the hardness of the surface by applying the post-process by heat processing. Further, instead of nickel, chromium, titanium or the like may be applied, and further polyimide may be applied.

  FIG. 5 is a plan view showing the mask. The mask 22 is entirely set to a size that surrounds the side surface of the base material 21, and slits are formed in a stripe shape. Here, in the pattern phase difference film 1, the area A for the right eye and the area B for the left eye are formed in close contact with each other with the same width W, and the mask 22 has a slit 22A with the width W corresponding thereto. It is repeatedly formed in the width direction of the slit 22 </ b> A corresponding to the axial direction of the roll plate 13 with a gap W. Further, in the mask 22, the length L of the slit 22A is set to be sufficiently shorter than the length around the roll plate 13, and the slit 22A extends in the length direction with a predetermined interval. It is formed repeatedly. Further, the slits 22A are arranged by shifting in the length direction by approximately L / 2 between the even-numbered columns and the odd-numbered columns, whereby the slits 22A are arranged in a staggered manner. With the arrangement of the slits 22A in the length direction at intervals and the staggered arrangement of the slits 22A, it is possible to ensure sufficient strength for the mask 22 and to create an uneven shape with high accuracy in a series of rubbing processes. it can. The mask 22 can be formed by etching a sheet material made of stainless steel, aluminum material or the like.

  As shown in FIG. 6, in this step, the mask 22 is attached and arranged around the base material 21 so that the extending direction of the slit 22 </ b> A is the circumferential direction of the base material 21. Subsequently, the entire surface of the base material 21 is rubbed using a rubbing roll or the like (FIG. 4, step SP3). As a result, in this step, for one of the region A for the right eye and the region B for the left eye provided on the pattern retardation film 1, an uneven shape by rubbing treatment is formed on a part of the region corresponding to the roll plate 13. Partially formed. In FIG. 6, the extending direction of the concavo-convex shape created by the rubbing process is indicated by an arrow A. Further, in FIG. 6, the mask 22 is shown in a narrowly emphasized manner so as to clarify the shift of the mask 22, which will be described later, in comparison with FIG.

  Subsequently, in this step, the mask 22 is shifted by L / 2 in the extending direction of the slit 22A, and the rubbing process is executed again (steps SP4-SP5). As a result, in this step, one of the right eye region A and the left eye region B provided on the pattern retardation film 1 is subjected to rubbing processing for the region remaining in the initial rubbing processing. Concave and convex shapes are formed in all the regions corresponding to.

  Subsequently, in this step, the mask 22 is shifted by W in the width direction of the slit 22A, and the rubbing process is performed. As a result, as shown by an arrow B in FIG. Are formed so as to be continuous (steps SP6 to SP7). Subsequently, the mask 22 is shifted by L / 2 in the extending direction of the slit 22A, and the rubbing process is executed again (steps SP8-SP9). Thereby, this process forms an uneven shape in the remaining area of the roll plate 13.

  As a result, in this embodiment, the concavo-convex shape of the roll plate can be created easily and in a short time by repeating the rubbing process using one mask. Therefore, by using this roll plate, a pattern retardation film can be produced easily and in a large amount as compared with the prior art.

  In addition, by repeatedly creating the slit in the longitudinal direction and shifting the mask in the longitudinal direction and repeating the rubbing, the strength of the mask can be sufficiently secured and the rubbing process with high accuracy can be repeated.

[Other Embodiments]
As mentioned above, although the specific structure suitable for implementation of this invention was explained in full detail, this invention can change the structure of the above-mentioned embodiment variously in the range which does not deviate from the meaning of this invention.

  That is, in the above-described embodiment, the case where the mask is formed by repeatedly creating the slit having the width W by the interval W and repeatedly forming the slit in the width direction is not limited thereto. It is also possible to use a slit of W as a mask by making a gap 3W, 5W, which is an odd multiple of the interval W, and repeatedly forming slits in the width direction. In this case, it is necessary to perform the rubbing process by repeating the shift in the width direction as much as the interval is increased.

  In the above-described embodiment, the case where the slits are arranged in a staggered manner has been described. However, the present invention is not limited to this, and the arrangement of the staggered portions may be omitted if the deformation of the slits can be prevented practically. The slits may be aligned.

  Further, in the above-described embodiment, the case where the roll base is produced by processing the cylindrical base material is described. However, the present invention is not limited to this, and the roll base is produced by processing the base material having a cylindrical shape. May be.

  In the above-described embodiment, the case where the mask is created with the size surrounding the side surface of the base material has been described, but the present invention is not limited to this, and the length of each side is determined from the total length of the base material and / or the circumferential length. The mask may be reduced in size by setting it to a short length. In this case, however, it is necessary to shift the mask by the size of the mask and repeat the rabin process related to the roll plate.

  Further, in the above-described embodiment, a case has been described in which an uneven region related to the right eye region and an uneven region related to the left eye region are sequentially formed on the outer periphery of the roll plate in a ring shape. The invention is not limited to this, and the uneven regions may be formed so as to extend in the axial direction, which is a direction orthogonal to the orthogonal direction. In this case, it is possible to change the orientation of the mask arranged on the base material.

  Moreover, although the above-mentioned embodiment described the case where a concavo-convex shape was continuously transferred using a roll plate, the present invention is not limited to this and can be widely applied to the case of using a flat plate.

  In the above-described embodiment, the case where a pattern retardation film is prepared on the premise that a liquid crystal display panel is used has been described. However, the present invention is not limited to this, and the use of an organic EL panel and a plasma display panel is assumed. Also, the present invention can be widely applied when the polarizing filter is provided integrally.

DESCRIPTION OF SYMBOLS 1 Pattern phase difference film 2 Base material 3 Orientation film 4 Phase difference layer 5 UV curable resin 10 Manufacturing apparatus 11 Supply reel 12, 19 Die 13 Roll plate 14 Pressure roller 15, 17 Ultraviolet irradiation apparatus 16 Peeling roller 18 Take-up reel 21 Base material 22 Mask 22A Slit

Claims (4)

In the method of creating a pattern retardation film that forms an alignment film by transferring the uneven shape formed on the transfer mold to a transparent sheet material,
The pattern retardation film is
By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternately formed
The transfer mold is
Created by forming the uneven shape on the surface of the base material,
The method of creating the pattern retardation film is as follows:
A sheet-like mask in which a slit according to the width of the region for the right eye or the left eye is repeatedly created in the width direction of the slit is disposed on the surface of the base material and rubbed, for the right eye or the left eye A first rubbing treatment step of creating an uneven shape corresponding to the region of the base material,
A shift step of shifting the mask in the width direction of the slit by the width of the slit;
By the arrangement by the shift process, the base material is rubbed in a direction orthogonal to the rubbing process in the first rubbing process, and the uneven shape corresponding to the left eye region or the right eye region is formed. And a second rubbing treatment step for producing a base material. A method for producing a patterned retardation film. The mask is
The slit is created repeatedly in the longitudinal direction of the slit,
The first rubbing treatment step includes
After the rubbing treatment by arranging the mask on the base material, the rubbing treatment is performed by shifting the mask in the longitudinal direction of the slit,
The second rubbing treatment step includes
After the base material is rubbed in a direction orthogonal to the rubbing treatment in the first rubbing treatment step, the mask is shifted in the longitudinal direction of the slit to perform the rubbing treatment by the arrangement in the shift step. The method for producing a patterned retardation film according to claim 1, wherein: A method of creating a mold for creating a pattern retardation film, which creates an alignment film of a pattern retardation film by transferring to a concavo-convex transparent sheet material formed on the surface,
The pattern retardation film is
By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternately formed
The mold for creating the pattern retardation film is
Created by forming the uneven shape on the surface of the base material,
The method for creating the mold for creating the pattern retardation film is as follows.
A sheet-like mask in which a slit having a width of the right-eye or left-eye region is repeatedly formed in the width direction of the slit is attached to the surface of the base material and rubbed, and the right-eye or left-eye A first rubbing treatment step of creating an uneven shape corresponding to the region of the base material,
A shift step of shifting the mask in the width direction of the slit by the width of the slit;
By the arrangement by the shift process, the base material is rubbed in a direction orthogonal to the rubbing process in the first rubbing process, and the uneven shape corresponding to the left eye region or the right eye region is formed. And a second rubbing treatment step for producing a base material. A method for producing a mold for producing a pattern retardation film. The mask is
In the longitudinal direction of the slit, repeatedly created,
The first rubbing treatment step includes
After the mask is pasted on the base material and rubbed, the mask is shifted in the longitudinal direction of the slit and rubbed.
The second rubbing treatment step includes
After the base material is rubbed in a direction orthogonal to the rubbing treatment in the first rubbing treatment step, the mask is shifted in the longitudinal direction of the slit to perform the rubbing treatment by the arrangement in the shift step. The method for producing a mold for producing a pattern retardation film according to claim 3.

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