JP2016064561A - Method of manufacturing optical member plate and method of manufacturing optical member roll plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing an optical member plate, by which a risk for wasting an original plate can be decreased and an optical member plate can be efficiently manufactured.SOLUTION: A method includes: a step of exposing the resist layer of a laminate for manufacturing an original plate including a substrate and a resist layer, based on a concavo-convex pattern of an optical member, and removing the resist layer in an exposed part or in an unexposed part to prepare an original plate 34; a step of bringing an uncured ionization radiation-curable resin into contact with the resist layer of the original plate, then curing the ionization radiation-curable resin, and releasing the original plate to prepare an electroforming sheet 37; a conductor-forming step of forming a conductive layer on a surface of the electroforming sheet on a side that has been in contact with the original plate; a step of depositing an electrolytic plating layer on the conductive layer; and a step of releasing the electroforming sheet to obtain an optical member plate.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a method for producing a plate for optical members, which is a mold for producing an optical member having fine irregularities on the surface, and a method for producing a roll plate for optical members. Specifically, the present invention relates to a method for producing the optical member plate by electroforming and a method for producing the optical member roll plate.

  The screens of televisions and the like become larger due to diversification of display devices, while the screens of portable terminals can be suppressed to a certain size due to their properties. However, a high quality image is required even on a small screen. For this reason, finer unevenness is applied to the optical member, and a configuration in which desired light can be emitted by utilizing the refraction and reflection can improve the image quality.

  For example, a technique described in Patent Document 1 is disclosed as one method for mass-producing an optical member having such fine irregularities. For this, a sheet-shaped mold having irregularities corresponding to the irregularities of the optical member on the surface is prepared, a plurality of sheet-shaped molds are wound around a roll, and adjacent sheet-shaped molds are bonded to each other. It is disclosed.

JP 2008-296466 A

  According to the invention described in Patent Document 1, a sheet-like mold is obtained by electroforming the original plate and releasing it. However, in electroforming, appearance defects tend to occur, and when a resist is used for the original, a part of the resist is broken when the electroformed sheet mold is released, and the broken resist is formed on the sheet mold side. In some cases, it could adhere and not be released properly. If such a problem occurs, the original plate cannot be used again and must be discarded, which is very wasteful. Since the original is often expensive due to its nature, it must be avoided that the original is wasted due to such a problem.

  In view of the above problems, it is an object of the present invention to provide a method for manufacturing a plate for an optical member that can reduce the risk of wasting the original plate and can be efficiently manufactured. Moreover, the manufacturing method of the roll plate for optical members is provided.

  The present invention will be described below. For ease of understanding, reference numerals in the drawings are appended here in parentheses, but the present invention is not limited to this.

  The invention according to claim 1 is a method for producing a plate (22) for an optical member, comprising: a substrate (30); and a resist layer of a master preparation laminate (33) having a resist layer (32). On the other hand, exposure is performed based on the uneven pattern of the optical member, and the resist layer in the exposed or unexposed part is removed to prepare an original (34), and the original resist layer is uncured. A step of contacting the ionizing radiation curable resin and then curing the ionizing radiation curable resin, releasing the original plate to produce an electroforming sheet (37), and the side of the electroforming sheet in contact with the original plate Forming a conductive layer (38) on the surface, a step of laminating an electroplating layer (39) on the conductive layer, a step of releasing an electroforming sheet to obtain a plate for an optical member, Is a method for producing a plate for an optical member.

  Invention of Claim 2 manufactures the plate for optical members (22) by the method of Claim 1, the step of winding the manufactured plate for optical members around a cylindrical roll (21), It is a manufacturing method of the roll plate (20) for optical members containing.

  According to the present invention, since it is not necessary to directly perform electroforming on the original plate, the original plate is not damaged by electroforming, and the possibility that the original plate can be reused can be increased. As a result, damage to the expensive original plate can be avoided, and an optical member plate and an optical member roll plate can be produced efficiently and inexpensively.

FIG. 1A is a plan view of the optical member 10, and FIG. 1B is a partial cross-sectional view of the optical member 10. 2 is a perspective view of a roll plate 20. FIG. 3A is a plan view of the optical member plate 22, and FIG. 3B is a partially enlarged view thereof. FIG. 4A to FIG. 4C are diagrams for explaining each scene for producing the optical member plate 22. FIG. 5A and FIG. 5B are diagrams for explaining each scene for producing the optical member plate 22. FIG. 6A to FIG. 6C are diagrams illustrating scenes for producing the optical member plate 22. It is a figure explaining the scene where the plate 22 for optical members is wound around the roll 21. FIG. It is a figure explaining the shaping sheet. It is a figure explaining one scene of the process which produces the shaping sheet 40 with the roll plate. It is a figure explaining one scene of the process in which the optical member is produced using the shaping sheet. It is a figure explaining one scene of the process in which the optical member 10 is produced from the roll plate 20 by the extrusion method. It is a figure explaining the optical member 110 of another form. It is a figure explaining one scene of the process in which the optical member 110 is produced.

  Hereinafter, the present invention will be described based on embodiments shown in the drawings. However, the present invention is not limited to these forms. In the drawings shown below, the size and ratio of members may be changed or exaggerated for easy understanding. Moreover, the code | symbol which becomes repeated may be abbreviate | omitted for legibility.

First, the optical member 10 will be described. The optical member 10 is an optical member manufactured using a roll plate 20 including an optical member plate 22 described later, and is a sheet-like optical member. Here, the optical member can be a general optical member that controls light by unevenness formed on the surface, such as a light guide plate, a prism sheet, a lens sheet, a diffractive structure, and a moth-eye structure.
1A is a plan view of the optical sheet 10, and FIG. 1B is a cross-sectional view taken along line Ia-Ia in FIG.

  The optical member 10 has a light control layer 12, and the light control layer 12 is a sheet-like member having light transmittance. Further, the light control layer 12 is provided with irregularities on at least one surface thereof to form an irregularity portion 13.

  In the concavo-convex portion 13 of this example, minute undulations are repeated as can be seen from FIGS. 1 (a) and 1 (b). For example, in the concavo-convex portion 13, a convex portion 13 a having a rectangular cross section and a concave portion 13 b having a rectangular cross section are repeated in the longitudinal direction of the light control layer 12, and this cross section is maintained to be one-dimensionally in the width direction of the light control layer 12. It extends. The unevenness is finely formed, and the depth of the recess is about 0.5 μm to 3.0 μm. The bottom width of the concave portion and the top width of the convex portion are about 1 μm or more and 30 μm or less. For example, in the case of a convex shape, the bottom width of the concave portion is 5 μm to 30 μm and the top width of the convex portion is 1 μm to 10 μm. In the case of the concave shape, the top width of the convex portion is 5 μm to 30 μm. The bottom width is formed to be 1 μm or more and 10 μm or less.

  The shape of the concavo-convex portion is not limited to this form, and other forms may be applied, or a plurality of forms may be used in combination. As another example of the concavo-convex part, a form having a predetermined cross section and extending obliquely with respect to the width direction of the light control layer, and a plurality of conical convex parts are arranged vertically and horizontally in plan view The form which has such a two-dimensional shape etc. can be mentioned.

  Various materials can be used as the material constituting the light control layer 12. Among them, it is possible to use a material that is widely used as a material for an optical member and has excellent mechanical characteristics, optical characteristics, stability, workability, and the like, and can be obtained at low cost. For example, a polymer resin having an alicyclic structure, a methacrylic resin, a polycarbonate, a polystyrene, an acrylonitrile-styrene copolymer, a methyl methacrylate-styrene copolymer, an ABS resin, a polyethersulfone, or a thermoplastic resin, Examples thereof include epoxy acrylate and urethane acrylate-based reactive resins (ionizing radiation curable resins and the like).

Next, the roll plate 20 for producing the shaping sheet 40 used when forming the optical member 10 as described above will be described. FIG. 2 is a perspective view schematically showing the appearance of the roll plate 20. 3A is a plan view of the optical member plate 22 provided in the roll plate 20, and FIG. 3B is an enlarged view of a part thereof.
As can be seen from FIG. 2, the roll plate 20 includes a roll 21 and an optical member plate 22.

The roll 21 has a cylindrical roll body 21a and a rotating shaft 21b that protrudes along the axis from the end surface of the roll body 21a. Thus, the roll 21 is configured to support the rotating shaft 21b and rotate around the rotating shaft 21b.
The roll body 21a is a part for securing rigidity, and constitutes most of the roll plate 20. From this point of view, the roll body 21a is preferably made of an iron-based material for machine structure. Further, from the viewpoint of reducing the weight while ensuring the necessary rigidity, the roll body 21a may be cylindrical with both sides being bottomed. Moreover, it is common to make a double structure so that cold water, warm water, steam or high-temperature oil can be circulated inside the roll body so that the temperature of the surface of the roll body 21a can be adjusted.

  The optical member plate 22 is a plate that functions as a mold for transferring the concavo-convex shape corresponding to the concavo-convex portion 13 of the optical member 10 to the shaped sheet 40, and is in the form of a sheet in this embodiment. FIG. 3A shows a plan view in which the optical member plate 22 is removed from the roll body 21a and developed. FIG. 3B is an enlarged view of the portion indicated by IIIb in FIG.

  As can be seen from these drawings, the optical member plate 22 has a plurality of unit mold portions 22a arranged vertically and horizontally on the surface thereof, and these are arranged seamlessly. In the drawing, the boundary between adjacent unit mold portions 22a is indicated by a dotted line, but this is for easy understanding and is not a joint. In other words, the optical member plate 22 is a single sheet having no joint portion. Accordingly, there is no step or unintended displacement between the adjacent unit mold parts 22a, and the unit mold parts 22a can be accurately arranged. And as for the magnitude | size of the plate 22 for optical members, it is preferable that the one side is 800 mm or more and 1500 mm or less. Thereby, many unit mold | type parts 22a can be included in one type | mold sheet | seat, and the outer periphery of the roll 21 can be made to make one round.

  As can be seen from FIG. 3 (b), each unit mold portion 22 a is provided with unevenness corresponding to the shape of the uneven portion 13 of the optical member 10.

Such an optical member plate 22 can be formed of an electroformed plate. Although the production method will be described later in detail, it is composed of a laminate in which an electrolytic nickel plating layer is formed on a conductive layer, and irregularities are formed on the surface of the conductive layer. Here, the electroplating layer and the conductive layer made of nickel will be described, but other materials may be used.
The optical member plate 22 is preferably provided with an alignment mark for positioning. This alignment mark is also transferred and serves as a positioning reference when the optical member 10 is punched.

  The roll plate 20 is obtained by winding and fixing the optical member plate 22 around the outer peripheral surface of the roll 21. In the present embodiment, there is no seam in the optical member plate 22 as described above. Therefore, when the roll plate 20 is formed, the seam has a unique seam 23 where the ends are butted together as shown in FIG. It becomes.

Next, a method for producing the optical member plate 22 will be described. The figure which followed the order of preparation to FIG.4 (a)-FIG.6 (c) was represented.
First, as shown in FIG. 4 (a), formed on a substrate 30 made of glass, metal, ceramic, synthetic quartz, plastic, etc., having the required strength and surface accuracy, with low-reflection chrome or the like on the surface. The photomask blank board which laminated | stacked the adhesive improvement layer 31 (it may be described as "the chromium layer 31" hereafter) laminated | stacked was prepared. Then, a resist layer 32 is formed on the chromium layer 31 in a thin film shape. Known resists can be used, and examples thereof include GRX-M220 and GRX-M100 manufactured by Nagase ChemteX Corporation. Here, the chromium layer 31 functions as a layer that improves the adhesion between the substrate 30 and the resist layer 32. A laminate including the substrate 30, the adhesion improving layer 31, and the resist layer 32 is referred to as a master preparation laminate 33.

  Next, as shown in FIG. 4 (b), the resist layer 32 of the precursor preparation laminate 33 is exposed with a pattern based on the uneven portion 13 of the optical member 10. Although this exposure method is not particularly limited, in this embodiment, exposure is performed by scanning with a laser beam L. In addition, scanning with an electron beam may be performed. By this exposure, an easily soluble portion 32a in which the resist resin constituting the resist layer 32 is cured and an unexposed portion 32b are formed. Then, as shown in FIG. 4C, development is performed by spray development performed by spraying a developing solution to remove the easily soluble portion 32a, and a resist pattern patterned by the unexposed portion 32b is obtained. This is the original version 34.

  In the above description, the process using a so-called positive resist is described in which the exposed portion is removed. However, by changing the resist material, the exposed portion remains and the unexposed portion is removed. A negative resist process may be used.

  Using the resist pattern of the formed original plate 34, an uncured ionizing radiation curable resin (in this embodiment, an ultraviolet curable resin) is applied between the base material layer 36 and the resist pattern as shown in FIG. The pattern layer 35 for electroforming is formed by filling and contacting. Thereby, the uncured ionizing radiation curable resin becomes a layer having unevenness corresponding to the unevenness of the resist pattern.

  Here, as the base material layer 36, polycarbonate (PC) resin, polyethylene terephthalate (PET) resin, methyl methacrylate / butadiene / styrene (MBS) resin, methyl methacrylate / styrene (MS) resin, acrylic / styrene (AS) ) Resin and transparent resin such as acrylonitrile / butadiene / styrene resin (ABS).

  On the other hand, the ionizing radiation curable resin of the electroforming pattern layer 35 is not particularly limited, but for example, ultraviolet rays such as urethane acrylate, polyester acrylate, epoxy acrylate, polyether acrylate, polythiol, and butadiene acrylate. A curable resin can be used.

  Next, as indicated by an arrow Va in FIG. 5A, ionizing radiation (for example, ultraviolet rays) is irradiated from the base material layer 36 side to cure the uncured ionizing radiation curable resin, and for electroforming having irregularities. The shape of the pattern layer 35 is fixed.

Thereafter, as shown in FIG. 5B, the base material layer 36 and the electroforming pattern layer 35 are released from the original plate 34 to obtain an electroforming sheet 37.
The original plate 34 and the electroforming sheet 37 are easy to release due to the nature of the materials and forming methods used here, and the problems such as the resist pattern of the original plate 34 being damaged during the release may be greatly reduced. it can. Therefore, the expensive original plate 34 can be used again.

Next, the plate 22 for optical members is produced by electroforming using the obtained sheet 37 for electroforming.
First, as shown in FIG. 6A, a conductive layer (conductive nickel layer in this embodiment) 38 is formed on the side of the electroforming sheet 37 on which the electroforming pattern layer 35 in contact with the original plate 34 is formed. It is formed by conducting treatment. At this time, the conductive layer 38 has a thickness of 10 nm to 1 μm.
Examples of the conductive treatment include electroless plating and vapor deposition (sputtering).
Next, as shown in FIG. 6B, an electrolytic nickel plating layer 39 is formed on the conductive layer 38 by electroforming. At this time, the electrolytic nickel plating layer 39 is formed by the electrolytic nickel plating layer 39 so that the total thickness of the conductive layer 38 and the electrolytic nickel plating layer 39 is about 0.3 mm.
And as shown in FIG.6 (c), the plate 22 for optical members is obtained by peeling the sheet | seat 37 for electroforming.

  According to the method for producing the optical member plate 22 described above, since there is no need to electroform the original plate 34, the possibility that the original plate 34 can be repeatedly used without damage is increased, and an expensive original plate is wasted. Can be suppressed.

  The optical member plate 22 produced as described above is wound around the roll body 21a as shown in FIG. 7 to form a roll plate 20 (see FIG. 2).

Next, a method for manufacturing the optical member 10 using the roll plate 20 will be described.
FIGS. 8 to 10 show diagrams for explanation. In this embodiment, prior to manufacturing the optical member 10 by the extrusion method, the shaping sheet 40 capable of shaping the shape of the uneven portion 13 is produced. The form of the shaping sheet 40 was shown with the conceptual perspective view in FIG.

  The shaping sheet 40 is a belt-like sheet that can shape the shape of the uneven portion 13 of the optical member 10 as described above. The shaped sheet 40 is configured to have a base material 41 having translucency and a mold part 42 laminated on one surface of the base material 41. In the mold part 42, a plurality of unit mold parts 42a for forming one uneven part 13 of the optical member 10 are arranged vertically and horizontally.

Such a shaped sheet 40 is produced as follows. FIG. 9 shows an explanatory diagram. As shown in FIG. 9, the base material 41 is sent out between the prepared roll plate 20 and the mold nip roll 45 as indicated by an arrow IX in FIG. 9. Then, the ultraviolet curable resin composition 42 ′ before being cured on the base material 41 is supplied from the nozzle 46. Thereby, the ultraviolet curing resin 42 ′ before curing is filled between the base material 41 and the roll plate 20. As a result, the ultraviolet curable resin composition 42 ′ before curing is filled in the unevenness formed on the optical member plate 22 of the roll plate 20.
In such a state of being filled, ultraviolet rays are irradiated from the ultraviolet irradiation device 47 and the ultraviolet curable resin composition is cured to form the mold part 42. Then, it molds with the peeling roll 48 and the shaping sheet 40 is obtained. The obtained shaped sheet 40 is wound up into a roll shape.

Next, the optical member 10 is obtained by an extrusion method using the shaping sheet 40. FIG. 10 shows a diagram for explanation.
As shown by the arrow X in FIG. 10, the shaped sheet 40 is sequentially sent out between the first roll 51 and the second roll 52 arranged with a predetermined gap with respect to the first roll 51. A melted thermoplastic resin composition 55 is caused to flow from the nozzle 56 between the shaping sheet 40 and the second roll 52. Here, the feeding direction of the shaped sheet 40 is the longitudinal direction of the shaped sheet 40 having a strip shape. Moreover, it is preferable that the thermoplastic resin composition 55 to be introduced has a belt-like shape having a size (width) that is approximately the same as the size in the width direction of the second roll 52 and the shaped sheet 40. Thereby, uniform material supply in the width direction is possible.

The supplied thermoplastic resin flows in between the second roll 52 and the shaping sheet 40 with a predetermined pressure. Thereby, the thermoplastic resin is filled in the unevenness formed on the surface of the mold part 42 of the shaped sheet 40, and the thermoplastic resin composition 55 has a shape along the unevenness. And it cools through the 3rd roll 53 and the 4th roll 54, and finally the thermoplastic resin composition 55 hardens | cures and a shape is fixed. As a result, an optical member belt-like sheet 10 ′ in which the optical members 10 are seamlessly arranged vertically and horizontally is obtained. And the strip | belt-shaped sheet | seat 10 'for optical members and the shaping sheet 40 are isolate | separated by the peeling roll 57. FIG.
In this state, it is preferable that an alignment mark is included in the optical member strip 10 '.

  Finally, the optical member 10 can be obtained by punching or cutting the optical member strip 10 '. In that case, the alignment mark serves as a positioning reference.

  The optical member 10 manufactured in this way has high positional accuracy of the unevenness, and can perform desired light control with high accuracy.

  Next, a method for obtaining the optical member 10 by the extrusion method without using the shaping sheet 40 will be described. FIG. 11 shows an explanatory diagram. At this time, the roll plate 20 is used to directly obtain the optical member strip 10 '. Therefore, the roll plate 20 of this example has a pattern that can directly transfer the concavo-convex portion 13 of the belt-like sheet 10 ′ for optical members.

  As can be seen from FIG. 11, the thermoplastic resin composition 55 melted between the first roll 51 and the roll plate 20 disposed with a predetermined gap with respect to the first roll 51 is discharged from the nozzle 56. Let it flow. The inflowing thermoplastic resin composition 55 is preferably in the form of a strip having the same size (width) as the size in the width direction of the roll plate 20. Thereby, uniform material supply in the width direction is possible.

  The supplied thermoplastic resin flows between the first roll 51 and the roll plate 20 with a predetermined pressure. Thereby, the thermoplastic resin is filled in the unevenness formed on the surface of the roll plate 20, and the thermoplastic resin composition 55 has a shape along the unevenness. And it cools through the 3rd roll 53 and the 4th roll 54, and finally the thermoplastic resin composition 55 hardens | cures and a shape is fixed. As a result, an optical member belt-like sheet 10 ′ in which the optical members 10 are seamlessly arranged vertically and horizontally is obtained. In this state, it is preferable that an alignment mark is included in the optical member strip 10 '.

  Finally, the optical member 10 can be obtained by punching or cutting the optical member strip 10 '. In that case, the alignment mark serves as a positioning reference.

  The optical member 10 manufactured in this way also has high unevenness position accuracy, and can perform desired light control with high accuracy.

  FIG. 12 shows another form of the optical member 110. FIG. 12 is a view from the same viewpoint as FIG. The optical member 110 has a two-layer structure in which the light control layer 12 described above is laminated on one surface of the substrate 11. The structure of the light control layer 12 is as described above.

  The base material 11 is a sheet-like member having light transmissivity to be a base material for forming the light control layer 12 on one surface of the base material 11. Examples of the material constituting the substrate 11 include polycarbonate (PC) resin, polyethylene terephthalate (PET) resin, methyl methacrylate / butadiene / styrene (MBS) resin, methyl methacrylate / styrene (MS) resin, acrylic Examples include styrene (AS) resin, acrylonitrile / butadiene / styrene resin (ABS), and the like.

  The optical member 110 can be manufactured as follows. That is, in the same manner as the roll plate 20 described above, the roll plate 120 having unevenness that can directly form the uneven portion 13 of the optical member 110 is produced. And the light control layer 12 is laminated | stacked on the base material 11 as shown in FIG.

More specifically, as shown in FIG. 13, the base material 11 is sent out between the prepared roll plate 120 and the mold nip roll 45 as indicated by an arrow XIII in FIG. 13. Then, the ultraviolet curable resin composition 12 ′ before being cured on the substrate 11 is supplied from the nozzle 46. Thus, the ultraviolet curable resin 12 ′ before curing is filled between the base material 11 and the roll plate 120. As a result, the ultraviolet curable resin composition 12 ′ before curing is filled in the unevenness formed on the roll plate 20.
In this filled state, ultraviolet rays are irradiated from the ultraviolet irradiation device 47, and the ultraviolet curable resin composition is cured to form the light control layer 12. Thereafter, the mold is released by the peeling roll 48. As a result, an optical member belt-like sheet 110 ′ in which the optical members 110 are seamlessly arranged vertically and horizontally is obtained.
In this state, it is preferable that the belt-shaped sheet 110 ′ for optical members also includes an alignment mark.

  Finally, the optical member 110 can be obtained by punching or cutting the optical member strip 110 '. In that case, the alignment mark serves as a positioning reference.

DESCRIPTION OF SYMBOLS 10 Optical member 11 Base material 12 Light control layer 13 Concavity and convexity 20 Roll plate 21 Roll 22 Plate for optical member 30 Substrate 31 Chromium layer (adhesion improvement layer)
32 Resist layer 33 Laminate for producing original plate 34 Original plate 35 Pattern layer for electroforming 36 Base material layer 37 Sheet for electroforming 38 Conductive layer (conductive nickel layer)
39 Electrolytic nickel plating layer (electrolytic plating layer)
40 Molding sheet

Claims (2)

A method for producing a plate for an optical member, comprising:
The substrate and the resist layer of the laminate for preparing an original plate having a resist layer are exposed based on the uneven pattern of the optical member, and the resist layer in the exposed portion or the unexposed portion is removed. Producing an original plate; and
The step of bringing the uncured ionizing radiation curable resin into contact with the resist layer of the original plate and then curing the ionizing radiation curable resin, releasing the original plate to produce an electroforming sheet; and
Conducting treatment step of forming a conductive layer on the surface of the electroforming sheet that was in contact with the original plate,
Laminating an electroplating layer on the conductive layer;
And a step of releasing the electroforming sheet to obtain the optical member plate. Producing a plate for optical members by the method according to claim 1;
Winding the manufactured plate for optical members around a cylindrical roll,
Manufacturing method of roll plate for optical member.

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