JP2019508727A - Composite reflective polarizing film - Google Patents

Abstract

The present invention relates to a method for manufacturing a composite reflective polarizing film, and more particularly to minimizing light loss and having excellent luminance, and at the same time, reliable in a module manufacturing process such as a display or in a high heat / humid environment during use. The present invention relates to a method for producing a composite reflective polarizing film having excellent properties, excellent film appearance quality, and remarkably excellent color reproducibility. [Selection] Figure 5

Description

  The present invention relates to a composite reflective polarizing film, and more particularly to minimizing light loss and having excellent brightness, and at the same time excellent reliability in a module manufacturing process such as a display or in a high heat / humid environment during use. The present invention relates to a composite reflective polarizing film having excellent film appearance quality and remarkably excellent color reproducibility.

  Flat panel display technologies are mainly liquid crystal displays (LCDs), projection displays and plasma displays (PDPs) that have already secured the market in the television field, and field emission displays (FEDs) and electroluminescent displays (ELDs). Is expected to occupy the field by each characteristic along with the improvement of related technology. Liquid crystal displays are currently used in notebook computers, personal computer monitors, liquid crystal televisions, automobiles, airplanes, etc., accounting for about 85% of the flat plate market. Has enjoyed a boom.

  A conventional liquid crystal display arranges a liquid crystal and an electrode matrix between a pair of light-absorbing optical films. In the liquid crystal display, the liquid crystal part has an optical state that is changed in accordance with the liquid crystal part being moved by an electric field generated by applying a voltage to two electrodes. Such processing displays an image using polarized light in a specific direction for “pixels” loaded with information. For this reason, liquid crystal displays include a front optical film and a back optical film that induce polarization.

  An optical film used in such a liquid crystal display does not always have high utilization efficiency of light emitted from the backlight. This is because 50% or more of the light irradiated from the backlight is absorbed by the back side optical film (absorptive polarizing film). Therefore, in order to increase the utilization efficiency of backlight light in the liquid crystal display, a reflective polarizing film may be installed between the optical cavity and the liquid crystal assembly.

  The reflective polarizing film prevents a decrease in optical performance due to light loss, and at the same time, the reflective polarizing film is slimmed according to the slimmed display panel thickness, thereby simplifying the manufacturing process and generating defects in the manufacturing process. Sustained research continues in the direction of minimization, productivity and economy.

  FIG. 1 is a diagram showing the optical principle of a conventional reflective polarizing film. Specifically, P-polarized light of the light traveling toward the optical cavity robot liquid crystal assembly is transmitted to the liquid crystal assembly through the reflective polarizing film, and the S-polarized light is reflected from the reflective polarizing film to the optical cavity. The light is reflected by the diffuse reflection surface of the optical cavity in a random state, and further transmitted to the reflective polarizing film. Eventually, the S-polarized light is converted into P-polarized light that can pass through the polarizer of the liquid crystal assembly. Then, after passing through the reflective polarizing film, it is transmitted to the liquid crystal assembly.

  The selective reflection of S-polarized light and the transmission of P-polarized light with respect to the incident light of the reflective polarizing film are performed by a flat optical layer having an anisotropic refractive index and a flat optical layer having an isotropic refractive index. It is made by the difference in refractive index between the optical layers in the state of being alternately laminated with each other, the setting of the optical thickness of each optical layer by the stretching process of the laminated optical layers, and the change in the refractive index of the optical layers.

  That is, the light incident on the reflective polarizing film repeats the S-polarized light reflection and the P-polarized light transmission action through each optical layer, and eventually only the P-polarized light is transmitted to the liquid crystal assembly. On the other hand, as described above, the reflected S-polarized light is reflected by the diffuse reflection surface of the optical cavity in a state where the polarization state is randomized and further transmitted to the reflective polarizing film. As a result, the waste of power as well as the loss of light generated from the light source can be reduced.

  However, in such a conventional reflective polarizing film, flat isotropic optical layers and anisotropic optical layers having different refractive indexes are alternately laminated, and this is stretched to selectively reflect and transmit incident polarized light. Since the optical polarizing layer is manufactured to have an optical thickness and a refractive index between the optical layers, the manufacturing process of the reflective polarizing film is complicated. In particular, each optical layer of the reflective polarizing film has a flat plate structure, and P-polarized light and S-polarized light must be separated corresponding to a wide range of incident angles of incident polarized light. There was a problem that the production cost increased exponentially due to excessive increase. In addition, there is a problem that the optical performance is deteriorated due to light loss due to the structure in which the number of stacked optical layers is excessive.

  FIG. 2 is a cross-sectional view of a conventional multilayer reflective polarizing film (DBEF). Specifically, in the multilayer reflective polarizing film, the skin layers 9 and 10 are formed on both surfaces of the substrate 8. The base material 8 is divided into four groups 1, 2, 3, and 4. In each group, isotropic layers and anisotropic layers are alternately laminated to form approximately 200 layers. On the other hand, separate adhesive layers 5, 6, and 7 are formed between the four groups 1, 2, 3, and 4 forming the substrate 8. Also, since each group has a very thin thickness inside and outside the 200 layers, when these groups are co-extruded individually, each group can be damaged, so that the groups are protected layers ( PBL) was often included. In this case, there has been a problem that the thickness of the base material is increased and the manufacturing cost is increased. In the case of a reflective polarizing film included in a display panel, since the thickness of the base material is limited for slimming, when an adhesive layer is formed on the base material and / or skin layer, only that thickness is required. Since the base material is reduced, there is a problem that the optical properties are not very good. As a result, since the inside of the base material and the base material and the skin layer are bonded with an adhesive layer, there is a problem that delamination phenomenon occurs when an external force is applied, a long time passes, or the storage location is not good. there were. In addition, the defect rate not only becomes excessively high in the adhesion process of the adhesive layer, but also there is a problem that canceling interference with the light source occurs due to the formation of the adhesive layer.

  Skin layers 9 and 10 are formed on both surfaces of the substrate 8, and separate adhesive layers 11 and 12 are formed between the substrate 8 and the skin layers 9 and 10 to bond them. When a conventional polycarbonate skin layer and PEN-coPEN are integrated with a substrate laminated alternately through coextrusion, peeling may occur due to the absence of compatibility, and the stretching process is performed depending on whether the crystallinity is 55% or not. Sometimes, there is a high risk of occurrence of birefringence with respect to the extension axis. In connection with this, in order to apply the polycarbonate sheet of a non-stretching process, there existed only the formation of the contact bonding layer. As a result, the yield decreases due to the generation of external foreign matter and process defects due to the addition of the adhesive layer process, and usually birefringence due to non-uniform shear pressure due to the winding process is produced when producing polycarbonate unstretched sheets for skin layers. In order to compensate for this, additional control such as deformation of the polymer molecular structure and speed control of the extrusion line was required, resulting in a decrease in productivity.

  The method for manufacturing the conventional multilayer reflective polarizing film will be briefly described. After coextruding four groups having different average optical thicknesses to form a substrate, four additional coextruded four After stretching the groups, the stretched four groups are bonded with an adhesive to produce a substrate. This is because a peeling phenomenon occurs when the substrate is stretched after the adhesive is bonded. Thereafter, the skin layer is bonded to both surfaces of the substrate. Eventually, in order to form a multilayer structure, a two-layer structure is folded to form a four-layer structure, and a group (209 layers) is formed through a process of forming a multilayer structure of a continuous folding method. Since co-extrusion does not change the thickness, it is difficult to form a group within the multilayer in one step. As a result, the actual situation is that after four groups having different average optical thicknesses are coextruded separately, they are bonded together.

  Since the process described above is performed intermittently, the manufacturing cost is significantly increased. As a result, there is a problem that the cost is the highest among all the optical films included in the backlight unit. Along with this, from the viewpoint of cost reduction, there has been a serious problem that liquid crystal displays except for the reflective polarizing film are frequently released even if the decrease in luminance is reduced.

  Along with this, instead of a multilayer reflective polarizing film, a reflective polarizing film in which a dispersion capable of achieving the function of a reflective polarizing film by arranging birefringent polymers extending in the length direction inside the substrate is proposed. It was done. FIG. 3 is a perspective view of the reflective polarizing film 20 containing a rod-shaped polymer, in which birefringent polymers 22 extending in the length direction are arranged in one direction inside the base material 21. Through this, a light modulation effect is induced by the birefringent interface between the base material 21 and the birefringent polymer 22, and the function of the reflective polarizing film can be performed. However, since it is difficult to reflect light in the entire visible light wavelength region as compared with the above-described alternately laminated reflective polarizing films, there is a problem that the light modulation efficiency is very inferior. Accordingly, there is a problem that an excessively large number of birefringent polymers 22 must be disposed inside the base material in order to have transmittance and reflectance similar to the alternately laminated reflective polarizing films. Specifically, when manufacturing a display panel having a width of 32 inches on the basis of the vertical cross section of the reflective polarizing film, the laminated type described above is formed inside the base material 21 having a width of 1580 mm and a height (thickness) of 400 μm or less. In order to have an optical property similar to that of a reflective polarizing film, a circular or elliptical birefringent polymer 22 having a cross-sectional diameter in the length direction of 0.1 to 0.3 μm must be included at least 100 million. However, in this case, not only is the production cost excessively high, but the equipment becomes excessively complicated, and it is almost impossible to manufacture the equipment that produces it, so that it is difficult to commercialize it. There was a problem. In addition, since it is difficult to make various optical thicknesses of the birefringent polymer 22 included in the sheet, it is difficult to reflect light in the entire visible light region, and there is a problem that physical properties are reduced. .

  In order to overcome this, a technical idea that includes a birefringent sea-island yarn inside the substrate has been proposed. FIG. 4 is a cross-sectional view of a birefringent sea-island yarn included in a base material, and the birefringent sea-island yarn generates a light modulation effect at a light modulation interface between the inner island portion and the sea portion. Therefore, the optical properties can be achieved even if a large number of sea-island yarns are not arranged as in the birefringent polymer described above. However, since the birefringent sea-island yarn is a fiber, there are problems of compatibility with the base material that is a polymer, ease of handling, and adhesion. As a result, light scattering is induced due to the circular shape, the reflection polarization efficiency with respect to the light wavelength in the visible light region is reduced, the polarization characteristics are lower than the existing products, and there is a limit to the improvement in luminance. Moreover, in the case of sea-island yarn, the sea component region is subdivided while reducing the island joining phenomenon, which caused light leakage due to the generation of pores, that is, the cause of light characteristic degradation due to light loss phenomenon. . In addition, when the structure is formed in the form of a woven fabric, there is a problem that a limit point occurs in the improvement of reflection and polarization characteristics due to the limit of the layer configuration. In the case of a dispersion-type reflective polarizing film, there is a problem in that bright line visibility is observed due to the spacing between layers and the separation space between dispersions.

  As described above, the reflective polarizing films proposed to date have all the disadvantages. In particular, the multilayer reflective polarizing film has a remarkably high manufacturing cost, so that it can be used in actual products. There is a problem that raises the product cost, because there are problems such as poor quality due to the intervention of foreign matter generated while joining multiple layers, complexity of the manufacturing process, brightness reduction due to containing too many adhesive layers, etc. More preferred is a polymer-dispersed reflective polarizing film in which a polymer is dispersed inside the substrate.

  However, the polymer-dispersed reflective polarizing film that has been developed so far has a translucent base material, and as a result of appearance of foreign matter in the appearance of the film, the appearance defect rate increases, light leakage, bright line visible phenomenon, Since the wide viewing angle is narrow and the optical loss cannot be minimized, there is a problem that the luminance is lowered.

  In addition, the reliability is remarkable such that the reflective polarizing film is bent due to high heat conditions applied in the process of manufacturing the reflective polarizing film in a module such as a backlight unit and / or heat generated in an environment where such a module is used. There were problems that decreased.

  As a result, in order to solve such problems, even in the case of a composite film in which a separate configuration is added to the polymer-dispersed reflective polarizing film, the problem of the reliability reduction that occurs in the reflective polarizing film is still not solved. At the same time, when the appearance of foreign matter is reduced, there is a problem that the brightness is remarkably reduced, and minimizing the decrease in brightness makes it difficult to prevent the appearance of foreign matter. At the same time, I could not be satisfied.

  The present invention has been made to solve the above-described problems, and minimizes light loss and has excellent luminance, and at the same time, in a module manufacturing process such as a display or in a high heat / humid environment during use. Is to provide a method for producing a composite reflective polarizing film having excellent reliability, excellent film appearance quality, and remarkably excellent color reproducibility.

  In order to solve the above-described problems, the present invention provides a composite reflective polarizing film including a reflective polarizing film in which a polymer is dispersed in a substrate, wherein the composite reflective polarizing film is formed on an upper surface of the reflective polarizing film. A composite reflective polarizing film comprising: a light diffusing layer; and a reliable support layer formed on a lower surface of the reflective polarizing film, wherein the following conditions (1) and (2) are satisfied.

(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.

  According to a preferred embodiment of the present invention, the light diffusing layer is one or more fine patterns selected from the group consisting of prisms, lenticulars, microlenses, triangular pyramids and pyramid patterns; and bead coating Any one or more of the layers; At this time, the fine pattern may include a microlens.

  According to another preferred embodiment of the present invention, the reliable support layer may be a polyester film stretched in at least one direction.

  According to still another preferred embodiment of the present invention, the reliable support layer may have a thickness of 10 to 600 μm.

  According to another preferred embodiment of the present invention, the reliability support layer can satisfy a linear expansion coefficient of 10 to 25 μm / m · ° C. in a temperature range of 70 to 80 ° C. under the condition (1).

According to still another preferred embodiment of the present invention, the reflective polarizing film is included in the base material and the base material, transmits the first polarized light irradiated from the outside, and reflects the second polarized light. A plurality of dispersions, wherein the plurality of dispersions have a refractive index different from that of the base material in at least one axial direction, and the plurality of dispersions are included in the base material. A dispersion in which the aspect ratio of the length of the minor axis to the length of the major axis is ½ or less with respect to a vertical section in the length direction of 80% or more, and the dispersion having the aspect ratio of ½ or less is It is included in at least three groups according to area, and the cross-sectional area of the dispersion of the first group is 0.2 to 2.0 μm ² among the groups, and the cross-sectional area of the dispersion of the second group is 2. 0μm is ² from exceeding 5.0 .mu.m ² or less, the cross-sectional area of the dispersion of the third group Is at 10.0 [mu] m ² or less from 5.0 .mu.m ² exceeded, dispersions of the first group to third group, may be those arranged randomly.

  According to another preferred embodiment of the present invention, a core layer including a base material and a plurality of dispersions included in the base material; and an integrated structure formed on at least one surface of the core layer A skin layer;

  According to still another preferred embodiment of the present invention, the haze value of the composite reflective polarizing film may be 73% or more under the condition (2).

  Further, the present invention provides a composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed in a substrate, wherein the composite reflective polarizing film comprises a reliable support layer formed on an upper surface of the reflective polarizing film; And a light diffusing layer formed on the upper surface of the reliable support layer, and satisfying the following conditions (1) and (2).

(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.

  The present invention also provides a composite reflective polarizing film including a reflective polarizing film in which a polymer is dispersed in a substrate, wherein the composite reflective polarizing film includes a light diffusion layer formed on an upper surface of the reflective polarizing film; And a reliable support layer formed on the upper surface of the diffusion layer. The composite reflective polarizing film is characterized by satisfying the following conditions (1) and (2).

(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.

  Further, the present invention provides a composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside a substrate, wherein the composite reflective polarizing film includes a light diffusion layer formed on an upper surface of the reflective polarizing film; A reliability support layer formed on the lower surface of the polarizing film; and a light-collecting layer formed on the lower surface of the reliability support layer, wherein the following conditions (1) and (2) are satisfied: A composite reflective polarizing film is provided.

(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.

  According to a preferred embodiment of the present invention, the condensing layer includes a support part and a prism pattern formed on the support part, and the prism pattern part faces a lower surface of the reliability support layer. Can be formed as follows.

  According to another preferred embodiment of the present invention, the support part may have a thickness of 10 to 300 μm.

  Further, the present invention provides a composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside a substrate, wherein the composite reflective polarizing film includes a light diffusion layer formed on an upper surface of the reflective polarizing film; A reliable support layer formed on the lower surface of the polarizing film; and a light-collecting layer including a support and formed on the lower surface of the reliable support layer. Provided is a composite reflective polarizing film, wherein the value of Equation 1 below is 0.3 to 2.0 with respect to the thickness of the layer and the thickness of the support portion of the light collecting layer.

  According to a preferred embodiment of the present invention, the value of Equation 2 below for the thickness of the reliable support layer and the thickness of the support portion of the light collecting layer may be 0.25-4.

  Meanwhile, the present invention provides a composite reflective polarizing film including a reflective polarizing film in which a polymer is dispersed in a substrate, wherein the composite reflective polarizing film includes a light diffusion layer formed on an upper surface of the reflective polarizing film; A reliability support layer formed on the lower surface of the polarizing film; and a multi-functional layer formed under the reliability support layer for guiding and condensing the light emitted from the light source. Provided is a composite reflective polarizing film characterized by satisfying (1) and condition (2).

(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.

  According to a preferred embodiment of the present invention, the multi-functional layer includes a fine pattern layer that collects light emitted from a light source; and is formed under the fine pattern layer to support the fine pattern layer from the light source. And a light guide layer for guiding the irradiated light.

  The present invention also provides a backlight unit including the above-described composite reflective polarizing film according to the present invention.

  As a result, this invention provides the liquid crystal display device containing the backlight unit by this invention.

  Hereinafter, terms used in this specification will be described.

  As used herein, the meaning of “dispersion has birefringence” means that when a fiber having a different refractive index depending on the direction is irradiated with light, the light incident on the dispersion is more than two lights having different directions. It means that it is refracted.

  The term “isotropic” as used herein means that the refractive index is constant regardless of direction when light passes through an object.

  The term “anisotropic” used in this specification means that the optical properties of an object differ depending on the direction of light. An anisotropic object has birefringence and isotropic properties. Corresponding to

  As used herein, the term “light modulation” means that irradiated light is reflected, refracted, scattered, or changes in light intensity, wave period or light properties. .

  The term “aspect ratio” as used herein refers to the ratio of the length of the minor axis to the length of the major axis with reference to the vertical cross section in the longitudinal direction of the dispersion.

  The terms used herein, which are spatially relative terms “below”, “beeneath”, “lower”, “above”, “ “Upper” or the like can be used to easily describe the correlation between one component and the other, as shown in the drawings. Spatial relative terms should be understood as terms that include different directions of components in use or operation in addition to the directions shown in the drawings. For example, if a component shown in the drawing is flipped over, the component described as “below” or “beeneath” of the other component is “above” the other component. Can be arranged. Thus, the exemplary term “below” can include both down and up directions. Components can be oriented in other directions, and as such, spatially relative terms can be interpreted by orientation.

  In addition, such spatially relative terms “upper”, “upper”, “upper”, “lower”, “lower”, “lower” are “directly” and “indirectly”. (Indirectly) includes both meanings.

  The method of manufacturing a composite reflective polarizing film according to the present invention minimizes light loss and has excellent brightness, and at the same time, the film is distorted or wrinkled even in a module manufacturing process such as a display or in a high heat / humid environment during use. The composite reflective polarizing film is excellent in quality and remarkably excellent in color reproducibility because there is no defect such as appearance change, excellent reliability, no foreign matter appearing on the film appearance, light leakage, bright lines, etc. Suitable for manufacturing.

It is the schematic explaining the principle of the conventional reflective polarizing film. It is sectional drawing of the multilayer reflective polarizing film (DBEF) currently used. It is a perspective view of the reflective polarizing film containing a rod-shaped type polymer. It is sectional drawing which shows the path | route of the light which injected into the birefringent sea island thread used for a reflective polarizing film. 1 is a cross-sectional view of a composite reflective polarizing film according to a first preferred embodiment of the present invention. 1 is a cross-sectional view of a reflective polarizing film in which a dispersion is randomly dispersed inside a substrate according to a preferred embodiment of the present invention. It is a vertical sectional view in the length direction of a dispersion used in a preferred embodiment of the present invention. 1 is a perspective view of a reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a cross-sectional view of a light diffusion layer in a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a cross-sectional view of a light diffusion layer in a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a cross-sectional view of a light diffusion layer in a composite reflective polarizing film according to a preferred embodiment of the present invention. 1 is a cross-sectional view of a composite reflective polarizing film according to a preferred embodiment of the present invention. It is sectional drawing of the coat-hanger die which is 1 type of the preferable flow control part which can be applied to this invention. FIG. 20 is a side view of FIG. 19. 1 is a schematic view of a fine pattern forming process according to a preferred embodiment of the present invention. It is sectional drawing which shows the detailed structure of the shaping | molding part of FIG. FIG. 5 is a schematic view of a fine pattern forming process according to another preferred embodiment of the present invention. FIG. 5 is a schematic view of a fine pattern forming process according to another preferred embodiment of the present invention. FIG. 3 is a cross-sectional view of a reflective film and a reliable support layer that are overlaid according to a preferred embodiment of the present invention. It is sectional drawing of the composite reflective polarizing film by the preferable 2nd example of implementation of this invention. FIG. 3 is a perspective view of a light collecting layer included in a preferred embodiment of the present invention. FIG. 5 is a schematic view of a fine pattern forming process of a light collecting layer according to a preferred embodiment of the present invention. FIG. 5 is a schematic view of a fine pattern forming process of a light collecting layer according to a preferred embodiment of the present invention. 1 is a cross-sectional view of a liquid crystal display device according to a preferred embodiment of the present invention. 1 is a liquid crystal display device employing a composite reflective polarizing film according to a preferred embodiment of the present invention. It is the schematic of the apparatus which manufactures the plate-shaped polymer dispersion | distribution reflective polarizing film contained in preferable one Example of this invention. FIG. 3 is a perspective view showing a coupling structure of a die-distribution plate of a sea-island type extrusion die capable of producing a plate-type polymer dispersed reflective polarizing film included in a preferred embodiment of the present invention. 1 is a cross-sectional view of a plate-type polymer dispersed reflective polarizing film according to a preferred embodiment of the present invention.

  Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  As described above, the polymer-dispersed reflective polarizing film has a semi-transparent base material, so that the appearance defect rate increases as foreign substances appear in the film appearance, and light leakage, bright line visible phenomenon, wide viewing angle. However, the light loss cannot be minimized, the brightness is reduced, and the high thermal conditions and / or the like are applied in the process of manufacturing the reflective polarizing film in a module such as a backlight unit. However, there is a problem that the reliability is remarkably reduced, for example, the reflective polarizing film is bent due to heat generated in an environment where various modules are used. As a result, in order to solve such problems, even in the case of a composite film in which a separate configuration is added to the polymer-dispersed reflective polarizing film, the problem of the reliability reduction that occurs in the reflective polarizing film is still not solved. At the same time, when the appearance of foreign matter is reduced, there is a problem that the brightness is remarkably reduced, and minimizing the decrease in brightness makes it difficult to prevent the appearance of foreign matter. At the same time, I could not be satisfied.

  Thus, in the first embodiment of the present invention, in the composite reflective polarizing film including the reflective polarizing film in which the polymer is dispersed in the base material, the composite reflective polarizing film is light formed on the upper surface of the reflective polarizing film. By providing a composite reflective polarizing film comprising: a diffusion layer; and a reliable support layer formed on a lower surface of the reflective polarizing film, wherein the following conditions (1) and (2) are satisfied: Sought to solve the problems mentioned above. Through this, there is no change in appearance such as minimizing light loss and having excellent brightness, and at the same time, there is no appearance change such as film distortion or wrinkle even in high temperature / high humidity environment during module manufacturing process such as display or in use. Since it is excellent in reliability and there are no defects such as foreign matters appearing on the film appearance, light leakage, or dotted lines, the quality is excellent and the color reproducibility can be remarkably improved.

  (1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C., and (2) the haze value of the composite reflective polarizing film is 65% or more. is there.

  As shown in FIG. 5, the composite reflective polarizing film 1000 according to the first embodiment is formed on the upper surface of the reflective polarizing film 200 and the lower surface of the reflective polarizing film 200. The first primer layer 400 may be included between the reflective polarizing film 200 and the reliable support layer 300 to enhance the adhesive force.

  First, the reflective polarizing film 200 will be described.

  The reflective polarizing film 200 may be an ordinary polymer-dispersed reflective polarizing film in which a polymer is dispersed inside a base material. The normal polymer-jet reflective polarizing film may be a known and commonly used reflective polarizing film containing a rod-shaped polymer as shown in FIG. 3, and the present invention is directed to the shape of the polymer dispersed in the substrate and the number of polymers. The dispersion form is not particularly limited.

  However, as described above, the reflective polarizing film in which the polymer is dispersed in the conventional base material has a light leakage, a bright line visible phenomenon, and a wide viewing angle, so that the light loss cannot be minimized. There was a problem of decreasing.

Accordingly, according to a preferred embodiment of the present invention, the reflective polarizing film is included in the base material and inside the base material, transmits the first polarized light irradiated from the outside, and reflects the second polarized light. A plurality of dispersions, wherein the plurality of dispersions have a refractive index different from that of the base material in at least one axial direction, and the plurality of dispersions are included in the base material. A dispersion in which the aspect ratio of the length of the minor axis to the length of the major axis is ½ or less with respect to a vertical section in the length direction of 80% or more, and the dispersion having the aspect ratio of ½ or less is It is included in at least three groups according to area, and the cross-sectional area of the dispersion of the first group is 0.2 to 2.0 μm ² among the groups, and the cross-sectional area of the dispersion of the second group is 2. 0μm is ² from exceeding 5.0 .mu.m ² or less, the cross-sectional area of the dispersion of the third group 5.0μm is ² from exceeding 10.0 [mu] m ² or less, dispersion of the first group to third group may be randomly arranged.

  According to another preferred embodiment of the present invention, the reflective polarizing film includes the above-described base material and a plurality of dispersions that are included in the base material and satisfy the conditions according to the preferred embodiment of the present invention. And a structure including an integrated skin layer formed on at least one surface of the core layer, and further comprising a skin layer to protect the core layer. Can contribute.

  The reflective polarizing film according to one embodiment that does not include a skin layer and the other embodiment that includes a skin layer may be different in use. For various general-purpose liquid crystal display devices such as a display, the reflective polarizing film includes a skin layer. In the case of a portable liquid crystal display device such as a portable electronic device, a smart electronic device, and a smartphone, it is preferable to use a reflective polarizing film that does not include a skin layer. Absent.

  On the other hand, the composite reflective polarizing film according to the present invention includes the reliability support layer described later on one surface of the reflective polarizing film, so that the core layer can be protected without having a skin layer for protecting the core layer. Can also be achieved.

  Hereinafter, the reflective polarizing film including the skin layer will be specifically described.

  Referring to FIG. 6, a core layer 210 in which a plurality of dispersions 202 to 207 are randomly dispersed in a base material 201 and a skin layer integrally formed on at least one surface of the core layer. 220 includes a reflective polarizing film.

  In the core layer 210, 80% or more of the plurality of dispersions included in the base material has an aspect ratio of the length of the short axis to the length of the long axis based on the vertical cross section in the length direction. May be 1/2 or less, and more preferably 90% or more can satisfy the aspect ratio of 1/2 or less.

  Specifically, FIG. 7 is a vertical cross section in the length direction of the dispersion used in a preferred embodiment of the present invention, wherein the length of the major axis is a, and the length of the minor axis is b. In other words, the relative length ratio (aspect ratio) of the length (a) of the major axis and the length (b) of the minor axis may be ½ or less. In other words, when the length (a) of the major axis is 2, the length (b) of the minor axis may be smaller than or equal to one half that is half. If the dispersion in which the ratio of the length of the short axis to the length of the long axis is greater than ½ is included in 20% or more of the total number of dispersions, it is difficult to achieve desired optical properties. .

The dispersion having an aspect ratio of 1/2 or less may include three or more groups having different cross-sectional areas. Referring to FIG. 6, the first group of dispersions 202 and 203 having the smallest cross-sectional area, the second group of dispersions 204 and 205 having an intermediate cross-sectional area, and the third group having the largest cross-sectional area. All of the dispersions 206 and 207 are randomly dispersed. In this case, the cross-sectional area of the first group is 0.2 to 2.0 [mu] m ^2, the cross-sectional area of the second group is from 2.0 .mu.m ² exceeding 5.0 .mu.m ² or less, the cross-sectional area of the third group is at 10.0 [mu] m ² or less from 5.0 .mu.m ² exceeded, dispersions of the first group, the dispersion of the dispersion, and a third group of the second group are arranged at random. If any one of the first to third group dispersions is not included, it is difficult to achieve desired optical properties (see Table 1).

  In this case, it is preferable that the number of the third group of dispersions having an aspect ratio of 1/2 or less is 10% or more. If it is less than 10%, the improvement of optical properties may be insufficient. More preferably, the number of dispersions corresponding to the first group among dispersions having an aspect ratio of 1/2 or less satisfies 30 to 50%, and the number of dispersions corresponding to the third group is 10 to 30%. The optical physical properties can be improved through this (see Table 1).

  On the other hand, when the value of the number of dispersions in the first group / the number of dispersions in the third group is 3 to 5, it can be very advantageous to maximize the optical properties (see Table 1). ).

  Preferably, the number of dispersions corresponding to the second group among dispersions having an aspect ratio of ½ or less may satisfy 25 to 45%. In addition, a dispersion outside the range of the cross-sectional area of the first to third dispersions may be included in the dispersion having an aspect ratio of 1/2 or less as the remaining amount. As a result, the bright line viewing phenomenon is improved as compared with the conventional dispersion-type reflective polarizing film, and the wide viewing angle is wide, and the improvement in luminance can be maximized while minimizing light loss.

  FIG. 8 is a perspective view of a reflective polarizing film included in a preferred embodiment of the present invention, in which a plurality of random dispersions 208 extend in the length direction inside the base material 201 of the core layer 210. The skin layer 220 is formed on the upper part and / or the lower part of the core layer 210. In this case, each of the random dispersions 208 can extend in various directions, but it is preferable that the random dispersion 208 extends in parallel with any one direction, and more preferably perpendicular to the light emitted from the external light source. It is effective to maximize the light modulation effect to extend in parallel between the extension members in the direction of the light.

  According to a preferred embodiment of the present invention, a birefringent interface may be formed between the dispersion (first component) and the substrate (second component) contained in the substrate. Specifically, in a reflective polarizing film including a dispersion inside the substrate, the size of the substantial coincidence or mismatch of the refractive indexes by the X, Y and Z axes on the space between the substrate and the dispersion is the axis. Affects the degree of scattering of light polarized along. In general, the scattering power changes in proportion to the square of the refractive index mismatch. Therefore, the greater the degree of refractive index mismatch with a particular axis, the more strongly the light beam polarized along that axis is scattered. Conversely, if the discrepancy by a particular axis is small, the light beam polarized along that axis is scattered to a lesser extent. When the refractive index of the substrate substantially matches the refractive index of the dispersion by any axis, the incident light polarized in the electric field parallel to such an axis is related to the size, morphology and density of the portion of the dispersion. Pass through the dispersion without scattering. Also, if the indices of refraction by their axes are substantially coincident, the light rays will not substantially scatter and pass through the object. More specifically, the first polarized light (P wave) is transmitted without being influenced by the birefringence interface formed at the boundary between the base material and the dispersion, while the second polarized light (S wave) is transmitted between the base material and the dispersion. Light modulation occurs under the influence of the birefringent interface formed at the boundary between the dispersions. Through this, the P wave is transmitted, and the S wave undergoes light modulation such as light scattering and reflection, and eventually the polarization is separated.

Therefore, when the substrate and the dispersion form a birefringent interface, a light modulation effect can be induced. Therefore, when the substrate is optically isotropic, the dispersion has a birefringence. On the contrary, when the substrate is optically birefringent, the dispersion can have optical isotropy. Specifically, the refractive index in the x-axis direction of the dispersion is nX ₁ , the refractive index in the y-axis direction is nY ₁ , the refractive index in the z-axis direction is nZ ₁ , and the refractive index of the substrate is nX ₂ , nY _{When 2} and nZ ₂ , in-plane birefringence between nX ₁ and nY ₁ can occur. More preferably, at least one of the X-, Y- and Z-axis refractive indexes of the substrate and the dispersion may be different, and more preferably, when the extension axis is the X-axis, the refraction in the Y-axis and Z-axis directions The difference in refractive index may be 0.05 or less, and the difference in refractive index with respect to the X-axis direction may be 0.1 or more. On the other hand, if the refractive index difference is 0.05 or less, it is interpreted as matching.

  In the present invention, the thickness of the core layer is preferably 20 to 350 μm, more preferably 50 to 250 μm. However, the thickness is not limited to this, and the specific use and inclusion of the skin layer Depending on the thickness of the skin layer, the thickness of the core layer can be designed differently. The total number of dispersions may be 25,000,000 to 80,000,000 when the substrate thickness is 120 μm based on 32 inches, but is not limited thereto.

  Next, the skin layer 220 that can be included in at least one surface of the core layer will be described.

  The skin layer component can be used without limitation as long as it is a component that can be used in a normal reflective polarizing film, preferably polyethylene naphthalate (PEN), copolyethylene naphthalate (co- PEN), polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate (PC) alloy, polystyrene (PS), heat-resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), Polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile mixed (SAN), ethylene vinyl acetate (EVA), polyethylene Amide (PA), polyacetal (POM), phenol, epoxy (EP), iodine (UF), melanin (MF), unsaturated polyester (UP), silicon (SI) and cycloolefin polymers are used alone or in combination. More preferably, it may be co-PEN in which monomers such as dimethyl-2,6-naphthalene dicarboxylate, dimethyl terephthalate and ethylene glycol, cyclohexanedimethanol (CHDM) are appropriately polymerized.

  According to a preferred embodiment of the present invention, the thickness of the skin layer may be 30 to 500 μm, but is not limited thereto. On the other hand, when the skin layer is formed, it is also integrally formed between the core layer 210 and the skin layer 220. As a result, it is possible not only to prevent a decrease in optical properties due to the adhesive layer, but also to add more layers to a limited thickness, so that the optical properties can be remarkably improved. As a result, since the skin layer is manufactured at the same time as the core layer, the stretching process is performed. Therefore, unlike the conventional method of bonding the unstretched skin layer after stretching the core layer, the skin layer of the present invention is It can be stretched in at least one axial direction. Through this, the surface hardness is improved as compared with the unstretched skin layer, the scratch resistance is improved, and the heat resistance can be improved.

  Next, the light diffusion layer 100 formed on the upper surface of the reflective polarizing film 200 will be described. The light diffusing layer 100 can improve the light collection effect, prevent irregular reflection on the surface and increase the luminance remarkably, increase the haze value of the composite reflective polarizing film through light scattering, Thus, it is possible to minimize the appearance defect in which foreign matters are expressed. The light diffusion layer 100 may be formed on the reflective polarizing film 200 or an adhesive layer (not shown) formed on the reflective polarizing film 200.

  The light diffusion layer 100 may include a fine pattern. The fine pattern is not particularly limited in a specific structure as long as it is a fine pattern that can simultaneously improve brightness, light collecting effect and haze value of the composite reflective polarizing film, but more preferably the fine pattern is Can include any one or more patterns selected from the group consisting of: prisms, lenticulars, microlenses, triangular pyramids and pyramid patterns, each of which can form or combine patterns alone More preferably, it may be any one or more of a lenticular, a microlens, and a prism, and more preferably a microlens that can simultaneously satisfy all physical properties.

  Specifically, FIG. 9 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. The reflective polarizing film 200 includes a plurality of dispersions extending in the length direction inside a substrate. These form the core layer 210. In this case, each of the dispersions can extend in various directions, but it is preferable to extend in parallel with any one direction, more preferably in a direction perpendicular to the light emitted from the external light source. Stretching in parallel between the elongated bodies is effective in maximizing the light modulation effect. The light diffusing layer 100 formed on the reflective polarizing film 200 includes a fine pattern, so that an improved light collecting function and a luminance improving function can be performed. FIG. 9 illustrates a light diffusing layer including a lenticular pattern. 110 is shown.

  The lenticular pattern will be described in more detail. The lenticular height h may be 10 to 50 μm. If the height of the lenticular pattern is less than 10 μm, a problem that pattern formation is difficult may occur. If the height of the lenticular pattern exceeds 50 μm, the brightness may decrease due to an increase in the total amount of reflected light.

  The pitch of the lenticular may be 20 to 100 μm. If the pitch of the lenticular pattern is less than 20 μm, the condensing effect of the lens shape is somewhat inferior due to the increase in the valley portion of the film per unit area, the limit of the precision of shape processing and the pattern shape are too narrow, and the pattern Problems that are difficult to implement may occur, and if it exceeds 100 μm, the possibility of moire between the pattern structure and the panel becomes very large.

  On the other hand, when the short axis radius of the elliptical cross section is defined as c and the long axis radius is defined as d per lenticular lens, the ratio of long axis / short axis (b / a) satisfies 1.0 to 3.0. Can do. If the ratio of the major axis / minor axis (d / c) is out of the above range, there may be a problem that the bright line concealing efficiency for the light passing through the birefringent polarizing layer is poor.

  In defining the height h of the lenticular lens, the tangential angle α at both end points of the lower end of the lens must satisfy 30 to 80 °. At this time, if α is smaller than 30 °, the bright line concealing efficiency is poor, and if it is larger than 80 °, it is difficult to produce a lens pattern. When the cross-sectional shape of the lenticular lens is a triangle, it is preferable that the vertex angle θ satisfies 90 to 120 ° for the bright line concealment effect.

  Further, the lenticular shape may be formed with patterns having the same height and pitch as shown in FIG. 9, or lenticular patterns 111 having different heights and pitches may be mixed as shown in FIG.

  FIG. 11 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention. The light diffusion layer 112 includes a microlens pattern. The micro lens pattern will be specifically described. The height of the micro lens may be 10 to 50 μm. If the height of the microlens pattern is less than 10 μm, the light condensing effect is somewhat inferior and the pattern may be difficult to implement. If it exceeds 50 μm, the moire phenomenon tends to occur and the pattern can be seen in the image. Can occur.

  The diameter of the microlens may be 20 to 100 μm. Preferably, it may be 30-60 micrometers. Appearance characteristics are good in the above range, and the microlens has a light condensing function and a light diffusing characteristic. If the diameter of the microlens pattern is less than 20 μm, there may be a problem of low light collection efficiency for incident light incident at an invalid angle, and if it exceeds 100 μm, the light collection efficiency for vertical light is reduced. In addition, the problem of moire phenomenon may occur.

  Also, the microlens pattern may be formed as a pattern having the same height and diameter as shown in FIG. 11, or the microlens pattern 113 having different height and diameter may be mixed as shown in FIG. Such a micro lens pattern has a large difference in optical characteristics depending on the lens density (Density) and the degree of impregnation (Aspect Ratio). Therefore, the density can be maximized and the degree of impregnation can be 1/2. Ideal.

  FIG. 13 is a perspective view of a composite reflective polarizing film according to a preferred embodiment of the present invention, and the light diffusion layer 113 includes a prism pattern. More specifically, the prism pattern may have a height h of 10 to 50 μm. If the height of the prism pattern is less than 10 μm, the base film can be damaged by pressure when manufacturing the shape of the prism pattern part, and if it exceeds 50 μm, the transmittance of light incident on the light source is increased. Decreasing problems can occur.

  In addition, the pitch of the prisms may be 20-100 μm. If the pitch of the prism pattern is less than 20 μm, the engraving is not performed well, and complicated problems may occur in the implementation and manufacturing process of the pattern layer. If the pitch exceeds 100 μm, the moire phenomenon is likely to occur, and the image There may be a problem that the pattern is visible.

  Further, the prism shape may be formed by patterns 113 having the same height and pitch as shown in FIG. 13, or prism patterns 115 having different heights and pitches may be mixed as shown in FIG. Such a prism pattern may be made of a material having a refractive index higher than that of the base film. However, if the refractive index of the base film is higher, a part of the light incident on the rear surface of the base film is reflected on the surface of the prism pattern. This is because they may be totally reflected and not enter the prism structure. The prism shape is preferably a linear prism shape, and the vertical cross section is a triangle, and it is preferable that the vertex of the triangle forms an angle of 60 to 110 ° facing the lower surface.

  The light diffusion layer including the fine pattern described above may be formed by being cured by including at least one polymer resin of a photocurable polymer resin or a thermosetting polymer resin. As a preferred example of the polymer resin, a polymer resin including a thermosetting or photocurable acrylic resin can be used. However, the type of the polymer resin used depending on the shape of the fine pattern specifically included in the light diffusion layer can be changed and used. For example, unsaturated fatty acid esters, aromatic vinyl compounds, unsaturated fatty acids and their derivatives, vinyl cyanide compounds such as methacrylonitrile, etc. can be used for the prism pattern. Specifically, urethane acrylate, methacrylate acrylate resin, etc. Can be used. The light diffusion layer can be made of a material having a higher refractive index than that of the reflective polarizing film.

  According to a preferred embodiment of the present invention, the light diffusion layer may include a bead coating layer. Specifically, the bead coating layer may be a coating layer (see FIG. 15) in which the beads 108 are included in the resin layer 107, and is formed by embedding a part of the beads above the resin layer (see FIG. 16). In this case, unlike FIG. 16, the protruding bead portion may be different in at least some of the beads, and the diameter of the included beads may be partially different. Can be configured. In addition, as shown in FIG. 17, the beads may be formed by attaching the beads to the upper surface of the resin layer and / or directly attaching the beads to the upper surface of the reflective polarizing film without the resin layer. The beads may have a diameter of 0.1 to 100 μm. When beads satisfying such a diameter are included, excellent optical properties can be realized. In the bead coating layer, the density of the beads and the interval between the beads can be designed differently depending on the intended optical properties, and therefore are not particularly limited in the present invention. However, if the distance between beads is too small, the light transmission property may be disadvantageous as the number of beads contained per unit area increases, and the distance between beads is preferably about 1 μm or more. However, it is not limited to this.

  The beads may include at least one of organic beads and inorganic beads. Examples of the organic beads include acrylic, styrene, melamine formaldehyde, propylene, ethylene, silicon, urethane, methyl (meth) acrylate, and polycarbonate. Examples thereof include homopolymers or copolymers obtained using the above monomers. Examples of the inorganic beads include silica, zirconia, calcium carbonate, barium sulfate, and titanium oxide.

  The resin constituting the resin layer is not particularly limited in the present invention, but may be a UV curable substance. Examples of the (meth) acrylate or polyfunctional (meth) acrylate monomer include 2-hydroxyethyl (meta) ) Acrylate, 2-hydroxypropyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, butoxyethyl (meth) acrylate, ethyldiethylene glycol (meth) acrylate, 2-ethylhexyl (meth) acrylate, cyclohexyl (meth) acrylate, phenoxyethyl (Meth) acrylate, dicyclopentadiene (meth) acrylate, polyethylene glycol (meth) acrylate, polypropylene glycol (meth) acrylate, methyltriethylene diglycol (meth) acrylic , Isobornyl (meth) acrylate, N-vinylpyrrolidone, N-vinylcaprolactam, diacetone acrylamide, isobutoxymethyl (meth) acrylamide, N, N-dimethyl (meth) acrylamide, t-octyl (meth) acrylamide, dimethyl Aminoethyl (meth) acrylate, acryloylmorpholine, diciclepentenyl (meth) acrylate, trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, ethylene glycol di (meth) acrylate , Tetraethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, trimethylolpropane trioxyethyl (meth) acrylate, tricyclodecane dimethanol di (meth) acrylate, dicyclodecane dimethanol di (meth) It may be an acrylate, tripropylene glycol di (meth) acrylate, dicyclopentane di (meth) acrylate, dicyclopentadiene di (meth) acrylate or the like, and the above listed substances may be used alone or in combination. it can.

  In addition to the enumerated resins, an additive can be further included, and a material having high lubricity can be applied as the additive. For example, at least one of a silicon-based additive and a fluorine-based additive can be applied. Specifically, a reactive monomer or reactive oligomer having a silicon group (for example, a silicon group-containing vinyl compound, a silicon group-containing (meth) acrylate compound, a (meth) acryloxy group-containing organosiloxane, a silicon polyacrylate) Etc.), reactive monomers or reactive oligomers having a fluorine group (for example, fluoroalkyl group-containing vinyl compounds, fluoroalkyl group-containing (meth) acrylate compounds, fluorine polyacrylates, etc.), silicon groups or fluorine groups. Resin (for example, polydimethylsiloxane, fluoropolymer, etc.), surfactant having silicon group or fluorine group, oil (for example, dimethylsilicone oil, etc.), etc. alone or mixed Can be applied.

  The content ratio of the UV curable substance and the additive may be in the range of 100: 0.001 weight ratio to 100: 10 weight ratio, preferably 100: 0.01 weight ratio to 100: 5 weight ratio. It is possible. In addition to the UV curable substance and the additive, a photoinitiator may be further included. The photoinitiator is one or more free radical initiators selected from benzyl ketals, benzoin ethers, acetophenone derivatives, ketoxime ethers, benzophenone, benzo or thioxanthone compounds, onium salts One or more cationic initiators selected from ferrocenium salts, diazonium salts, or mixtures thereof.

  As described above, the degree of physical properties expressed in the composite reflective polarizing film through the light diffusion layer may vary depending on the specific shape of the fine pattern described above. However, when the fine pattern is specifically a prism and / or lenticular shape, the light collecting effect Although it can be further maximized, the increase in the haze value of the composite reflective polarizing film can be relatively reduced as compared to the case of the microlens shape. In addition, when the light diffusion layer does not include a fine pattern and is a bead coating layer, the haze value of the composite reflective polarizing film can be remarkably increased to realize a very excellent surface appearance quality. The transmittance is remarkably lowered, and the optical characteristics such as the light condensing effect and the brightness can be remarkably reduced as compared with the case where the fine pattern, preferably the fine pattern is a microlens shape. Accordingly, the shape of the light diffusing layer can be selected differently depending on the desired physical properties, but not only through optical characteristics such as light collection and luminance, but also through an increase in the haze value of the composite reflective polarizing film. In order to simultaneously improve the surface appearance quality, it is more preferable that the light diffusion layer includes a microlens-shaped fine pattern.

  Meanwhile, an adhesive layer (not shown) may be selectively formed on the upper surface of the skin layer 220a of the reflective polarizing film 200. Through this, the adhesive strength, appearance, and electroluminescence characteristics of the light diffusion layer 100 can be improved. As the material, acrylic, ester, urethane and the like can be used, but are not limited thereto. The adhesive layer may be formed thinner than the other layers, and the light transmittance can be improved by adjusting the thickness of the adhesive layer, and the reflectance can be reduced. The thickness of such an adhesive layer can be 5 nm to 300 nm. If the thickness of the adhesive layer is less than 5 nm, the adhesive force between the reflective polarizing film and the light diffusing layer may be very weak. If the thickness of the adhesive layer exceeds 300 nm, unevenness or Molecular lumps can occur.

  Next, the reliable support layer 300 formed on the lower surface of the reflective polarizing film 200 will be described. The reliability support layer 300 significantly improves the decrease in thermal reliability caused by various processes for manufacturing a backlight unit, etc., with a reflective polarizing film including a polymer dispersed in a base material, and further improves haze. Thus, it is possible to remarkably improve the appearance defect in which foreign matters, bright lines, and the like are manifested in the appearance, and at the same time, to minimize a decrease in luminance that may occur when a separate configuration is included for improving reliability.

  In the description of the present invention, the reliability of the composite reflective polarizing film means that the reflective polarizing film usually has a very high linear expansion coefficient due to the characteristics of the material, and the module manufacturing process such as the composite reflective polarizing film and the backlight unit. In addition, the surface of the reflective polarizing film is affected by changes in the appearance of the wrinkle like a curtain, bending, and / or optical properties such as a decrease in luminance due to the high temperature in a hot and humid environment of a product to which this is applied. If the reflective polarizing film is stretched on at least one axis, there will be no unevenness of the panel due to the occurrence of wrinkles in the appearance, the occurrence of wrinkles in the wrinkles, and the occurrence of a difference in the gap between the valleys. It means that there is no appearance damage such as easy rupture or damage in the selected direction.

  The composite reflective polarizing film according to the present invention remarkably improves the reliability as described above, and at the same time, in order to maintain the optical physical properties such as luminance, the reliability support layer according to the present invention has the condition (1) according to the present invention. The linear expansion coefficient must satisfy 4 to 35 μm / m · ° C. in the temperature range of 70 to 80 ° C., and preferably the linear expansion coefficient of 10 to 25 μm / m · ° C. in the temperature range of 70 to 80 ° C. Can be satisfied. As this is satisfied, the reflective polarizing film is subject to changes in appearance such as wrinkles and bends due to high temperatures even in a high temperature and humidity environment of a module manufacturing process such as a composite reflective polarizing film and a backlight unit and / or a product to which this is applied. Alternatively, it is possible to make an excellent composite reflective polarizing film have excellent reliability as it prevents the deterioration of the optical characteristics generated thereby. If the above range is not satisfied, there may be a problem that physical properties such as target optical characteristics, reliability, and surface appearance defect prevention are not realized. Specifically, when the linear expansion coefficient exceeds 35 μm / m · ° C. in the temperature range of 70 to 80 ° C., such a problem can be further deepened, and therefore it is not used in the backlight unit as a composite reflective polarizing film. When the coefficient of linear expansion is less than 4 μm / m · ° C, it is excellent in terms of reliability, but it is difficult to develop a material that has such thermal characteristics and at the same time has excellent optical characteristics. Even if it is developed, it is very expensive and is difficult to select because of production cost.

  On the other hand, the material of the reliable support layer is not limited as long as it satisfies the above-described condition (1) according to the present invention, but preferably has optical characteristics, heat resistance, chemical resistance, mechanical properties, and economical efficiency. In consideration of the above, it may be a polyester resin. The polyester resin is polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytetramethylene terephthalate (PTT), polyhexylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyethylene-1, 2-bis (phenoxy). ) Selected from the group consisting of ethane-4,4'-dicarboxylate, polyethylene isophthalate / terephthalate copolymer, polybutylene terephthalate / isophthalate copolymer and polybutylene terephthalate / decane-dicarboxylate copolymer. At least one component, preferably polyethylene terephthalate (PET) or modified polyethylene terephthalate, more preferably polyethylene. It may be a terephthalate (PET). As a non-limiting example for the modified polyethylene terephthalate, in addition to ethylene glycol as a diol component as a monomer and terephthalic acid as an acidic component, a sulfonated metal salt may further be included. There may be sulfaisophthalate sodium salt and the like. In addition, an aromatic polyvalent carboxylic acid other than terephthalic acid can be further included as a monomer, and as an example, one or more of dimethyl terephthalate, isophthalate, and dimethyl isophthalate can be used. As a result, the diol component except ethylene glycol as a diol component may further be included as a monomer. An example of such a diol component may be neopentyl glycol, diethylene glycol, neopentyl glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and the like. The specific composition and composition ratio of the modified polyethylene terephthalate are not particularly limited in the present invention.

  In addition, the reliable support layer may be a film stretched in at least one direction, and more preferably biaxially stretched, in order to further develop physical properties such as improved strength, dimensional stability, and heat resistance. It may be a film, more preferably a film that is heat-set at 175 to 225 ° C. after biaxial stretching, and still more preferably a polyethylene terephthalate film that is heat-set after biaxial stretching. sell.

  Further, the thickness of the reliable support layer may be 10 to 600 μm, and more preferably to minimize the decrease in luminance due to the increase in the thickness of the support layer and at the same time to realize the desired reliability. Further, the thickness may be 60 to 300 μm, more preferably 100 to 200 μm. Through this, the physical properties of the composite reflective polarizing film, such as the desired reliability, can be realized while minimizing the decrease in luminance that may occur by including the reliability support layer. If the thickness of the reliable support layer is less than 10 μm, the target reliability cannot be realized, and it may not cover the appearance of foreign matters on the appearance of the reflective polarizing film, particularly reflective polarized light. When a film does not contain a skin layer, the protective function of a reflective polarizing film may not be performed favorably. If the thickness of the reliable support layer exceeds 600 μm, high reliability can be realized. However, there may be a problem that the luminance is remarkably lowered depending on the thickness of the reliable support layer. However, it is not limited to the preferable thickness range of the reliability support layer described above, and may be adjusted differently depending on the thickness of the reflective polarizing film used.

  Meanwhile, a first primer layer may be further included between the reflective polarizing film 200 and the reliable support layer 300 to enhance the adhesive force. The first primer layer may be formed by curing including at least one polymer resin of a photocurable polymer resin or a thermosetting polymer resin. As a specific kind of such a polymer resin, any polymer resin that can minimize the brightness decrease due to the primer layer can be used without limitation, and the material thereof is silicon-based, urethane-based, silicon-urethane hybrid structure And a polymer resin containing a polymer material classified into an acrylic polymer, an isocyanate type, a polyvinyl alcohol type, a gelatin type, a vinyl type, a latex type, a polyester type, and a water-based polyester type. As a non-limiting example to this, it may be a UV curable adhesive composition containing oligomers and monomers in a weight ratio of about 20-80%: 80-20%.

  As the oligomer, one or more oligomers selected from urethane, epoxy acrylate, and polyester may be used. Examples of the monomer include DPHA (Dipentaerythritol Hexaacrylate), DPPA (Dipentaerythritol Pentaacrylate), TMPTA (Trimethylolpropylene triacrylate), TMPTMA (Tripropylatriate), TMPTMA (Triptayltriatriate), TMPTMA (Trimethylatriate). DPGDA (Dipropylene Glycol Diacrylate), TPGDA (Tripropylene Glycol Diacrylate), phenoxyethyl acrylate (PEA), isobornyl methacrylate (IBOA), 2-hydroxyethyl methacrylate Acrylate (2-HEMA), and 2-hydroxyethyl acrylate (2-HEA) one or more monomers selected from may be applied. More specifically, as non-limiting examples for this, the monomers include DPAH (5-30%), DPPA (5-30%), TMTPA (3-20), PEA (10-50%), IBOA ( 10-40%), 2-HEMA (1-10), 2-HEA (1-10%), and other monomers (1-30%).

  The first primer layer can be formed thinner than layers having different thicknesses, and the light transmittance can be improved by adjusting the thickness of the first primer layer, and the reflectance can be reduced along with this. Can do. The thickness of the first primer layer may be 1 μm to 10 μm. If the thickness of the first primer layer is less than 1 μm, the adhesive force between the reflective polarizing film and the reliable support layer may be very weak. If the thickness of the first primer layer exceeds 10 μm, the first Unevenness and molecular agglomeration can occur during processing of the primer layer.

  As described above, the composite reflective polarizing film according to the first embodiment of the present invention described above has a haze value of 65% or more, preferably 73% or more, as the condition (2) according to the present invention. Preferably it may be 85% or more, more preferably 90% or more.

  By satisfy | filling the said haze value, it can prevent that the various foreign material, bubble, etc. which may be contained in a film at a manufacturing process are expressed in an external appearance, and can improve the quality of an external appearance. If the above range is not satisfied, the quality of the appearance is deteriorated, and there is a problem that a separate device or a separate other configuration must be added to prevent the appearance of foreign matters. This is not preferable in slimming the composite reflective polarizing film, and there is a problem that increases manufacturing time and manufacturing cost due to the added structure.

  Meanwhile, the present invention includes embodiments in which the light diffusion layer 100, the reflective polarizing film 200, and the reliability support layer 300 are stacked in the first embodiment according to the present invention. As an example, the composite reflective polarizing film includes: As shown in FIG. 18, the reflective polarizing film 200 ′, the reliable support layer 300 ′, and the light diffusion layer 100 ′ may be stacked in this order. The composite reflective polarizing film as shown in FIG. 18 can be slightly reduced in luminance by the reliability support layer as compared with the composite reflective polarizing film as shown in FIG. Can be prevented.

  As another example, unlike FIGS. 5 and 18, a composite reflective polarizing film may be realized by laminating a reflective polarizing film, a light diffusion layer, and a reliability supporting layer in this order. When compared with the composite reflective polarizing film of FIG. 5, the luminance can be reduced by the reliability support layer, but there is an advantage that it is possible to prevent the appearance of excellent reliability at a similar level and poor surface appearance. is there. However, the light diffusion layer may include a fine pattern, more preferably a prism pattern, in order to improve the decreasing optical characteristics.

  As described above, the first embodiment described above is manufactured through the following manufacturing method, but is not limited thereto. Specifically, (1) a step of forming a light diffusion layer on the upper surface of the reflective polarizing film; and (2) a step of forming a reliability support layer on the lower surface of the reflective polarizing film. The steps (1) and (2) may be performed regardless of the order. Hereinafter, the same description as that described above for each component will be omitted, and the manufacturing method will be specifically described.

  First, in step (1), a step of forming a light diffusion layer on the upper surface of the reflective polarizing film is performed.

The reflective polarizing film includes (a) a base material, and a plurality of dispersions that are included in the base material and transmit the first polarized light irradiated from the outside and reflect the second polarized light. The plurality of dispersions have a refractive index different from that of the base material in at least one axial direction, and more than 80% of the plurality of dispersions included in the base material have a vertical cross section in the length direction. The aspect ratio of the length of the minor axis to the length of the major axis is 1/2 or less with reference to , the cross-sectional area of the dispersion of the first group among the groups is 0.2 to 2.0 [mu] m ^2, the cross-sectional area of the dispersion of the second group, the 2.0 .mu.m ² exceeding 5.0 .mu.m ² below There, the cross-sectional area of the dispersion of the third group, 10.0Myu from 5.0 .mu.m ² exceeded ² or less, dispersion of the first group to third group comprises the steps of to be arranged at random; may be prepared include.

  According to another preferred embodiment of the present invention, the reflective polarizing film manufactured through the step (a) is used as a core layer (b), and a skin layer integrated with at least one surface of the core layer is formed. A reflective polarizing film can be produced.

  Hereinafter, although the process of performing the said (a) and (b) together is demonstrated concretely, it is not limited to this. Further, the steps (a) and (b) are not intermittent and can be performed through an integrated process described later.

  Specifically, first, the base material component, the dispersion component, and the skin layer component are supplied to the extrusion unit. The base material component and the dispersion component can be individually supplied to an independent extrusion section. In this case, the extrusion section can be composed of two or more. Further, it is also included in the present invention to supply to one extruding part including a separate supply path and a distribution port so that the polymer is not mixed. The extruding unit may be an extruder, and may further include a heating unit or the like so that the solid supplied polymer can be converted into a liquid state.

  The viscosity is designed to be different so that the dispersion component can be arranged inside the substrate component so that the flow property of the polymer is different, and preferably the substrate component has better flowability than the dispersion component. To. Next, the dispersion component is randomly arranged in the substrate through the difference in viscosity while the substrate component and the dispersion component pass through the mixing zone and the mesh filter zone.

  Next, at least one surface of the manufactured core layer is overlapped with the skin layer component transferred by the extrusion unit. Preferably, the skin layer component is entirely superimposed on both sides of the core layer. When skin layers are superimposed on both surfaces, the material and thickness of the skin layer may be the same or different from each other.

  Next, the spread is induced by the flow control unit so that the dispersion components contained in the base material can be randomly arranged. Specifically, the size and arrangement of the cross-sectional areas of the dispersion components are adjusted randomly by appropriately adjusting the extent of spreading of the base material through a coat-hanger die which is a kind of flow control unit as shown in FIGS. can do. In FIG. 19, the base material on which the skin layers transferred through the flow path are spread widely left and right by the coat-hanger die, so that the dispersion component contained therein also spreads widely left and right.

  According to a preferred embodiment of the present invention, the step of cooling and smoothing the reflective polarizing film guided by the spread transferred by the flow controller, and the step of stretching the reflective polarizing film after the smoothing step; And heat fixing the stretched reflective polarizing film.

  First, it is a step of cooling and smoothing the polarizer transferred by the flow control unit, cooling it by the method used in the production of a normal reflective polarizing film, solidifying it, and then casting roll process etc. A smoothing step can be performed through.

  Then, it passes through the process of extending | stretching the reflective polarizing film which passed the said smoothing step.

  The stretching may be performed through a normal reflective polarizing film stretching process, through which a difference in refractive index between the base material component and the dispersion component can be induced to induce a light modulation phenomenon at the interface. The induced first component (dispersion component) further decreases in aspect ratio through stretching. For this purpose, the stretching step can preferably be uniaxial stretching or biaxial stretching, more preferably uniaxial stretching. In the case of uniaxial stretching, the stretching direction can be performed in the length direction of the first component. The stretch ratio may be 3 to 12 times. On the other hand, methods for changing an isotropic material to birefringence are generally known. For example, when stretching under appropriate temperature conditions, the dispersion molecules are oriented and the material becomes birefringent. Can be.

  Next, a final reflective polarizing film can be manufactured through a step of heat-fixing the stretched reflective polarizing film. The heat setting can be performed by a normal method, preferably 180-200 and 0.1-3 minutes through an IR heater.

  As described above, the step of forming the light diffusion layer on the upper surface of the reflective polarizing film that can be manufactured by the above-described method is performed.

  At this time, an adhesive layer can be further formed on the upper surface of the reflective polarizing film in order to facilitate the formation of the light diffusing layer and improve the adhesive strength, appearance, and electroluminescence characteristics of the light diffusing layer.

  A manufacturing method when the light diffusion layer is a fine pattern will be described. A specific method is not particularly limited in the present invention, but preferably a master roll engraved with a reverse pattern of the fine pattern or the fine pattern of the fine pattern. The reverse pattern may be formed on the reflective polarizing film through a pattern molding mold film.

  First, in the case of a method using a master roll in which a reverse pattern of the fine pattern is engraved, 1-i) any one selected from the group consisting of a prism, a lenticular, a microlens, a triangular pyramid, a bead and a pyramid pattern A reflective polarizing film is closely transferred to a master roll in which a pattern having an opposite phase to one or more fine patterns is formed on the outer surface, and a polymer resin melted on the patterned surface of the master roll or the reflective polarizing film is used. And 1-ii) applying one or more of light and heat to cure the polymer resin while the polymer resin is pressure-molded on the pattern surface of the master roll; Separating it; and

  In addition, after the step 1-ii), the method may further include a step of second-curing the polymer resin by irradiating UV or heat again.

  Specifically, FIG. 21 is a schematic view of a fine pattern forming process according to a preferred embodiment of the present invention, and FIG. 22 is a cross-sectional view showing a detailed structure of a forming part of FIG. In FIG. 22, the reflective polarizing film 770 passes through the guide roll 754 while passing from the start roll 755 and passes through the infrared lamp 751. In this process, the reflective polarizing film 770 is surface-modified with infrared rays from an infrared lamp, and adhesion to the light diffusion layer 771 is improved. When the reflective polarizing film 770 that has left the start roll 755 is drawn into the master roll 705 via the pattern guide roll 764, the reflective polarizing film 770 is formed on the pattern surface of the master roll 705 from the injection portion 742 to the light diffusion layer 771. Molecules are applied and bonded to the reflective polarizing film 770. In this process, the resin is a resin melted at room temperature, and can be primarily cured by the primary UV light irradiated by the primary UV curing device 752 disposed under the master roll 705. At this time, the temperature around the curing device 752 is 20 to 30 ° C., the temperature of heat generated while the resin is cured is 40 to 80 ° C., and the glass transition temperature (Tg: high) of the resin. In the molecular resin, it may be in the vicinity of a temperature) that exhibits a changed characteristic like a soft rubber before undergoing a complete phase change from solid to liquid. The light diffusing layer 771 in which the pattern shape on the surface of the master roll is completely transferred in the glass transition state passes through the pattern guide roll 764 and further escapes, and the reflective polarizing film 770 and the light diffusing layer 771 are combined. And passed through the guide roll 754 and wound around the finish roll 756.

  As shown in FIG. 20, the cross section of the reflective polarizing film 772 formed with the turn produced by irradiating UV twice is a surface having a form opposite to the cross section of the master roll 705. For example, the master roll is indented. In the case of an engraved surface, the reflective polarizing film (772) on which the turn is formed becomes an embossed surface.

  Next, in the case of a method using a pattern forming mold film in which a reverse pattern of a fine pattern is formed, the material of the pattern forming mold film is transparent and flexible, and has a predetermined tensile strength and durability. It is preferable to use a PET film.

  In this case, according to a preferred embodiment of the present invention, the step (1) is selected from the group consisting of 1-1) a reflective polarizing film and a prism, a lenticular, a microlens, a triangular pyramid, a bead and a pyramid pattern. Transferring a pattern forming mold film in which a pattern opposite in phase to any one or more fine patterns formed is transferred; 1-2) an upper surface of the reflective polarizing film and the pattern formation; Forming a pattern on the mold film; and 1-3) forming a pattern by injecting a fluid material between the reflective polarizing film and the pattern forming mold film. Filling the empty space between the two films; 1-4) curing the filled material and May be performed include: a down-forming mold film step of separating and.

  In addition, between the steps 1-3) and 1-4), a pressure was applied to the reflective polarizing film and the pattern forming mold film which were in close contact with each other, and a gap was formed between the two films formed by the pattern. The method may further include filling the space uniformly. In addition, the step 1-4) may include a step of applying one or more of heat and light to a material filled in a vacant space between two films formed by a pattern.

  Specifically, FIG. 23 is a schematic view of a fine pattern forming process according to another preferred embodiment of the present invention.

  First, the reflective polarizing film 810 wound around the first roll 820 is transferred by the guide rolls 830a to 830c. At this time, the molding mold 842 of the pattern molding unit 840 is also in a state of being transferred / rotated while being wound around the master roll 844 and the pattern guide rolls 846a and 846b). At this time, since the master roll 844 meshes with the guide rolls 830c and 830d, the reflective polarizing film 810 is guided by the guide roll 830c and meshes with the molding mold 842. Here, the guide roll 830c performs a gap adjusting function of adjusting the thickness of the coating liquid applied to the reflective polarizing film 810, that is, the pattern of the light diffusing layer in which the light diffusing layer is engraved with resin. More specifically, if the guide roll 830c is in close contact with the master roll 844, the light diffusion layer pattern can be formed thinner. Conversely, when the guide roll 830c is further separated from the master roll, the light diffusion layer pattern is changed. It can be formed thicker. The pattern thickness of such a light diffusion layer can be adjusted by the viscosity of the coating liquid, the patterning speed, the tension of the reflective polarizing film, and the like, in addition to the distance between the guide roll 830c and the master roll 844.

  On the other hand, the coating liquid is injected by the coating liquid injection means 860 at the point where the reflective polarizing film 810 meshes with the guide roll 830c and the master roll 844, and is pressed between the patterns of the molding mold 842 to be filled. The pattern is uniformly distributed by the pressure between the roll 830c and the master roll 844. The coating liquid distributed between the patterns is cured by heat and / or UV emitted from the curing means 870. The reflective polarizing film on which the pattern-formed coating liquid is cured and applied is separated from the molding mold 842 while being guided by the guide roll 830d, and the reflective polarizing film 812 having the pattern formed thereon is transferred by the guide roll 830e. And wound around the second roll 850. Here, the guide roll 830d performs a peeling function for separating the reflective polarizing film 812, to which the coating liquid is applied, that is, the light diffusion layer is formed, from the molding mold 842.

  The reflective polarizing film 812 having the reflective polarizing film 810 and the light diffusion layer formed on one surface is connected to each other, and the names are classified for convenience of explanation. That is, the reflective polarizing film 810 means a state before the light diffusing layer is formed, and the reflective polarizing film 812 on which the light diffusing layer is formed passes through the pattern molding unit 840 and is subjected to pattern forming. Means a state where is applied to the reflective polarizing film and completed. Further, FIG. 23 shows only a part of the pattern layer formed on the reflective polarizing film 812 on which the light diffusion layer is formed, and actually, on the reflective polarizing film wound around the second roll 850. As a result, a light diffusion layer is formed.

  FIG. 24 is a schematic view of a fine pattern forming process according to another preferred embodiment of the present invention. Specifically, in this embodiment, the mold 942 is formed in a roll type that is longer by the length of the reflective polarizing film 910 so that the reflective polarizing film 912 formed with the light diffusion layer is seamless.

  In the second embodiment of the optical member manufacturing apparatus according to the present invention, the first roll 920 around which the reflective polarizing film 910 is wound and the second roll 950 around which the reflective polarizing film 912 formed with the light diffusion layer is wound are provided on both sides. The guide rolls 930a to 930f for transferring the reflective polarizing film on which the reflective polarizing film and the light diffusion layer are formed are provided between the first roll 920 and the second roll 950. In addition, the master roll 946 of the pattern molding unit 940 is in close contact between the guide roll 930c and the guide roll 930d in order to apply a coating liquid that is patterned on the reflective polarizing film 910. Of course, the number and position of the guide rolls 930a to 930f can be changed according to the implementation state. The pattern molding unit 940 includes a film-shaped molding mold 942 in which the pattern shape is embodied, a third roll 944 around which the molding mold is wound, and a coating liquid to be injected is pressure-bonded to the molding mold along the pattern of the molding mold. The coating liquid is formed into a pattern, and includes a master roll 946 for applying the coating liquid to the reflective polarizing film 910, pattern guide rolls 947a to 947d for transferring the forming mold, and a fourth roll 948 around which the transferred forming mold is wound. Of course, the number and positions of the pattern guide rolls 947a to 947d can be changed according to the implementation state.

  Unlike the embodiment of FIG. 23, the mold 942 is a pattern made of a coating liquid on the reflective polarizing film 910 while being wound around the third roll 944 and being transferred by the master roll 946 and the guide rolls 947a to 947d. Is then wound around a fourth roll 948. At this time, the molding mold 942 is preferably formed to have the same length as that of the reflective polarizing film 910, and the reflective polarizing film 912, through which the light diffusion layer including the pattern is formed, has no pattern defect or pattern breakage due to the joint. A pattern is uniformly formed over the entire region. FIG. 24 shows only a part of the pattern in which the pattern is embodied in the molding mold. However, in actual implementation, the pattern is embodied in the entire molding mold.

  A coating liquid injection means 960 for injecting the coating liquid is provided at a point where the reflective polarizing film 910 is drawn into the pattern molding unit 940, that is, a point where the guide roll 930c and the master roll 946 are in close contact with each other. A curing means 970 for curing the coating liquid by irradiating heat or UV is provided at a point where the molding mold 942 moves in close contact.

  On the other hand, the method for forming the bead coating layer on the reflective polarizing film is not particularly limited, and the bead coating layer forming composition can be coated on the reflective polarizing film by an ordinary method. Preferably, the coating method may be formed by any one of comma coating, reverse coating, clavia coating, blade coating, silk screen coating, and slot die head coating. In this case, the bead coat layer can be formed so that the beads are included in the resin layer by adjusting the thickness according to the bead diameter included in the composition and the amount of the composition to be applied. It is also possible to form a bead coat layer in which only a part is embedded. The coated composition can be cured through light and / or heat depending on the type of resin included under normal conditions, and the light can preferably be UV.

  Next, as the step (2) according to the present invention, a step of forming a reliable support layer on the lower surface of the reflective polarizing film is performed.

  The step (2) includes: 2-1) forming a first primer layer on the upper surface of the reliable support layer in order to enhance the adhesive strength between the reflective polarizing film and the reliable support layer; 2-2) Superimposing the first primer layer and the lower surface of the reflective polarizing film so as to contact each other.

  As the method for forming the first primer layer on the reliability support layer, a known method can be selected. In the present invention, the method is not particularly limited, and a comma coating, a reverse coat, It can be formed by any one method among a clavia coat, a blade coat, a silk screen coat and a slot die head coat.

  Next, as a step 2-2), a step of superimposing the lower surface of the reflective polarizing film in contact with the formed first primer layer is performed. At this time, the first primer layer may be cured by being superimposed on the reflective polarizing film in a semi-cured state, or may be cured after being superimposed on the reflective polarizing film as it is being coated. The curing is determined by a specific method according to the type of the polymer resin used as the first primer layer, and can be preferably cured through heat and / or light. A method can be employed, and the present invention is not particularly limited.

  Meanwhile, the steps (1) and (2) according to the method for manufacturing the composite reflective polarizing film according to the preferred embodiment of the present invention described above may be performed regardless of the order, and may be manufactured in different order depending on the manufacturing equipment. Can do. More specifically, FIG. 25 is a cross-sectional view of a reflective polarizing film and a reliable support layer that are superimposed according to a preferred embodiment of the present invention. After the reliability support layer 300 on which the layer 400 is formed is overlaid so that the first primer layer 400 is in contact with the lower surface of the reflective polarizing film 200, the overlaid reflective polarizing film / first primer layer / reliability The support layer may be put into the start roll 755 in FIG. 22 or the first roll 820 in FIG. 23 to form a light diffusion layer on the upper surface of the reflective polarizing film.

  Next, the composite reflective polarizing film according to the second embodiment of the present invention will be described. Referring to FIG. 26, the composite reflective polarizing film 1000 includes a light diffusion layer 100 formed on the upper surface of the reflective polarizing film 200, a reliability support layer 300 formed on the lower surface of the reflective polarizing film 200, and the reliability. A light-condensing layer 600 formed on a lower surface of the support layer; and a first primer layer 400 for enhancing adhesion between the reflective polarizing film 200 and the reliable support layer 300; A second primer layer 500 may be further included for enhancing the adhesive strength of the light collecting layer 600.

  Of the components in the second embodiment described above, descriptions of the same parts as those in the first embodiment are omitted, and differences and configurations not provided in the first embodiment are described.

  The reliability support layer 300 may have a thickness of 10 to 300 μm by a light collection layer 600 described below, and more preferably, the reliability can be more easily realized while minimizing a decrease in luminance. Therefore, the thickness may be 30 to 200 μm, more preferably 80 to 150 μm. If the thickness of the reliability support layer is less than 10 μm, the target reliability may not be realized. Even if the reliability is complemented through a condensing layer described later, the target reliability is realized. In order to do this, a thick light-collecting layer must be used, and with this, the luminance can be remarkably reduced, and the appearance of foreign matter may not be covered in the appearance of the reflective polarizing film. Also, if the thickness of the reliable support layer exceeds 300 μm, high reliability can be realized, but the brightness can be remarkably lowered, and the product such as a backlight unit including a composite reflective polarizing film In consideration of the above, the composite reflective polarizing film has only a limited thickness, but the thickness of the condensing layer, which will be described later, decreases due to the increase in the thickness of the reliable support layer, and the target condensing There is a problem that the effect of the layer is not realized. However, it is not limited to the preferred thickness range of the above-described reliability support layer, and is adjusted differently depending on the thickness of the reflective polarizing film used and the thickness range of the support portion in the light condensing layer described later. Can be done.

  The condensing layer 600 formed on the lower surface of the reliable support layer 300 with the composite reflective polarizing film will be described.

  Specifically, FIG. 27 is a perspective view of a light collecting layer included in a preferred embodiment of the present invention, wherein the light collecting layer 600 is formed on one surface of a support part 620 and the support part 620. A prism pattern part 610 may be included, and the prism pattern part 610 may be coupled to face the lower surface of the reliability support layer (not shown) or the lower surface of the second primer layer (not shown). .

  The support part 620 serves to support the prism pattern part 610 included in the light condensing layer 600, and at the same time, has a function of further improving the reliability of the composite reflective polarizing film. That is, as the light collecting layer for the light collecting function is integrated into the composite reflective polarizing film, the light collecting layer can simultaneously perform not only the light collecting function but also the function of supporting the composite reflective polarizing film, Even if a reliable support layer is realized with a thin thickness by the function of the light collecting layer, the composite reflective polarizing film has no problem in maintaining the reliability as a whole, so all physical properties are satisfied at the same time. Also, it can be very advantageous for thinning the optical film included in the backlight unit.

  The support part 620 is a material that can support various structured patterns to be included in the industry for improving optical properties, and at the same time, the support part 620 can be used without limitation if it is a material that does not inhibit light transmission. . Examples of this include polycarbonate, polysulfone, polyacrylate, polystyrene, polyvinyl chloride, polyvinyl alcohol, polyvinyl alcohol, and poly alcohol alcohol. However, the present invention is not limited thereto, but may include a polynorbornene-based material or a polyester-based material. However, in consideration of remarkably excellent support capability, product cost, heat resistance, and light transmittance, the support portion 620 preferably includes a polyester material, and more preferably, the polyester material includes polyethylene terephthalate ( PET). The polyethylene terephthalate film may be a film stretched in at least one axial direction.

  The thickness of the support part 620 is the desired physical properties such as the height of the prism pattern part formed on the support part, the total thickness of the composite reflective polarizing film, the thickness of the reliable support layer, and the minimization of luminance reduction. In order to significantly improve the reliability of the composite reflective polarizing film by the minimum support function for the light collecting layer and the phase rising effect with the reliable support layer. It is preferable to have a thickness of 10 to 300 μm, more preferably 60 to 200 μm, and more preferably 80 to 200 μm. If the thickness of the support portion is less than 10 μm, the support function of the prism pattern portion may not be performed smoothly, and the improvement in the reliability of the composite reflective polarizing film may be very weak. Further, if the thickness exceeds 300 μm, it may be advantageous for the development of the reliability of the target composite reflective polarizing film, but there may be a problem that the optical characteristics such as luminance are remarkably lowered.

  On the other hand, from the viewpoint of reliability by the reliability support layer and the support part, the support part should satisfy a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C. for the phase rising effect. More preferably, the linear expansion coefficient can satisfy 10 to 25 μm / m · ° C. in a temperature range of 70 to 80 ° C. As this is satisfied, the reflective polarizing film can be prevented from being bent due to high temperature even in a high temperature and humidity environment of a module manufacturing process such as a composite reflective polarizing film and a backlight unit and / or a product to which this is applied. Accordingly, an excellent composite reflective polarizing film can have excellent reliability. Specifically, when the linear expansion coefficient exceeds 35 μm / m · ° C. in a temperature range of 70 to 80 ° C., such a problem can be further deepened, so that it is not used for a backlight unit as a composite reflective polarizing film. If there is a point and the linear expansion coefficient is less than 4 μm / m · ° C, the reliability aspect is excellent, but the reliability support layer having such thermal characteristics is manufactured in the form of a film on the material. In order to produce a material used for an optical film with a linear expansion coefficient of less than 4 μm / m · ° C., the draw ratio is very high. There is a problem in that optical characteristics such as luminance are greatly deteriorated by increasing the thickness or increasing the thickness of itself.

  Next, the prism pattern part 610 formed on one surface of the support part 620 will be described.

  The prism pattern part 610 is for strengthening the light collecting function at the lower part of the composite reflective polarizing film, and is formed of a plurality of prisms 611 and 612 formed on the support part 620 as shown in FIG. obtain. At this time, each prism 611 includes a prism surface that is inclined on both sides with respect to the peak portion 611a at the upper end. The apex angle of the prisms 611, 612 may be in the range of 45 ° to 135 °, in the range of 60 ° to 130 °, or 85 ° to 105 °. Further, the pitch of the prisms 611 may be about 20 to 100 μm, and the height may be about 10 to 60 μm. The prism 611 may be continuously formed from one side of the support part 620 to the other side. Adjacent prisms 611, 612) may be adjacent to each other, but may be partially separated. Here, the fact that the prisms 611 and 612 are adjacent means that the bottom surfaces of the prisms are adjacent to each other.

  Further, the prisms 611 and 612 may be formed on the entire surface of the support part 620. When the support part 620 is rectangular on the plan view, the first direction X1 in the extending direction of the prisms 611 and 612 can be parallel to the long side or the short side of the support part 620. In some other embodiments, the first direction X1 may have an acute angle with the long side and / or the short side of the support part 620. For example, the crossing angle may be in the range of ± 5 ± 30 °.

  The prism pattern unit 610 includes silicon-based, urethane-based, silicon-urethane hybrid SU polymers, acrylic-based, isocyanate-based, polyvinyl alcohol-based, gelatin-based, vinyl-based, latex-based, polyester-based, water-based polyester-based, and the like. It may be formed of a polymer resin, and preferably may be formed by curing through heat and / or light.

  Meanwhile, according to a preferred embodiment of the present invention, a second primer layer 500 may be further included between the reliability support layer and the light collecting layer to enhance the adhesive force.

  The second primer layer 500 may be formed by curing including at least one polymer resin of a photo-curable polymer resin or a thermosetting polymer resin. In the first embodiment described above, the material of the first primer layer can be employed. In addition, the second primer layer can be formed thinner than layers having different thicknesses, and the light transmittance can be improved by adjusting the thickness of the second primer layer, which also reduces the reflectance. can do. The thickness of the second primer layer may be 3 μm to 10 μm. If the thickness of the second primer layer is less than 3 μm, the adhesive force between the reliable support layer and the light collecting layer may be very weak, and if the thickness of the second primer layer exceeds 10 μm, the second Unevenness and molecular agglomeration can occur during processing of the primer layer.

  Meanwhile, the composite reflective polarizing film according to the second embodiment of the present invention may be implemented such that the value of Equation 1 below satisfies 0.3 to 2.0.

  As can be seen from FIG. 26, a composite reflective polarizing film according to a preferred embodiment of the present invention includes a reflective polarizing film 200 and a reliable support layer 300 for maintaining the reliability of the reflective polarizing film. In order to express the improved optical physical properties, the light-collecting layer 600 is provided, and the multiple functions are combined together. The light condensing layer 600 includes a support portion 620 that performs a function of supporting the light condensing layer. However, when the thickness of the reliability supporting layer 300 provided to ensure high reliability is increased, However, there is a problem that optical properties such as luminance are remarkably lowered, which is very unfavorable for thinning the composite reflective polarizing film.

  Thereby, the support part 620 of the light collecting layer 600 provided to increase the light collecting power shares the support function of the reliability support layer provided to maintain the reliability of the composite reflective polarizing film, The reliability of the composite reflective polarizing film can be achieved without increasing the thickness of the reliable support layer 300, and at the same time, the decrease in optical properties such as luminance that can occur by providing the support layer can be minimized. . Accordingly, in the composite reflective polarizing film according to a preferred embodiment of the present invention, the value of the following formula 1 according to the present invention must satisfy 0.3 to 2.0, and preferably the value of the formula 1 is 0.00. It can be 6-1.6. Through this, the reliability of the composite reflective polarizing film can be remarkably improved and optical properties such as brightness can be developed at the same time, and while maintaining excellent physical properties, the composite reflective polarizing film can be made thin and slim. Very preferred for mold displays.

  If the value of Equation 1 according to the present invention is less than 0.3, the reflective polarizing film is distorted at high temperatures and / or bent and / or the composite reflective polarizing film is heated due to the difference in coefficient of linear expansion between the reflective polarizing film and the reliable support layer. Therefore, it may be difficult to prevent a change in appearance such as bending as a whole, reliability is extremely lowered, and the wrinkles and bends can induce a panel unevenness phenomenon. In addition, since the thickness of the support portion is reduced and the support function for the light condensing layer is lowered, the original physical properties of the light condensing layer may be difficult to be realized. There can be. Also, if the value of Formula 1 exceeds 2.0, the optical properties such as brightness are significantly lowered, so that the desired properties cannot be obtained, which is very preferable for thinning the composite reflective polarizing film. Absent.

  On the other hand, even if the total thickness of the support portion 620 of the reliability support layer 300 and the light collecting layer 600 satisfies the value of Formula 1 according to the present invention, the thickness of any one of the two layers is relative. If the thickness of the reflective polarizing film is too thick, the reflective polarizing film may not be able to prevent the appearance of wrinkles or bends from changing, or the brightness may be lowered. The value can satisfy 0.25 to 4.0, more preferably 0.6 to 2.5, and more preferably 0.9 to 2.0.

  If the value of Formula 2 is less than 0.25, the reliability support layer becomes relatively thin, and it may be difficult to prevent appearance changes such as wrinkles and bending that may occur in the reflective polarizing film. It may be difficult to prevent damage such as the polarizing film easily rupturing. In addition, if the value of Formula 2 exceeds 4, there is a problem that the thickness of the reliability support layer becomes too thick and the optical properties such as luminance are greatly deteriorated.

  The composite reflective polarizing film according to the second embodiment of the present invention includes (a) a step of forming a light diffusion layer on the upper surface of the reflective polarizing film; and (b) a reliable support layer on the lower surface of the reflective polarizing film. And (c) forming a light-collecting layer on the lower surface of the reliability support layer.

  Since the steps (a) and (b) are the same as the steps (1) and (2) according to the first embodiment of the present invention, detailed description thereof will be omitted.

  As a second embodiment according to the present invention, step (c) is a step of forming a light collecting layer on the lower surface of the reliability support layer. Hereinafter, step (c) will be described by taking as an example the case where the light condensing portion of the light condensing layer is a prism pattern.

  A specific method for forming the prism pattern on the upper surface of the support portion is not particularly limited in the present invention, but preferably a master roll in which a reverse pattern of the prism pattern is engraved or a reverse pattern of the prism pattern is formed. It may be formed on the upper part of the support part through a pattern molding mold film.

  First, in the case of a method using a master roll in which a reverse pattern of the prism pattern is engraved, according to a preferred embodiment of the present invention, a master having a pattern opposite in phase to the prism pattern formed on the outer surface. A step of closely transferring the support portion to the roll, and applying a molten polymer resin to the pattern surface of the master roll or the support portion; while the polymer resin is pressure-molded on the pattern surface of the master roll And applying at least one of light and heat to cure the polymer resin and separating the polymer resin.

  Specifically, FIG. 28 is a schematic view of a process for forming a fine pattern of a condensing layer according to a preferred embodiment of the present invention. In FIG. 28, the support unit 1070 is fed out from the start roll 1055 while being guided by the guide roll 1054. Through the infrared lamp 1051. In this process, the support portion 1070 is surface-modified by the infrared rays of the infrared lamp, so that the adhesion with the prism pattern portion 1071 is improved. When the support portion 1070 separated from the start roll 755 is drawn into the master roll 1005 through the pattern guide roll 1064, a polymer serving as a material of the prism pattern portion 1071 is formed on the pattern surface of the master roll 705 from the injection portion 1042. Is applied and combined with the support portion 1070. In this process, the resin is a resin melted at room temperature, and can be primarily cured by the primary UV light irradiated by the primary UV curing device 1052 disposed below the master roll 1005. At this time, the temperature around the curing device 1052 is 20 to 30 ° C., the enthusiasm temperature generated by curing the resin is 40 to 80 ° C., and the glass transition temperature (Tg: polymer) of the resin. Before the resin undergoes a complete phase change from a solid to a liquid, it can be near a temperature that exhibits a changed characteristic like a soft rubber. The prism pattern portion 1071 that has completely transferred the pattern shape on the surface of the master roll in the glass transition state passes through the pattern guide roll 1064 and further escapes to the condensing layer 1072 to which the support portion 1070 and the prism pattern portion 1071 are coupled. After being formed, it passes through the guide roll 1054 and is wound around the finish roll 1056.

  The cross section of the condensing layer 1072 formed with the turn produced by irradiating UV twice as shown in FIG. 28 is a surface having a form opposite to the cross section of the master roll 1005. For example, the master roll is indented. In the case of an engraved surface, the reflective polarizing film 772 on which the turn is formed becomes an embossed surface.

  Next, in the case of a method using a pattern forming mold film in which a reverse pattern of the prism pattern is formed, the material of the pattern forming mold film is transparent, flexible, and has a predetermined tensile strength and durability. It is preferable to use a PET film. In this case, according to a preferred embodiment of the present invention, a step of transferring a pattern forming mold film having a pattern opposite in phase to the support portion and the prism pattern is transferred; and an upper surface of the support portion And a step of closely contacting one surface on which the pattern is formed in the pattern forming mold film; and injecting a fluid material between the closely supporting portion and the pattern forming mold film to form two patterns formed by the pattern Filling the vacant space between the substrates; and curing the filled material to separate the patterning mold film. Preferably, the method may further include a step of applying a pressure to the closely supporting support portion and the pattern forming mold film to uniformly fill the empty space between the two films formed by the pattern. Preferably, the curing may be performed by applying one or more of heat and light to a material filled in an empty space between two films formed by a pattern.

  FIG. 29 is a schematic view of a fine pattern forming process of the light collecting layer according to another preferred embodiment of the present invention. First, the support part 1110 wound around the first roll 1120 includes guide rolls 1130a to 1130c. It is transferred by. At this time, the molding mold 1142 of the pattern molding unit 1140 is also transferred / rotated while being wound around the master roll 1144 and the pattern guide rolls 1146a and 1146b. At this time, since the master roll 1144 meshes with the guide rolls 1130c and 1130d, the support portion 1110 is guided by the guide roll 1130c and meshes with the molding mold 1142. Here, the guide roll 1130c performs a gap adjusting function of adjusting the thickness of the coating liquid applied to the support portion 1110, that is, the pattern thickness of the prism pattern portion in which the prism pattern portion is engraved with resin. More specifically, if the guide roll 1130c is in close contact with the master roll 1144, the pattern of the prism pattern portion can be formed thinner. Conversely, if the guide roll 1130c is slightly separated from the master roll, the prism pattern portion This pattern can be formed thicker. The pattern thickness of such a prism pattern portion can be adjusted by the viscosity of the coating liquid, the patterning speed, the tension of the reflective polarizing film, and the like, in addition to the distance between the guide roll 1130c and the master roll 1144.

  On the other hand, the coating liquid is injected by the coating liquid injection means 1160 at the point where the support portion 1110 meshes with the guide roll 1130c and the master roll 1144, and is pushed between the patterns of the molding mold 1142 to be filled. The pattern is uniformly distributed by the pressure between the roll 1130c and the master roll 1144. The coating liquid distributed between the patterns is cured by heat and / or UV emitted from the curing means 1170. The reflective polarizing film on which the pattern-formed coating liquid is cured and applied is separated from the forming mold 1142 while being guided by the guide roll 1130d, and the condensing layer 1112 having the prism pattern portion formed on the support portion 1110 is Then, it is transported by the guide roll 1130e and wound around the second roll 1150. Here, the guide roll 1130d performs a peeling function for separating the support portion 1110 on which the coating liquid is applied, that is, the prism pattern portion is formed, from the molding mold 1042.

  The support part 1110 having the support part 1110 and the prism pattern part formed on the same surface is connected to each other, and the names are classified for convenience of explanation. That is, the support part 1110 means a state before the prism pattern part is formed, and the support part 1110 on which the prism pattern part is formed has a coating liquid formed by pattern forming while passing through the pattern molding part 1040. It means a state where it is applied to 1110 and completed. FIG. 28 shows only a part of the pattern formed on the support part 1110 on which the prism pattern part is formed. In practice, the support part wound on the second roll 1150) is also shown on the support part 1110. The prism pattern portion is formed.

  The step (c) is a step of superimposing the light collecting layer manufactured through the manufacturing process as shown in FIG. 28 or 29 on the lower surface of the reliability support layer, specifically, c-1). A step of forming a second primer layer on the lower surface of the reliability support layer to enhance the adhesion between the reliability support layer and the light collection layer; c-2) one surface of the second primer layer and the light collection layer Superimposing to abut each other.

  A known method can be selected as a method for forming the second primer layer below the reliability support layer in the step c-1). In the present invention, the method is not particularly limited. (coma coating), reverse coating, clavia coating, blade coating, silk screen coating, slot die head coating, and the like.

  Next, in step c-2), it is possible to perform a step of superimposing the formed second primer layer so that one surface of the condensing layer, more preferably the prism pattern portions of the condensing layer are in contact with each other. At this time, the second primer layer may be cured by being superimposed on the light collecting layer in a semi-cured state, or may be cured after being superimposed on the reflective polarizing film as it is. The curing is determined by a specific method depending on the type of the polymer resin used as the second primer layer, and preferably by curing through heat and / or light. This method can be employed and is not particularly limited in the present invention.

  In step c-2), the second primer layer is overlaid so as to be in contact with the prism pattern portion of the condensing layer. In order to develop more improved optical characteristics and bonding force, the second primer layer May be engraved with negative intaglios for all or part of the prism pattern. At this time, the degree of engraving may be engraved so as to correspond to the reverse phase of a part or all of the prism crest portion with reference to the cross section of one prism. When the peak portion of the prism pattern and the second primer layer in which the negative pattern corresponding to the peak portion is engraved and bonded together, more improved optical characteristics and bonding force can be exhibited.

  At this time, the portion of the second primer layer that is not engraved with the reverse phase can form a certain inclined surface with reference to the support portion of the light collecting layer. An inclination angle of about 1 to 4.5 ° can be formed with respect to the surface, and in this case, more light is refracted as the incident angle can be further increased by the obtuse angle pattern at the interface of the second primer layer. Therefore, there is an advantage that more light can be collected in the upward direction and the luminance can be improved in general.

  The prism pattern of the second primer layer and the condensing layer may be formed such that a space between the upper surface of the support portion of the condensing layer and the valley portion of the prism pattern formed on the upper surface is joined without a gap, or A space may be coupled between the upper surface of the support portion of the light collecting layer and the valley of the prism pattern formed on the upper surface, and the space may be filled with a vacuum or an air layer.

  Meanwhile, the method for manufacturing a composite reflective polarizing film according to the second embodiment of the present invention may be manufactured by performing steps (a) to (c) regardless of the order.

  More specifically, the reliability support layer 300 in which the first primer layer 400 is formed on the lower surface of the reflective polarizing film 200 is disposed so that the first primer layer 400 contacts the lower surface of the reflective polarizing film 200. After the step (b) of superimposing is performed first, the reflective polarizing film / first primer layer / reliable support layer superimposed for performing the step (a) is placed on the start roll 755 of FIG. 21 or the first roll of FIG. It can be put into a roll 820 to form a light diffusion layer on the upper surface of the reflective polarizing film, and step (c) can be performed thereafter.

  In addition, after performing the step (b) of superimposing the reflective polarizing film 200 and the reliability support layer 400, the step (c) of superimposing the light collecting layer 600 on the lower surface of the reliability support layer 400 is performed to manufacture ( After performing the step (c) from the order (b) to (c)) or superimposing the light collecting layer 600 on the lower surface of the reliable support layer 400, the reflective polarizing film 200 and the reliable support layer 400 are formed. The superposed reflective polarizing film / reliable support layer / light-collecting layer is shown by being manufactured by performing the step (b) of superposition (from (order (c) to (b)). When the reflected polarizing film / reliable support layer / condensing layer is put into the start roll 755 of FIG. 21 or the first roll 820 of FIG. 23 to form a light diffusion layer on the upper surface of the reflective polarizing film, Composite including layers It can be produced Ihen light film.

  As described above, the steps (a) to (c) are performed regardless of the order, and the present invention does not particularly limit any specific order.

  The composite reflective polarizing film manufactured according to the second embodiment described above includes the reliability support layer 300 for maintaining the reliability of the reflective polarizing film, and enhances light collection to develop improved optical properties. Therefore, the light collecting layer 600 includes a support portion 620 that performs a function of supporting the light collecting layer. However, the thickness of the reliability supporting layer 300 provided to ensure high reliability. When the thickness increases, the appearance change of the fine wrinkles and bends is reduced, but the composite reflective polarizing film is bent as a whole like the bimetal due to the difference in the coefficient of linear expansion between the reflective polarizing film and the reliable support layer. Can occur frequently. Further, as the thickness of the reliable support layer is increased, there may be a problem that optical properties such as luminance are lowered. This supports the light collecting layer 600 provided to increase the light collecting power of the support function of the reliability supporting layer for maintaining the reliability of the composite reflective polarizing film without increasing the thickness of the reliability supporting layer 300. The supporting portion 620 is divided and shared, so that the warping phenomenon that the composite reflective polarizing film is bent as a whole can be prevented, and the decrease in optical physical properties such as luminance that can occur by providing the supporting layer. The physical properties of the present invention can be realized, such as minimization.

  Meanwhile, the composite reflective polarizing film according to the third embodiment of the present invention is a composite reflective polarizing film including a reflective polarizing film in which a polymer is dispersed in a base material, and the composite reflective polarizing film is disposed on an upper surface of the reflective polarizing film. A light diffusion layer formed; a reliability support layer formed on a lower surface of the reflective polarizing film; and a multi-layer formed on the lower surface of the reliability support layer for guiding and condensing light emitted from a light source. A functional layer, and is implemented to satisfy the following condition (1) and condition (2).

  (1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C., and (2) the haze value of the composite reflective polarizing film is 65% or more. is there.

  Below, it demonstrates centering around difference with the 1st example of implementation mentioned above and the 2nd example of implementation.

  The reliable support layer may have a thickness of 10 to 300 μm, and more preferably a thickness for realizing a desired reliability while minimizing a decrease in luminance due to an increase in the thickness of the support layer. May be 60 to 220 μm, more preferably 80 to 200 μm in thickness. Through this, the physical properties of the composite reflective polarizing film, such as the desired reliability, can be realized while minimizing the decrease in luminance that may occur by including the reliability support layer. If the thickness of the reliability support layer is less than 10 μm, the target reliability may not be manifested only by the light guide layer of the multi-functional layer described later, and the multi-function is to improve the reliability. Even if the thickness of the light guide layer is increased, appearance changes such as wrinkles and bends can occur in the reflective polarizing film. In addition, a multi-functional layer including a light guide layer having a large thickness can significantly reduce optical properties such as luminance. Also, if the thickness of the reliable support layer exceeds 300 μm, the luminance can be remarkably lowered, and the thickness of the reliable support layer becomes very unfavorable for reducing the thickness of the composite reflective polarizing film. There is a problem that the use can be limited in light of the trend toward slimming of a backlight unit including a polarizing film and a display panel including such a unit. In addition, the thickness of the multi-functional layer, which will be described later, decreases due to the increase in the thickness of the reliable support layer, and there is a problem that the effect of the target multi-functional layer cannot be realized.

  Next, the multi-functional layer may be implemented including a light guide layer and a fine pattern layer including a prism pattern formed on one surface of the light guide layer. At this time, the fine pattern layer is the same as the description of the fine pattern layer of the condensing layer in the above-described second embodiment, and a specific description thereof will be omitted.

  The light guide layer serves to guide the light emitted from the light source and at the same time supports the fine pattern layer included in the multi-functional layer, and also shares the role of the reliability support layer described above. In charge of the function to further improve the reliability of the composite reflective polarizing film. Usually, in order to improve the light focusing function of the optical film included in the backlight unit, it is necessary to include a fine pattern layer to be described later. In this case, the fine pattern layer is the same as that of the second embodiment described above. Similarly, it is common to provide a separate support layer for supporting this. However, the multi-functional layer included in the present invention can support the fine pattern layer through the light guide layer without a separate support layer for supporting the fine pattern layer, and by not including a separate support layer, While preventing a decrease in optical characteristics such as luminance, it can be further advantageous in reducing the thickness of the optical film included in the backlight unit. As a result, when a heat-resistant material is used for the light guide layer, from the viewpoint of reliability, the light guide layer can play a part of the role of the reliability support layer, thereby reducing the thickness of the reliability support layer. This is very preferable because all the desired physical properties can be realized and the optical film can be made thin.

  If the material of the light guide layer is a material of the light guide layer normally used in the industry, it can be used without limitation. Preferred examples thereof include polycarbonate (polycarbonate), polysulfone (polysulfone), polyacrylate (polyacrylate). Polyacrylate type, polystyrene type, polyvinyl chloride type, polyvinyl alcohol type, polynorbornene type, polyester (polyester) type 1 or polyester type 2 species The above can be included.

  However, in the case of a polysulfone or polyacrylic film among the above materials, the optical characteristics are excellent, but the heat resistance is not good, so it is not preferable for the enhancement of the reliability of the composite reflective polarizing film. Since the material is very solid, it can be easily broken, so that the composite reflective polarizing film cannot be combined through a continuous manufacturing process in the manufacturing process, and each layer is placed on the light guide layer cut individually. Since they must be laminated, the production process is complicated, and productivity may be inferior.

  Accordingly, according to a preferred embodiment of the present invention, the optical film can be wound on a roller on the remarkably excellent support capability, product cost, heat resistance, light guide property and manufacturing process for the fine pattern layer. When considering all flexibility, it is preferable to include a polycarbonate system. Through this, other layers can be continuously combined without individually cutting the light guide layer, and the film can be wound on a roller in the combining process, which greatly increases productivity. is there.

  The thickness of the light guide layer is the minimum thickness necessary for maintaining the function of the light guide layer, the height of the fine pattern layer formed on the layer, the total thickness of the composite reflective polarizing film, minimizing the decrease in luminance, etc. Since it can be designed differently depending on the intended physical properties, etc., it is not particularly limited, but the light guiding property to be achieved through the multi-functional layer, the support of the fine pattern layer, and the reliability of the composite reflective polarizing film In view of the above, it is preferable to have a thickness of 400 to 1000 μm, more preferably 600 to 900 μm, in order to exhibit a remarkable phase rising effect with the reliable support layer. If the thickness of the light guide layer is less than 400 μm, the function of guiding the original light of the light guide layer may be deteriorated. In addition, if the thickness of the light guide layer exceeds 1000 μm, the luminance can be significantly reduced, and the thickness of the light guide layer that becomes thick is very unfavorable for thinning the composite reflective polarizing film. There is a problem that the use can be restricted in light of the trend of slimming the backlight unit including the display unit and the display panel including the unit. In consideration of the reliability of the composite reflective polarizing film, the total thickness of the reliability support layer and the light guide layer preferably has a certain thickness range, but the increase in the thickness of the light guide layer is As a result, the thickness of the reliable support layer is relatively reduced, and accordingly, the reliability support layer does not prevent the wrinkles or bends from occurring in the reflective polarizing film. Is very unfavorable.

  In addition, a second primer layer for strengthening the adhesive force may be further included between the reliability support layer and the multi-functional layer, which is the same as the second embodiment described above. The explanation is omitted.

  On the other hand, in the third embodiment described above, (A) a step of forming a light diffusion layer on the upper surface of the reflective polarizing film; and (B) an upper surface of the reliability supporting layer is in contact with the lower surface of the reflective polarizing film. And (C) forming a multi-functional layer on the lower surface of the reliable support layer, wherein the steps (A) to (B) are performed in order. It can be manufactured regardless of going.

  Steps (A) to (C) correspond to steps (a) to (c) of the second section (tool) described above, and a multi-functional layer is formed instead of the light collecting layer in step (c). Except for this, the description on the manufacturing method is the same, and a specific description is omitted.

  On the other hand, the composite reflective polarizing film manufactured according to the first to third exemplary embodiments of the present invention may have a haze value of 65% or more, preferably 73% or more. Preferably, it may be 85% or more. By satisfy | filling the said haze value, it can prevent that the various foreign material, bubble, etc. which may be contained in a film in a manufacturing process are expressed in an external appearance, and can improve the quality of an external appearance. If the above range is not satisfied, the quality of the appearance is deteriorated, and there is a problem that a separate device or a separate other configuration must be added to prevent the appearance of foreign matters. It is not preferable in slimming the composite reflective polarizing film, and there is a problem that increases the manufacturing time and manufacturing cost due to the added structure.

  The composite reflective polarizing film described above can be used in a light source assembly, a liquid crystal display device including the light source assembly, and the like to improve light efficiency. The light source assembly is classified into a direct type light source assembly in which a lamp is positioned at a lower portion, an edge type light source assembly in which a lamp is positioned at a side, and the composite reflective polarizing film according to an embodiment of the present invention may be any type of light source assembly. It can also be adopted. Further, the present invention can also be applied to a backlight assembly disposed on the lower side of the liquid crystal panel and a front light assembly disposed on the upper side of the liquid crystal panel. Hereinafter, as an example of various applications, a case where a composite reflective polarizing film according to an embodiment as shown in FIG. 5 or FIG. 26 is applied to a liquid crystal display device including an edge type light source assembly will be described.

  FIG. 30 is a cross-sectional view of a liquid crystal display device according to a preferred embodiment of the present invention. The liquid crystal display device 2000 includes a backlight unit 2400 and a liquid crystal panel assembly 2500.

  The backlight unit 2400 includes a composite reflective polarizing film 2111 that modulates the optical characteristics of emitted light. At this time, other configurations included in the backlight unit and the other configurations and the position of the composite reflective polarizing film 2111 are included. Since the relationship can be changed depending on the purpose, it is not particularly limited in the present invention.

  However, according to a preferred embodiment of the present invention, as shown in FIG. 30, the light source 2410, the light guide plate 2420 for guiding the light emitted from the light source 2410, the reflection film 2315 disposed below the light guide plate 2420, and the light guide It can be constructed and arranged with a composite reflective polarizing film 2111 arranged above the light plate 2420.

  At this time, the light source 2410 is disposed on both sides of the light guide plate 2420. The light source 2410 can be, for example, an LED (Light Emitting Diode), a CCFL (Cold Cathode Fluorescent Lamp), an HCFL (Hot Cathode Fluorescent Lamp), or an EEFL (External Electrode Fluorescent). In other embodiments, the light source 2410 may be disposed only on one side of the light guide plate 2420.

  The light guide plate 2420 moves the light emitted from the light source 2410 through total internal reflection, and emits the light upward through a scattering pattern or the like formed on the lower surface of the light guide plate 2420. A reflective film 2415 is disposed below the light guide plate 2420 to reflect light emitted downward from the light guide plate 2420 upward.

  A composite reflective polarizing film 2111 is disposed on the light guide plate 2420. Since the composite reflective polarizing film 2111 has been described in detail above, a duplicate description is omitted. Another optical sheet may be further disposed above or below the composite reflective polarizing film 2111. For example, a liquid crystal film that partially reflects incident circularly polarized light, a retardation film that converts circularly polarized light into linearly polarized light, and / or a protective film can be further provided.

  The light source 2410, the light guide plate 2420, the reflective film 2415, and the composite reflective polarizing film 2111 can be accommodated by the bottom chassis 2440.

  The liquid crystal panel assembly 2500 includes a first display plate 2511, a second display plate 2212, and a liquid crystal layer (not shown) interposed therebetween, and is attached to the surfaces of the first display plate 2411 and the second display plate 2412, respectively. A polarizing plate (not shown) can be further included.

  The liquid crystal display device 2000 may further include a top chassis 2600 that covers the frame of the liquid crystal panel assembly 2500 and surrounds the side surfaces of the liquid crystal panel assembly 2500 and the backlight unit 2300.

  On the other hand, FIG. 31 shows an example of a liquid crystal display device employing the composite reflective polarizing film of the present invention, in which a reflector 3280 is inserted on a frame 3270, and a cold cathode fluorescent lamp 3290 is positioned on the upper surface of the reflector 3280. To do. An optical film 3320 is positioned on the upper surface of the cold cathode fluorescent lamp 3290, and the optical film 3320 may be laminated in the order of a diffusion plate 3321, a composite reflective polarizing film 3322, and an absorbing polarizing film 3323. The configuration included in the optical film The order of stacking between the components can be changed depending on the purpose, and some of the components may be omitted or a plurality of components may be provided. As a result, a retardation film (not shown) or the like can also be inserted at an appropriate position in the liquid crystal display device. Meanwhile, a liquid crystal display panel 3310 may be fitted on the mold frame 3300 on the optical film 3320.

  The description will focus on the light path. Light emitted from the cold cathode fluorescent lamp 3290 reaches the diffusion plate 3321 in the optical film 3320. The light transmitted through the diffusion plate 3321 undergoes light modulation while passing through the composite reflective polarizing film 3322 so that the traveling direction of the light travels perpendicular to the optical film 3320. Specifically, the P wave passes through the reflective polarizing film without loss, but in the case of the S wave, light modulation (reflection, scattering, refraction, etc.) occurs, and the reflection on the back surface of the cold cathode fluorescent lamp 3290 occurs. The light is reflected by the plate 3280, and after the light property is randomly changed to a P wave or an S wave, it further passes through the composite reflective polarizing film 3322. Thereafter, the light passes through the absorption polarizing film 3323 and then reaches the liquid crystal display panel 3310. Meanwhile, the cold cathode fluorescent lamp 3290 may be replaced with an LED.

  In the embodiment described above, a composite reflective polarizing film according to an embodiment of the present invention can be applied to effectively exhibit a plurality of light modulation characteristics, improve brightness, light leakage, bright line. Thus, there is an advantage that it is possible to prevent the appearance defect in which foreign matters appear in the appearance and to ensure the reliability of the composite reflective polarizing film even in a high temperature and high humidity environment where the liquid crystal display device is used. Further, by integrating the light diffusing layer and the condensing layer each having a function into the reflective polarizing film, the thickness of the light source assembly can be reduced, and the assembling process can be simplified. Accordingly, the image quality of the liquid crystal display device including such a light source assembly can be improved.

  On the other hand, in the present invention, the application of the reflective polarizing film has been described mainly for liquid crystal displays, but is not limited to this, and is widely used in flat display technologies such as projection displays, plasma displays, field emission displays, and electroluminescence displays. Can be done.

  The present invention will be described more specifically with reference to the following examples. However, the following examples should not be construed as limiting the scope of the present invention, which should be construed as an aid to understanding the present invention.

<Example 1>
Polyethylene naphthalate (PEN) having a refractive index of 1.65 as a dispersion component, and polycyclohexylene dipolymerized by polymerization of terephthalate, ethyl glycol and cyclohexanedimethanol in a molar ratio of 1: 2 to 60% by weight of polycarbonate as a base component. A raw material containing 38% by weight of methylene terephthalate (PCTG) and 2% by weight of a thermal stabilizer containing phosphate was added to the first and second extrusion parts, respectively. As a skin layer component, 60% by weight of polycarbonate contains 38% by weight of polycyclohexylene dimethylene terephthalate (PCTG) obtained by polymerization reaction of terephthalate, ethyl glycol, and cyclohexanedimethanol at a molar ratio of 1: 2 and phosphate. 2% by weight of the obtained heat stabilizer was charged into the third extrusion section.

  The extrusion temperature of the base material component and the dispersion component was 245 ° C., and Cap. Check Rheometer and check I.D. V. The flow of the polymer is corrected through the adjustment, and the polymer is passed through the flow path to which the filter mixer is applied, and the dispersion is guided to be randomly dispersed inside the base material. Thereafter, the skin layer component is applied to both sides of the base material layer component. Superimposed. The polymer was spread by the coat-hanger die of FIGS. 18 and 19, which corrects the flow rate and pressure gradient. Specifically, the width of the die inlet is 200 mm, the thickness is 10 mm, the width of the die outlet is 1,260 mm, the thickness is 2.5 mm, and the flow rate is 1.0 m / min. Then, the smoothing process was performed with cooling and a cast roll, and it extended 6 times in MD direction. Next, heat setting was performed at 180 ° C. for 2 minutes using a heater chamber to produce a random dispersion type reflective polarizing film having a thickness of 120 μm (a thickness including the skin layer is 300 μm). The refractive index of the polyethylene naphthalate (PEN) component of the produced reflective polarizing film is (nx: 1.88, ny: 1.58, nz: 1.58), and terephthalate and ethyl glycol are added to 60% by weight of polycarbonate. The refractive index of 38% by weight of polycyclohexylene dimethylene terephthalate (PCTG) polymerized by a 1: 2 molar ratio of cyclohexanedimethanol and 2% by weight of a thermal stabilizer containing a phosphate is 1 .58. At this time, the thickness of the core layer was 120 μm, the thickness of the skin layer was 40 μm on the upper and lower surfaces, and the total thickness of the reflective polarizing film was 200 μm.

  Thereafter, a light diffusion layer including a urethane acrylic microlens pattern having a refractive index of 1.59 was formed on the upper surface of the reflective polarizing film through the process shown in FIG. 21 through the manufactured reflective polarizing film. At this time, the height of the lens in the microlens pattern was 20 μm.

  On the other hand, a polyethylene terephthalate (PET) film (EXCELL, Toray's advanced material) having a thickness of 188 μm, biaxially stretched four times in the longitudinal and lateral directions as a reliable support layer and then heat-set at 190 ° C. On one side, DPHA (Dipentaerythritol Hexaacrylate) 15 wt%, DPPA (Dipentaerythritol Pentaacrylate) 15 wt%, TMPTA (trimethylpropylene triacylate) 12 wt%, Phenoxyethyl Acrylate (PEA 25 wt%) %, 2-hydroxyethyl methacrylate (2-HEMA) 8% by weight and 2-hydroxyethyl acrylate (2-HEA) 5 After manufacturing a reliable support layer in which an adhesive containing 5% by weight is formed with a thickness of 5 μm, the lower surface of the reflective polarizing film on which the light diffusion layer is formed and the surface on which the adhesive is formed on the PET film, The composite reflective polarizing films as shown in Table 1 were manufactured by laminating so as to be in contact with each other.

<Examples 2 to 11>
A composite reflective polarizing film was produced in the same manner as in Example 1 except for the conditions shown in Table 1 below.

  At this time, the height of the lenticular lens of Example 8 was 20 μm, the pitch was 40 μm, the height of the prism pattern of Example 9 was 20 μm, and the pitch was 40 μm.

  In Example 10, the reliable support layer was a PET film (EXCELL, Toray's advanced material) having a linear expansion coefficient of 24.69 μm / m · ° C. in a temperature range of 70 to 80 ° C.

  In Example 11, as the reliable support layer, a PET film (Toyobo Co., Ltd.) having a linear expansion coefficient of 27.27 μm / m · ° C. in a temperature range of 70 to 80 ° C. was used.

<Example 12>
In the same manner as in Example 1, a plate-like polymer dispersed reflective polarizing film produced through the following method was produced instead of the random dispersed reflective polarizing film, as shown in Table 2. A composite reflective polarizing film was produced.

  The plate type polymer dispersed reflective polarizing film was processed as shown in FIG. Specifically, a PEN having a refractive index of 1.65 as a first component and a material in which dimethyl terephthalate and dimethyl-2,6-naphthalenedicarboxylate are mixed at a molar ratio of 6: 4 as a second component are ethylene glycol. Co-PEN having a refractive index of 1.64 reacted with (EG) at a molar ratio of 1.64, and 90% by weight of polycarbonate and polycyclohexylene dimethylene terephthalate (PCTG) as skin layer components. Polycarbonate alloys having a refractive index of 1.58 polymerized at 10% by weight were put into the first extrusion unit 220, the second extrusion unit 221 and the third extrusion unit 222, respectively. The extrusion temperature of the first component and the second component is 295 ° C., and Cap. Check Rheometer and check I.D. V. The polymer flow was corrected through the adjustment, and the skin layer was extruded at a temperature level of 280 ° C. The first component was transferred to the first pressurizing means 230 (Kawasaki Gear Pump), and the second component was also transferred to the second pressurizing means 231 (Kawasaki Gear Pump). The discharge amount of the first pressurizing unit is 8.9 kg / h in order, and the discharge amount of the second pressurizing unit is 8.9 kg / h. A sea-island type composite flow was produced using a sea-island type extrusion die as shown in FIG. Specifically, the number of island component layers of the fourth die distribution plate S4 in the sea island type extrusion die is 400, and the diameter of the mouth hole of the island component supply path is 0.17 mm, and the island component supply path The number of each was 25,000. The diameter of the discharge port of the sixth die distribution plate was 15 mm × 15 mm. In the feed block having a three-layer structure, the skin layer components flowed from the third extruding part through the flow path to form skin layers on the upper and lower surfaces of the sea-island type composite flow (core layer polymer). The spread of the core layer polymer on which the skin layer was formed was induced by the coat-hanger die of FIGS. 19 and 20 for correcting the flow velocity and the pressure gradient so that the aspect ratio of the sea-island type composite flow was 1/30295. Specifically, the die entrance width was 200 mm, the thickness was 20 mm, the die exit width was 960 mm, the thickness was 2.4 mm, and the flow rate was 1 m / min. . Then, the smoothing process was performed with cooling and a cast roll, and it extended 6 times in MD direction. As a result, the length of the major axis of the first component did not change, but the length of the minor axis decreased. Thereafter, heat fixation was performed through an IR heater at 180 ° C. for 2 minutes to produce a reflective polarizing film in which the polymer as shown in FIG. 34 was dispersed. The refractive index of the first component of the manufactured reflective polarizing film is (nx: 1.88, ny: 1.64, nz: 1.64), and the refractive index of the second component is 1.64. It was. The aspect ratio of the polymer is approximately 1/18000, the number of layers is 400 layers, the minor axis length (thickness direction) is 84 nm, the major axis length is 15.5 mm, and the average optical thickness. The thickness was 138 nm. At this time, the thickness of the manufactured reflective polarizing film core layer was 59 μm, and the total thickness of the upper and lower surfaces of the skin layer was 141 μm.

<Comparative Examples 1-4>
A composite reflective polarizing film was produced in the same manner as in Example 1 except for the conditions shown in Table 2 below.

  Under the present circumstances, the PET film (TSI company) whose linear expansion coefficient is 36.25 micrometer / m * degreeC in the temperature area of 70-80 degreeC was used for the reliable support layer in the comparative example 4. FIG.

<Experimental example 1>
The following physical properties were evaluated for the composite reflective polarizing films produced through Examples 1-12 and Comparative Examples 1-5, and the results are shown in Tables 1 and 2.

1. Relative luminance In order to measure the luminance of the manufactured composite reflective polarizing film, the following procedure was performed. After assembling a panel on a 32 "direct backlight unit provided with a diffuser plate and a composite reflective polarizing film, the brightness was measured at 9 points using a Topcon BM-7 measuring machine and averaged. The relative luminance represents the relative value of the luminance of the other examples and the comparative example, where the luminance of the composite reflective polarizing film of Example 1 is 100 (reference).

2. Visualization of bright lines After assembling a panel on a 32 "backlight unit provided with a composite reflective polarizing film, a diffusion plate, a diffusion sheet, a prism sheet, and a brightness enhancement film, visual recognition of the bright lines was evaluated. The evaluation of observing bright lines visually is very good if the number of bright lines is zero, good if one, and usually if it is 2-3, it should be 4-5 or more. It was evaluated as bad.

3. Degree of polarization The degree of polarization was measured using a RETS-100 analytical facility from OTSKA.

  4). Haze measurement

Haze was measured using a haze and permeability measuring machine (Nippon Denshoku Kogyo Co.) analysis equipment.

5. Applicability of foreign matter expression By visually observing the appearance of the composite reflective polarizing film and evaluating whether the foreign matter in the film can be seen visually, as a result, when the foreign matter is not expressed, it is indicated by 0, depending on the degree to which the foreign matter is expressed. Shown in 1-5.

6). Reliability Evaluation After leaving the composite reflective polarizing film at 60 ° C. and a relative humidity of 75%, first observing for 96 hours and then observing the degree of change until 1000 hours, the appearance of the composite reflective polarizing film is distorted or wrinkled. It was evaluated whether there was a change such as As a result of the evaluation, the case where there was no change in the appearance was indicated by 0, and the degree of change was increased as indicated by 1-5.

  Specifically, as can be seen from Tables 1 and 2, Examples 1 to 5 were superior in brightness, degree of polarization, and bright line visibility compared to Examples 6 and 7.

  On the other hand, according to a preferred embodiment of the present invention, Example 1 belonging to the range of 1/3 group exhibited superior optical properties compared to Examples 2 to 4 which do not satisfy this. As a result, compared with Example 5 in which the content of one group is out of the range, the optical properties of Example 1 were very excellent.

  In addition, when the fine pattern included in the light diffusion layer through Examples 1, 8 and 9 is a microlens, it is remarkably superior in the expression of high haze properties than when it is a prism or lenticular shape. Accordingly, it can be confirmed that Example 1 is further superior in physical properties such as bright line visual recognition and foreign substance expression.

  In addition, when the linear expansion coefficient of the reliability support layer exceeds 25 μm / m · ° C. through Example 1, Example 10, and Example 11, the reliability may be lower than that of Example 1 and Example 10. Can be confirmed.

  Moreover, in the case of Example 12 which changed to the plate-type polymer dispersion type reflective polarizing film, it can be confirmed from Example 1 that the optical characteristics such as luminance and polarization degree are not very good.

  Further, in the case of Example 1 including the reliability support layer, it can be confirmed that excellent physical properties have been realized by the evaluation of reliability, but the remaining configuration is the same, and only the reliability support layer is used. Comparative Example 1 that does not include the effect of improving the luminance by not including the reliability support layer can confirm that the reliability has been significantly reduced.

  Further, in Comparative Examples 2 and 3 not including the light diffusion layer, it was confirmed that the haze value was remarkably reduced compared to Example 1 including the light diffusion layer, the line was visually inferior, and the foreign matter was remarkably expressed. can do.

  Moreover, in the case of the comparative example 4 which does not satisfy | fill the linear expansion coefficient of the reliability support layer by this invention, it can confirm that the target reliability cannot be achieved.

<Example 13>
Polyethylene naphthalate (PEN) having a refractive index of 1.65 as a dispersion component, and polycyclohexylene dipolymerized by polymerization of terephthalate, ethyl glycol and cyclohexanedimethanol in a molar ratio of 1: 2 to 60% by weight of polycarbonate as a base component. A raw material containing 38% by weight of methylene terephthalate (PCTG) and 2% by weight of a thermal stabilizer containing phosphate was charged into the first and second extrusion parts, respectively. As a skin layer component, 60% by weight of polycarbonate contains 38% by weight of polycyclohexylene dimethylene terephthalate (PCTG) obtained by polymerization reaction of terephthalate, ethyl glycol, and cyclohexanedimethanol at a molar ratio of 1: 2 and phosphate. 2% by weight of the obtained heat stabilizer was charged into the third extrusion section.

  The extrusion temperature of the base material component and the dispersion component was 245 ° C., and Cap. Check Rheometer and check I.D. V. The flow of the polymer is corrected through adjustment, and the dispersion layer is guided to pass through the flow channel to which the Filter Mixer is applied, so that the dispersion is randomly dispersed inside the substrate. After that, the skin layer component is superimposed on both sides of the substrate layer component. Combined. The polymer was spread by the coat-hanger die of FIGS. 19 and 20, which correct for flow rate and pressure gradient. Specifically, the width of the die inlet is 200 mm, the thickness is 10 mm, the width of the die outlet is 1,260 mm, the thickness is 2.5 mm, and the flow rate is 1.0 m / min. Then, the smoothing process was performed with cooling and a cast roll, and it extended 6 times in MD direction. Next, heat fixation was performed through a heater chamber at 180 ° C. for 2 minutes to produce a random dispersion type reflective polarizing film having a thickness of 120 μm (the thickness including the skin layer is 300 μm). The refractive index of the polyethylene naphthalate (PEN) component of the produced reflective polarizing film is (nx: 1.88, ny: 1.58, nz: 1.58), terephthalate and ethyl glycol are added to 60% by weight of polycarbonate. The refractive index of polycyclohexylene dimethylene terephthalate (PCTG) polymerized by a 1: 2 molar ratio with cyclohexanedimethanol is 38% by weight, and the thermal stabilizer containing 2% by weight of phosphate contains: 1.58. At this time, the thickness of the core layer was 120 μm, the thickness of the skin layer was 40 μm on the upper and lower surfaces, and the total thickness of the reflective polarizing film was 200 μm.

  Thereafter, a light diffusion layer including a urethane acrylic microlens pattern having a refractive index of 1.59 was formed on the upper surface of the reflective polarizing film through the process shown in FIG. 21 through the manufactured reflective polarizing film. At this time, the height of the lens in the microlens pattern was 20 μm.

  On the other hand, a polyethylene terephthalate (PET) film (EXCEL, Toray's advanced material) with a thickness of 188 μm, which was biaxially stretched 4 times in the longitudinal direction and the transverse direction in the reliable support layer and then thermally fixed to 190 DPHA (Dipentaerythritol Hexaacrylate) 15 wt%, DPPA (Dipentaerythritol Pentaacrylate) 15 wt%, TMPTA (trimethylpropylene triacrylate) 12 wt%, Phenoxyethyl acrylate (PEA25 wt%) %, 2-hydroxyethyl methacrylate (2-HEMA) 8% by weight and 2-hydroxyethyl acrylate (2 -HEA) After manufacturing a reliable support layer in which a second primer containing 5% by weight was formed to a thickness of 5 μm, the second primer layer was adhered to the prism pattern portion of the prepared light collecting layer so as to contact each other. It was. At this time, the condensing layer was biaxially stretched four times in the longitudinal and lateral directions at the support part, and then heat-fixed to 190, and a thickness of 100 μm of polyethylene terephthalate (PET) film (EXCEL, Toray) 25 was prepared so as to include a urethane acrylic prism pattern (height 20 μm, pitch 40 μm) having a refractive index of 1.59 through the process shown in FIG.

Thereafter, DPHA (Dipentaerythritol Hexaacrylate) 15 wt%, DPPA (Dipentaerythritol Pentaacrylate) 15 wt%, TMPTA (trimethylpropylene triacrylate) 12 wt%
5 μm of the first primer containing 25% by weight, 20% by weight of isobornyl methacrylate (IBOA), 8% by weight of 2-hydroxyethyl methacrylate (2-HEMA) and 5% by weight of 2-hydroxyethyl acrylate (2-HEA) Then, the lower surface of the reflective polarizing film on which the light diffusion layer is formed and the surface on which the first primer is formed on the PET film of the reliability supporting layer are laminated so as to contact each other. A composite reflective polarizing film as shown in Table 1 was produced.

<Examples 14 to 18>
A composite reflective polarizing film was produced in the same manner as in Example 13 except for the conditions shown in Table 3 below. At this time, the height of the lenticular lens of Example 14 was 20 μm, the pitch was 40 μm, the height of the prism pattern of Example 15 was 20 μm, and the pitch was 40 μm. In Example 16, the reliability support layer was a PET film (EXCELL, Toray's advanced material) having a linear expansion coefficient of 24.69 μm / m · ° C. in the temperature range of 70 to 80 ° C. In Example 17, a PET film (Toyobo Co., Ltd.) having a linear expansion coefficient of 27.27 μm / m · ° C. in a temperature range of 70 to 80 ° C. was used as the reliable support layer.

<Example 19>
A composite reflective polarizing film as shown in Table 3 was manufactured in the same manner as in Example 13 except that the plate-like polymer dispersed reflective polarizing film in Example 12 was used instead of the random dispersed reflective polarizing film. did.

<Examples 20 to 22>
A composite reflective polarizing film as shown in Table 4 below was carried out in the same manner as in Example 13 except that the thickness of the reliability support layer and / or the light collecting layer support was changed under the conditions shown in Table 4 below. Manufactured.

<Comparative Examples 5-9>
A composite reflective polarizing film was produced in the same manner as in Example 13 except for the conditions shown in Table 4 below.

  Under the present circumstances, the PET film (TSI company) whose linear expansion coefficient is 36.25 micrometer / m * degreeC in the temperature area of 70-80 degreeC was used for the reliable support layer in the comparative example 9.

<Experimental example 2>
The following physical properties were evaluated for the composite reflective polarizing films produced through Examples 13-22 and Comparative Examples 5-9, and the results are shown in Tables 3-4.

1. Relative luminance, degree of polarization, bright line visibility, haze, presence / absence of foreign matter, reliability The same physical properties as in Experimental Example 1 were evaluated. At this time, relative luminance was relatively shown based on Example 13 and the remaining examples and comparative examples.

2. Satisfaction of numerical formula When the value of the following numerical formula 1 satisfies 0.16 to 2.0, it is indicated by ○, and when it is not satisfied, it is indicated by ×, and the value of the following numerical formula 2 satisfies 0.25 to 4.0 In the case, it was indicated by ◯, and when it was not satisfactory, it was indicated by ×.

  Specifically, as can be seen from Table 3 and Table 4, the case where the fine pattern included in the light diffusion layer is microlens through Examples 13 to 15 is more haze than the prism or lenticular. It can be confirmed that it is remarkably excellent in the expression of physical properties, and along with this, it can be confirmed that Example 13 is further superior in physical properties such as bright line visual recognition and foreign substance expression.

  In addition, when the linear expansion coefficient of the reliability support layer exceeds 25 μm / m · ° C. through Example 13, Example 16, and Example 17, the reliability may be lower than that of Example 13 and Example 16. Can be confirmed. Moreover, it can confirm that the comparative example 9 in which the linear expansion coefficient of a reliability support layer exceeds 35 micrometers / m * degreeC has a remarkably bad reliability compared with an Example.

  Moreover, in the case of Example 19 which changed to the plate-type polymer dispersion type reflective polarizing film, it can be confirmed from Example 13 that the optical characteristics such as luminance and polarization degree are not very good.

  On the other hand, in the case of the comparative example 5 which does not include a condensing layer as compared with the example 13, it can be confirmed that the optical characteristics such as the luminance are remarkably lowered. Further, although the surface of the film was not wrinkled or bent, it can be confirmed that a warping phenomenon in which the film is bent as a whole has occurred.

  Further, in the case of Comparative Example 6 that does not include the reliability support layer, the optical properties such as luminance were expressed at a level similar to that of Example 13, but the surface appearance of the film was wrinkled and bent, and the film was entirely It can be confirmed that even a bending warp phenomenon has occurred.

  Moreover, in the case of the comparative example 7 which does not satisfy Formula 1 by this invention, it can confirm that the defect which a wrinkle and a bending generate | occur | produce on the surface, or the severe warp phenomenon generate | occur | produced on the film, In this case, although the reliability is excellent, it can be confirmed that the luminance is remarkably lowered, and it can be seen that the composite reflective polarizing film is not thinned and very unfavorable.

Further, even when Expression 1 according to the present invention is satisfied, Example 21 that does not satisfy Expression 2 has defects that cause wrinkles or bends on the surface as compared with Example 1, and Example 22 has a condensing layer. It can be confirmed that the thickness is reduced so much that the luminance is reduced as compared with the similar example 1 in which the total thickness of the reliability supporting layer and the light collecting layer is similar.

Claims (21)

In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A light diffusing layer formed on the upper surface of the reflective polarizing film;
A reliable support layer formed on the lower surface of the reflective polarizing film;
A composite reflective polarizing film characterized by satisfying the following conditions (1) and (2):
(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more.   2. The composite reflection according to claim 1, wherein the light diffusion layer includes at least one fine pattern selected from the group consisting of a prism, a lenticular, a microlens, a triangular pyramid, and a pyramid pattern. Polarized film.   The composite reflective polarizing film according to claim 2, wherein the fine pattern includes a microlens.   The composite reflective polarizing film according to claim 1, wherein the light diffusion layer includes a bead coat layer.   The composite reflective polarizing film according to claim 1, wherein the reliable support layer is a polyester film stretched in at least one direction.   The composite reflective polarizing film according to claim 1, wherein the reliability support layer has a thickness of 10 to 600 μm.   2. The composite reflective polarizing film according to claim 1, wherein the reliability support layer satisfies the condition (1) and the linear expansion coefficient satisfies 10 to 25 μm / m · ° C. in a temperature range of 70 to 80 ° C. 3. The reflective polarizing film is
A base material, and a plurality of dispersions that are included in the base material and transmit the first polarized light irradiated from the outside and reflect the second polarized light. The refractive index is different from the base material in at least one axial direction,
More than 80% of the plurality of dispersions contained in the base material have a minor axis length aspect ratio of ½ or less with respect to the major axis length based on the vertical section in the length direction. ,
The dispersion having an aspect ratio of ½ or less is included in at least three groups according to a cross-sectional area,
Sectional area of the dispersion of the first group among the groups is 0.2 to 2.0 [mu] m ^2, the cross-sectional area of the dispersion of the second group is an 5.0 .mu.m ² or less from the 2.0 .mu.m ² exceeded , the cross-sectional area of the dispersion of the third group is a 10.0 [mu] m ² or less from 5.0 .mu.m ² exceeded,
The composite reflective polarizing film according to claim 1, wherein the dispersions of the first group to the third group are randomly arranged. The reflective polarizing film is
A core layer including a base material and a plurality of dispersions contained in the base material; and an integrated skin layer formed on at least one surface of the core layer. Item 9. The composite reflective polarizing film according to Item 8.   2. The composite reflective polarizing film according to claim 1, wherein a haze value of the composite reflective polarizing film is 73% or more under the condition (2). In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A reliable support layer formed on the upper surface of the reflective polarizing film;
A light diffusion layer formed on the upper surface of the reliable support layer; and
A composite reflective polarizing film characterized by satisfying the following conditions (1) and (2):
(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more. In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A light diffusing layer formed on the upper surface of the reflective polarizing film;
A reliable support layer formed on an upper surface of the light diffusion layer;
A composite reflective polarizing film characterized by satisfying the following conditions (1) and (2):
(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more. In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A light diffusing layer formed on the upper surface of the reflective polarizing film;
A reliable support layer formed on the lower surface of the reflective polarizing film;
A light collecting layer formed on a lower surface of the reliable support layer;
A composite reflective polarizing film characterized by satisfying the following conditions (1) and (2):
(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more. The condensing layer is
A support part, and a prism pattern part formed on the support part,
The composite reflective polarizing film according to claim 13, wherein the prism pattern portion is formed to face a lower surface of the reliability support layer.   The composite reflective polarizing film according to claim 14, wherein the support portion has a thickness of 10 to 300 μm. In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A light diffusing layer formed on the upper surface of the reflective polarizing film;
A reliable support layer formed on the lower surface of the reflective polarizing film;
And a light collecting layer formed on a lower surface of the reliable support layer.
The composite reflective polarizing film, wherein the value of the following Equation 1 is 0.3 to 2.0 with respect to the thickness of the reflective polarizing film, the thickness of the reliable support layer, and the thickness of the support portion of the light collecting layer .

17. The composite reflective polarizing film according to claim 16, wherein a value of the following formula 2 with respect to the thickness of the reliable support layer and the thickness of the support portion of the light collecting layer is 0.25 to 4.

In the composite reflective polarizing film comprising a reflective polarizing film in which a polymer is dispersed inside the substrate, the composite reflective polarizing film is:
A light diffusing layer formed on the upper surface of the reflective polarizing film;
A reliable support layer formed on the lower surface of the reflective polarizing film;
A multi-functional layer that is formed under the reliability support layer and guides and collects light emitted from a light source;
A composite reflective polarizing film satisfying the following condition (1) and condition (2):
(1) The reliability support layer has a linear expansion coefficient of 4 to 35 μm / m · ° C. in a temperature range of 70 to 80 ° C.
(2) The haze value of the composite reflective polarizing film is 65% or more. The multi-functional layer is
A fine pattern layer for condensing the light emitted from the light source;
The composite reflective polarizing film according to claim 18, further comprising: a light guide layer that is formed under the fine pattern layer and supports the fine pattern layer and guides light emitted from a light source.   The backlight unit (unit) containing the composite reflective polarizing film as described in any one of Claims 1-19. A liquid crystal display device comprising the backlight unit according to claim 20.

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