JP2021113968A - Polarization element, method for manufacturing polarization element, and head-up display device - Google Patents

Abstract

To provide a polarization element excellent in polarization property, heat radiation property and manufacturing cost.SOLUTION: A polarization element 1 comprises a substrate 10 made of transparent inorganic material, a grid structure 20 made of transparent material and having a base part 21 provided along the surface of the substrate 10 and projection parts 22 projecting like a lattice from the base part 21, and optical functional films 30 formed on the projection parts 22 and consisting of an absorption film which absorbs light, a reflection film which reflects light or a multilayer film which has at least the absorption film and the reflection film.SELECTED DRAWING: Figure 1

Description

The present invention relates to a polarizing element and a method for manufacturing a polarizing element, which has good polarization characteristics and is excellent in heat dissipation and manufacturing cost, and a head-up display device having excellent polarization characteristics and heat resistance. ..

In recent years, many head-up display devices for vehicles have been developed that display images on the windshield of a vehicle or a semitransparent plate such as a combiner (hereinafter collectively referred to as a "display surface"). The vehicle head-up display device is, for example, an image display device that is arranged on the dashboard of a vehicle, projects image light onto a windshield, and displays driving information as a virtual image. Since the driver can visually recognize the virtual image at the same time as the scenery through the windshield, the movement of the line of sight is less than that of a conventional display device such as a liquid crystal display installed outside the range of the windshield. There are advantages.

However, in the head-up display device described above, since the display image is emitted from below toward the windshield surface (upward), sunlight enters in the direction opposite to the emission direction of the display image and is incident on the display element. I had something to do. Head-up display devices are often provided with a reflector for reflecting and enlarging the displayed image for the purpose of requesting miniaturization and enlarging the displayed image. In such a case, the head-up display is provided with a reflector. The incident sunlight is condensed in the vicinity of the display element, and the heat may cause deterioration or failure of the display element.

Therefore, for the purpose of preventing sunlight from entering the display element, a technique for providing a reflective polarizing element in the head-up display has been developed. For example, Patent Document 1 discloses a head-up display in which a reflective polarizing element (wire grid polarizing plate) is provided between a reflector and a display element.

Here, as the polarizing element provided in the head-up display used above, for example, a polarizing element made of a polarizing element made of birefringent resin, or a plurality of conductors (thin metal wires) extending in parallel on a transparent substrate. Examples thereof include a wire grid type polarizing element and a polarizing element made of a cholesteric phase liquid crystal. Among these, wire grid type polarizing elements are often used as those having excellent polarization characteristics. In the wire grid polarizing element, a wire grid is formed in which conductor lines made of metal or the like are arranged in a grid pattern at a specific pitch, and the arrangement pitch of the wire grid is set to incident light (for example, visible light). By setting the pitch (less than half) smaller than the wavelength of the electric field vector, the light of the electric field vector component that vibrates parallel to the conductor wire is almost reflected, and the electric field vector perpendicular to the conductor wire. As a result of being able to transmit most of the light of the component, it can be used as a polarizing element that produces a single polarized light, and the light that is not transmitted can be reflected and reused, which is desirable from the viewpoint of effective use of light.

As such a wire grid polarizing element, for example, Patent Document 2 is provided so as to cover at least a part of a resin base material having a grid-like convex portion, the grid-like convex portion of the resin base material, and a side surface thereof. A wire grid polarizing plate including a dielectric layer and a metal wire provided on the dielectric layer is disclosed.
Further, in Patent Document 3, a base material made of a resin or the like having a concavo-convex structure extending in a specific direction on the surface and a conductor provided so as to be unevenly distributed on one side surface of the convex portion of the concavo-convex structure are described. A wire grid polarizing plate having a wire grid in which the pitch and the height of the convex portions, which are the distances between two adjacent convex portions, are adjusted in a cross-sectional view in a direction perpendicular to the extending direction of the concave-convex structure. The polarizing plate is disclosed.

Japanese Unexamined Patent Publication No. 2018-72507 Japanese Unexamined Patent Publication No. 2008-83657 Japanese Unexamined Patent Publication No. 2017-173832

Generally, the temperature environment required for equipment used in a car is -40 to 105 ° C, but it should be used in a high temperature environment such as a head-up display mounted on the dashboard in a car in summer. Considering the above, high heat resistance and heat dissipation are required. However, the techniques of Patent Documents 1 to 3 are basically wire grid polarizing elements using a resin base material, and the wire grid polarizing plate itself does not have sufficient heat resistance and heat dissipation. In addition, the wire grit polarizing element using the above resin base material is generally used by adhering it to a glass base material using double-sided tape (OCA: Optically Clear Adhesive), but there is a problem of stray light due to the swell of the film base material. There was a problem that the polarizing film was warped due to heat and heat, and there was a demand for further improvement.

Further, in the wire grid polarizing element of Patent Document 3, since a grid-like uneven shape is formed on the surface of the base material at the time of manufacture, it is difficult to select a material in consideration of workability and heat dissipation, and the polarization characteristics are improved. There is also a problem that it is difficult to achieve both heat dissipation and heat dissipation.

Further, the conventional wire grid polarizing element has a problem that the uneven shape of the surface is generally formed by a photolithography technique or an etching technique, so that the manufacturing cost rises and it is not suitable for mass production.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a polarizing element and a method for manufacturing a polarizing element, which have good polarization characteristics and are excellent in heat dissipation and manufacturing cost. do. Another object of the present invention is to provide a head-up display device having excellent polarization characteristics and heat resistance.

As a result of intensive research to solve the above problems, the present inventors have formed a substrate of a polarizing element from a transparent inorganic material, and a grid structure having a concavo-convex structure formed on the surface of the substrate. It has been found that the heat dissipation effect can be improved while maintaining excellent polarization characteristics by configuring the base portion along the base portion and the protrusions protruding from the base portion in a grid pattern. Further, the above-mentioned grid structure has a base portion and a protrusion portion, which can be formed by a technique such as nanoimprinting, so that the manufacturing cost is lower than when the photolithography technique or the etching technique is used. We have found that it can be reduced and mass production is possible.

The present invention has been made based on the above findings, and the gist thereof is as follows.
(1) A substrate made of a transparent inorganic material and
A grid structure made of a transparent material and having a base portion provided along the surface of the substrate and protrusions protruding in a grid pattern from the base portion.
An optical functional film formed on the protrusions, which is an absorption film that absorbs light, a reflection film that reflects light, or a multilayer film having at least the absorption film and the reflection film.
A polarizing element, characterized in that it is provided with.
(2) The polarizing element according to (1) above, wherein the thickness of the base portion is 1 nm or more.
(3) The above (1), wherein the shape of the protrusion when viewed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element is rectangular, trapezoidal, polygonal or elliptical. ) Or (2).
(4) The polarizing element according to any one of (1) to (3) above, wherein the optical functional film is formed at least at the tip of the protrusion.
(5) The polarizing element according to any one of (1) to (4) above, wherein the optical functional film is not formed on the base portion.
(6) The polarizing element according to (4) or (5) above, wherein the optical functional film is formed on a tip of the protrusion and a part of a side surface of the protrusion.
(7) The optical functional film is characterized in that the optical functional film formed on a part of the side surface of the protrusion is formed in a range covering 10% or more of the height of the protrusion. The polarizing element according to (6) above.
(8) The polarizing element according to any one of (1) to (7) above, wherein the inorganic material constituting the substrate is different from the material constituting the grid structure.
(9) The polarizing element according to any one of (1) to (8) above, further comprising a protective film formed so as to cover at least the surface of the optical functional film.
(10) The polarizing element according to (9) above, wherein the protective film includes a water-repellent coating or an oil-repellent coating.
(11) The polarizing element according to any one of (1) to (10) above, wherein the optical functional film is composed of a multilayer film having at least the absorption film and the reflection film.
(12) The polarizing element according to (11) above, wherein the optical functional film further has a dielectric film between the reflective film and the absorbing film.
(13) A step of forming a grid structure material made of a transparent material on a substrate made of an inorganic material, and
A step of forming a grid structure having a base portion provided along the surface of the substrate and protrusions protruding in a grid pattern from the base portion by applying nanoimprint to the grid structure material.
A step of forming an absorption film that absorbs light, a reflection film that reflects light, or an optical functional film composed of a multilayer film having at least the absorption film and the reflection film is provided on the protrusion. A characteristic method for manufacturing a polarizing element.
(14) The polarizing element according to (13) above, wherein the step of forming the optical functional film is characterized by alternately forming a film on the protrusions from a plurality of directions by a sputtering or a thin film deposition method. Manufacturing method.
(15) A head-up display device including the polarizing element according to any one of (1) to (14) above.
(16) The head-up display device according to (15) above, wherein a heat radiating member is provided around the polarizing element.

According to the present invention, it is possible to provide a polarizing element and a method for manufacturing a polarizing element, which have good polarization characteristics and are excellent in heat dissipation and manufacturing cost. Further, according to the present invention, it is possible to provide a head-up display device having excellent polarization characteristics and heat resistance.

It is a figure which showed one Embodiment of the polarization element of this invention, (a) is the cross-sectional view which showed one Embodiment of the polarization element of this invention schematically, (b) is the polarization of this invention. It is a top view which shows one Embodiment of an element schematically. It is a figure which showed typically the example of the cross-sectional shape about the protrusion of the grid structure of the polarizing element of this invention. It is sectional drawing which shows one Embodiment of the polarizing element of this invention schematically. It is sectional drawing which shows one Embodiment of the polarizing element of this invention schematically. It is sectional drawing which shows one Embodiment of the polarizing element of this invention schematically. (A) is a cross-sectional view schematically showing one embodiment of the polarizing element of the present invention, and (b) is a cross-sectional view schematically showing another embodiment of the polarizing element of the present invention. .. It is a perspective view which shows one Embodiment of the polarizing element of this invention schematically. An embodiment of the polarizing element of the present invention is a photograph taken in a magnified manner using a scanning electron microscope (SEM). FIG. (C) shows a state in which (b) is further magnified and observed, and (d) shows a state in which (c) is further magnified and observed. It is a figure for demonstrating one Embodiment of the manufacturing method of the polarizing element of this invention, (a) is the state which formed the grid structure material on the substrate, (b) is the state which nanoimprint is formed on the grid structure material. In the applied state, (c) is a state in which a grid structure is formed on a substrate, and (d) is a state in which an optical functional film is formed on a protrusion of the grid structure, and further, the grid structure and the optical Indicates a state in which a protective film is formed on the surface of the functional film. It is a figure for demonstrating an example of the manufacturing method of the conventional polarizing element, (a) is a state in which a metal material and an optical functional film material are formed on a substrate, (b) is a resist on an optical functional film material. The state in which the mask is formed, (c) is the state after etching the metal material and the optical functional film material, (d) is the state after the resist mask is peeled off, and (e) is the state where the surface is protected. Indicates a state in which a film is formed. It is a figure which showed an example of the process of manufacturing the mold used for nanoimprint of a grid structure material, (a) is the state which formed the metal material on the substrate, (b) is the state which formed the resist mask on the metal material. The state (c) is the state after etching the metal material, (d) is the state after the resist mask is peeled off, and (e) is the release coating on the surface of the obtained mold. Indicates the formed state. It is sectional drawing which shows typically one Embodiment of the head-up display apparatus of this invention. It is sectional drawing which shows typically the other embodiment of the head-up display apparatus of this invention. 2 is a graph comparing the optical characteristics when the material of the grid structure is changed in Example 2. 2 is a graph comparing the optical characteristics when the thickness of the base portion of the grid structure is changed in the second embodiment. 2 is a graph comparing the optical characteristics when the height of the protrusions of the grid structure is changed in the second embodiment. It is a graph comparing the optical characteristics when the thickness of the absorption film formed on the protrusion is changed in Example 2. FIG. It is a graph which compared the optical property when the material of the absorption film formed on the protrusion is changed in Example 2. FIG. It is a graph which compared the optical characteristics when the width of the absorption film formed on the protrusion is changed in Example 2. FIG. It is a graph comparing the optical characteristics when the formation state of the absorption film formed on the protrusion is changed in an Example. It is a graph which compared the optical characteristics when the thickness of the reflective film formed on the protrusion is changed in an Example. (A) is a graph comparing the optical characteristics when the combination of films in the optical functional film formed on the protrusion is changed in the example, and (b) is the optical characteristics shown in (a). Of these, only the CR results are shown in an easy-to-understand manner. (A) is an enlarged photograph of the cross section of the polarizing element of the present invention actually produced by using a scanning electron microscope (SEM), and (b) is a photograph obtained by further magnifying a part of (a). It is a photograph shown in. In the example, it is a graph comparing the optical characteristics before and after the high temperature test injection. It is a figure which showed typically the example of the cross-sectional shape about the shape of the concave part between the protrusions in the base part of the grid structure of the polarizing element of this invention. It is sectional drawing which shows one Embodiment of the polarizing element of this invention schematically. (A) is the ratio of the range covering the protrusion (the ratio of the height range covered by the optical functional film to the height of the protrusion) of the reflective film formed on the tip and a part of the side surface of the protrusion in the embodiment. ) Is a graph comparing the optical characteristics when the above is changed, and (b) is a graph in which the height range covering the protrusion of the reflective film formed on the tip and a part of the side surface of the protrusion was changed in the embodiment. It is a graph which compared the contrast of the case.

Hereinafter, an embodiment of the polarizing element of the present invention and an embodiment of the head-up display of the present invention will be specifically described with reference to drawings as necessary. For convenience of explanation, some of the members disclosed in FIGS. 1 to 13 are schematically represented by a scale and a shape different from the actual ones.

<Polarizing element>
First, an embodiment of the polarizing element of the present invention will be described.
As shown in FIGS. 1A and 1B, the polarizing element of the present invention is made of a substrate 10 made of a transparent inorganic material and a base portion made of a transparent material and provided along the surface of the substrate 10. A grid structure 20 having a 21 and protrusions 22 protruding from the base portion 21 in a grid pattern, and a light absorbing film, a light reflecting film, or a light reflecting film formed on the protrusions 22. The polarizing element 1 includes an optical functional film 30 formed of a multilayer film having at least the absorbing film and the reflecting film.

The substrate 10 of the polarizing element 1 is made of an inorganic material having high thermal conductivity, and the grid structure 20 having a concavo-convex structure formed therein is provided along the surface of the substrate 10 with a base portion 21 and a base portion thereof. By having the protrusions 22 protruding from the 21 in a grid pattern, the grid structure 20 can be composed of the substrate 10 made of an inorganic material and the thin base portion 21, and an advantageous effect can be obtained in terms of thermal resistance value. It is possible to improve the heat dissipation effect while realizing excellent polarization characteristics. Further, as described above, the grid structure 20 has a base portion 21 and a protrusion portion 22, which can be formed by a technique such as nanoimprint. Therefore, a photolithography technique or an etching technique. It is possible to reduce the cost and complexity of manufacturing as compared with the case of using.
On the other hand, the conventional film-type organic polarizing plate uses a large amount of organic material, and the thickness of the substrate (base film), double-sided tape (OCA: Opticically Clear Adhesive), and grid structure becomes large. It is considered that the heat dissipation and heat resistance are inferior to those of the polarizing element.

Hereinafter, the constituent members of one embodiment of the polarizing element of the present invention will be described.
(substrate)
As shown in FIG. 1A, the polarizing element 1 of the present invention includes a substrate 10.
The substrate 10 is made of a transparent inorganic material. By using the inorganic material as the substrate 10, the thermal conductivity of the substrate 10 is increased, so that the heat dissipation of the polarizing element 1 can be improved.
In the present specification, "transparent" means that the transmittance of light having a wavelength belonging to the used band (visible light and infrared light band) is high, and for example, the transmittance of the light is 70% or more. Means that Since the polarizing element 1 uses a material that is transparent to light in the band used, it does not adversely affect the polarization characteristics of the polarizing element 1, the light transmission, and the like.

Examples of the material of the substrate 10 include various types of glass, quartz, quartz, sapphire, and the like. Among these, as the material of the substrate 10, a material having a thermal conductivity of 1.0 W / m · K or more is preferable, and a material having a thermal conductivity of 8.0 W / m · K or more is more preferable. This is because better heat dissipation can be obtained.

The shape of the substrate 10 is not particularly limited, and can be appropriately selected depending on the performance required for the polarizing element 1. For example, it can be configured to have a plate shape or a curved surface. Further, the surface of the substrate 10 can be made a flat surface from the viewpoint of not affecting the polarization characteristics of the polarizing element 1.
Further, the thickness TS of the substrate 10 is not particularly limited, and may be, for example, in the range of 0.3 to 10.0 mm.

(Grid structure)
In the first embodiment of the polarizing element of the present invention, as shown in FIG. 1A, a base portion 21 made of a transparent material on the substrate 10 and provided along the surface of the substrate 10 and the base thereof. A grid structure 20 having protrusions 22 protruding from the portion 21 in a grid pattern is further provided.
The grid structure 20 can obtain desired polarization characteristics by providing the optical functional film 30 described later on the lattice-shaped protrusions 22 formed on the surface of the grid structure 20.

When the optical functional film 30 described later has absorption performance, a part of the light incident from the surface on which the protrusion 22 of the grid structure 20 is formed is absorbed when passing through the optical functional film 30. Being attenuated. Further, when the optical functional film 30 has a reflection performance, a part of the incident light is reflected when passing through the optical functional film 30. Of the light transmitted through the optical functional film 30, the light having an electric field component in the direction (transmission axis direction) orthogonal to the longitudinal direction (absorption axis direction or reflection axis direction) of the protrusion 22 has a high transmittance and the polarizing element 1 Is transparent. On the other hand, most of the light transmitted through the optical functional film 30 having an electric field component in the direction parallel to the longitudinal direction of the protrusion 22 (absorption axis direction or reflection axis direction) is reflected by the optical functional film 30. And / or absorbed. Therefore, in the first embodiment of the polarizing element of the present invention, a single polarized light can be created by providing the grid structure 20 on which the optical functional film 30 described later is formed. It should be noted that this polarization effect has the same effect on the incident light from the back surface side of the substrate 10.

The grid structure 20 has a base portion 21 as shown in FIG. 1 (a). The base portion 21 is a portion provided along the surface of the substrate 10 for supporting the protrusion 22. It is inevitably formed when the uneven shape (projection portion 22) of the grid structure 20 is formed by nanoimprint or the like. Further, since the base portion 21 is formed in the grid structure 20, the strength of the protrusion 22 can be increased as compared with the case where the protrusion 22 is directly formed on the substrate 10. The durability of the grid structure 20 can be enhanced, and further, since the base portion 21 is in close contact with the substrate 10 over the entire surface, the peel resistance of the grid structure 20 can be enhanced.

The thickness TB of the base portion 21 is not particularly limited, but is preferably 1 nm or more, preferably 10 nm or more, from the viewpoint of more reliably supporting the protrusion 22 and easy imprint molding. The above is more preferable. Further, from the viewpoint of ensuring good heat dissipation, the thickness TB of the base portion 21 is preferably 50 μm or less, and more preferably 30 μm or less.

Further, the grid structure 20 has a protrusion 22 protruding from the base 21 as shown in FIGS. 1A and 1B. As shown in FIG. 1B, the protrusions 22 extend in the absorption axis direction or the reflection axis direction of the polarizing element 1 of the present invention as the longitudinal direction, and the presence of a plurality of protrusions 22 results in a lattice. It has a shape.

Here, as shown in FIGS. 1A and 1B, the formation interval P of the protrusions 22 when observed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element 1 is the used band. It needs to be shorter than the wavelength of light. This is to obtain the above-mentioned polarization action. More specifically, the formation interval P of the protrusions 22 is preferably 50 to 300 nm, preferably 100 to 200 nm, from the viewpoint of compatibility between the ease of manufacturing the protrusions 22 and the polarization characteristics. More preferably, it is particularly preferably 100 to 150 nm.

Further, as shown in FIGS. 1A and 1B, the width W of the protrusion 22 when observed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element 1 is not particularly limited. From the viewpoint of achieving both ease of manufacture and polarization characteristics, it is preferably about 20 to 150 nm, and more preferably about 30 to 100 nm.
The width W of the protrusion 22 can be measured by observing with a scanning electron microscope or a transmission electron microscope. In the present invention, a scanning electron microscope or a transmission electron microscope is used to observe a cross section of the polarizing element 1 orthogonal to the absorption axis direction or the reflection axis direction, and the center position of the height H with respect to any four protrusions 22. The width in the above can be measured, and the arithmetic average value thereof can be defined as the width W of the protrusion 22.

Further, as shown in FIG. 1A, the height H of the protrusion 22 when observed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element 1 is not particularly limited, but is easy to manufacture. From the viewpoint of achieving both properties and polarization characteristics, it is preferably about 50 to 300 nm, and more preferably about 100 to 250 nm.
The height H of the protrusion 22 can be measured by observing with a scanning electron microscope or a transmission electron microscope. In the present invention, a scanning electron microscope or a transmission electron microscope is used to observe a cross section of the polarizing element 1 orthogonal to the absorption axis direction or the reflection axis direction, and at any four positions at the center position of the width W of the protrusion 22. The height can be measured, and the arithmetic average value thereof can be defined as the height H of the protrusion 22.

The shape of the protrusion 22 of the grid structure 20 is not particularly limited except that it protrudes from the base 21 in a grid pattern in order to obtain polarization characteristics.
As a shape when observing a cross section of the polarizing element 1 orthogonal to the absorption axis direction or the reflection axis direction, for example, as shown in FIG. 2, a rectangular shape, a trapezoidal shape, a triangular shape, a bell shape, or the like can be provided. By having these shapes, it is easy to form the optical functional film 30 on the protrusion 22, and it is possible to impart polarization characteristics to the polarizing element 1, and since these shapes can also be formed by nanoimprint, it is easy to manufacture. It is also advantageous in terms of. Further, the shape of the recesses formed between the protrusions 22 protruding in a grid pattern of the base portion 21 can also be rectangular, trapezoidal, triangular, bell-shaped or the like as shown in FIG. For these shapes, the optimum shape can be appropriately selected in consideration of productivity such as releasability at the time of nanoimprint formation.

The material constituting the grid structure 20 is not particularly limited as long as it is a transparent material, and known organic materials and inorganic materials can be used.
For example, from the viewpoint of ensuring transparency and excellent manufacturability, various thermosetting resins, various ultraviolet curable resins, glass (spin-on glass: SOG), etc. are used in the grid structure 20. It is preferably used as a material.

Further, the material constituting the grid structure 20 may be the same material as that of the substrate 10, or a different material may be used. However, from the viewpoint of ease of manufacture and production cost, it is preferable that the materials constituting the grid structure are different. In addition, when the materials of the grid structure 20 and the substrate 10 are different, the refractive indexes of the two are different, so that the refractive index of the entire polarizing element 1 can be easily adjusted.

The method for forming the grid structure 20 is not particularly limited as long as it can form the base portion 21 and the protrusion 22 described above. For example, photolithography or a method of forming irregularities by imprint can be used.
Among these, from the point that the uneven pattern can be easily formed in a short time and the base 21 can be reliably formed, the base portion 21 and the protrusion 22 of the grid structure 20 are formed by imprinting. Is preferable.

When the base portion 21 and the protrusion 22 of the grid structure 20 are formed by the nanoimprint, for example, a material for forming the grid structure 20 (grid structure material) is applied onto the substrate 10. After that, the mold having the unevenness formed is pressed against the grid structure material, and in that state, ultraviolet rays are irradiated or heat is applied to cure the grid structure material. As a result, the grid structure 20 having the base portion 21 and the protrusions 22 can be formed.

(Optical functional film)
In the first embodiment of the polarizing element of the present invention, as shown in FIG. 1A, an absorption film that absorbs light and a reflection film that reflects light, which are formed on the protrusion 22 of the grid structure 20. Alternatively, an optical functional film 30 made of a multilayer film having at least the absorbing film and the reflecting film is further provided.
The multilayer film 30 can impart desired polarization characteristics to the polarizing element 1 by absorbing and / or reflecting a part of the incident light.

As shown in FIG. 1A, the reflective film constituting the optical functional film 30 is formed on the protrusion 22 of the grid structure 20, so that the light incident on the polarizing element 1 is described as described above. Light having an electric field component can be reflected in a direction parallel to the longitudinal direction of the protrusion 22 (reflection axis direction).

The material constituting the reflective film is not particularly limited as long as it is a material having reflectivity to light in the band of use. Examples thereof include elemental elements such as Al, Ag, Cu, Mo, Cr, Ti, Ni, W, Fe, Si, Ge and Te, and alloys containing one or more of these elements.

As shown in FIG. 1A, the absorption film constituting the optical functional film 30 is formed on the protrusion 22 of the grid structure 20, so that the light incident on the polarizing element 1 is described as described above. Light having an electric field component can be absorbed in a direction parallel to the longitudinal direction of the protrusion 22 (absorption axis direction). The absorbed light is converted into heat and dissipated through the substrate 10 described above.

The material constituting the absorption film is not particularly limited as long as it is a material capable of absorbing light in the band of use. For example, those including a dielectric material and a non-dielectric material can be mentioned.

Examples of the dielectric material include oxides of elements such as Si, Al, Be, Bi, Ti, Ta, and B; nitrides of elements such as Si and B; fluorides of elements such as Mg and Ca; Si, Ge, carbon, cryolite and the like can be mentioned. These dielectric materials may be used alone or in combination of two or more. When two or more kinds of dielectric materials are used in combination, two or more kinds of dielectric materials may be mixed and used, or different dielectric materials may be used in the film thickness direction.

Examples of the non-dielectric material include simple substances (excluding Si simple substances) or alloys of at least one element selected from the group consisting of Fe, Ta, Si, Ti, Mg, W, Mo, and Al. Can be mentioned. Examples of the alloy include FeSi alloy and TaSi alloy. The Fe content of the FeSi alloy is preferably 50 atm% or less, more preferably 10 atm% or less, from the viewpoint of reflectance and transmittance. The Ta content of the TaSi alloy is preferably 40 atm% or less from the viewpoint of reflectance and transmittance. These non-dielectric materials may be used alone or in combination of two or more. When two or more types of non-dielectric materials are used in combination, two or more types of non-dielectric materials may be mixed and used, or non-dielectric materials different in the film thickness direction may be used.

Among these, it is preferable that the dielectric material contains at least one of Si and Si oxide (for example, silica), and the non-dielectric material contains a metal. Examples of the metal include simple substances of at least one metal selected from the group consisting of Fe, Ta, W, Mo, and Al, or alloys of the metals. By combining at least one of Si and Si oxide with a metal to form a cermet, the heat resistance of the absorption film tends to be further improved.

Further, the content of the non-dielectric material in the absorption film can be changed in the film thickness direction. Due to such changes, the optical characteristics of the polarizing element 1 tend to be improved. Further, the wavelength at the minimum point of the absorption shaft reflectance Rs can be adjusted by adjusting the change mode of the content of the non-dielectric material.

Further, the multilayer film constituting the optical functional film 30 is a film including at least both the above-mentioned reflective film and the absorbing film. By using a multilayer film as the optical functional film 30, it is possible to obtain more excellent polarization characteristics by having both the effects of light reflection by the reflection film and light absorption by the absorption film.

The multilayer film may have a two-layer structure of the reflection film and the absorption film, and may further have a three-layer structure having a dielectric film between the reflection film and the absorption film. can.
When the dielectric film is provided, it is preferable that the dielectric film is formed with a film thickness that allows the incident light to pass through the absorption film and the phase of the polarized light reflected by the reflection film is shifted by half a wavelength. .. The specific film thickness is appropriately set in the range of 1 to 500 nm, which can adjust the phase of polarized light and enhance the interference effect.

Further, as the material of the dielectric film, general materials such as _{SiO 2} , Al ₂ O ₃ , and Mg F _{2 can be used.} Further, the refractive index of the dielectric film is preferably larger than 1.0 and 2.5 or less. Since the optical characteristics of the absorption film are also affected by the refractive index of the surroundings, the polarization characteristics may be controlled by the material of the dielectric film.

As shown in FIG. 3, the optical functional film 30 is preferably formed at least at the tip of the protrusion 22.
By forming the optical functional film 30 at the tip of the protrusion 22, the above-mentioned light reflecting action and light absorbing action can be more reliably exhibited, and the polarization performance of the entire polarizing element 1 can be further enhanced. Because it can be done.

Further, as shown in FIG. 3, it is preferable that the optical functional film 30 is not formed on the base portion 21. This is because when the optical functional film 30 is formed on the base portion 21, the transmission of light is hindered, which may lead to deterioration of the polarization characteristics of the polarizing element 1.

Here, in order to form the optical functional film 30 not on the base portion 21 of the grid structure 20 but on the tip of the protruding portion 22, as shown in FIG. 3, the optical functional film 30 is formed. It is preferable to perform sputtering or vapor deposition on the protrusion 22 of the grid structure 20 from an oblique direction. As a result, the optical functional film 30 can be formed only at the tip of the protrusion 22. Specifically, the angle θ of sputtering and vapor deposition for forming the optical functional film 30 is set to about 5 to 70 ° with respect to the surface of the substrate 10.

By forming the optical functional film 30 by sputtering or a vapor deposition method after forming the grid structure 20 made of a transparent material in this way, the film forming conditions, materials, and film thickness can be easily changed. be able to. Further, since it is possible to easily cope with the case where the optical functional film 30 is a multilayer film, it is possible to design a film utilizing the interference effect by combining a metal, a semiconductor, and a dielectric, as in the prior art. When forming the optical functional film 30, it is not necessary to consider the material composition that can be etched. Thereby, it is possible to easily adjust the absorption rate (attenuation amount) of the polarized wave parallel to the grid structure 20 and the transmittance (transmission amount) of the polarized wave perpendicular to the grid structure 20. Become. In addition, by forming the optical functional film 30 after forming the grid structure 20, equipment such as a vacuum dry etching apparatus is not required, and a gas or abatement apparatus suitable for a complicated process or etching material is not required. Since it is not necessary to prepare such safety devices, running costs such as capital investment and maintenance can be reduced, and cost benefits can be obtained.

As for the formed state of the optical functional film 30, for example, as shown in FIG. 3, the optical functional film 30 can be formed only at the tip of the protrusion 22 of the grid structure 20.
Further, as shown in FIG. 4, when the optical functional film 30 is formed by sputtering from an oblique direction with respect to the protrusion 22 of the grid structure 20, among the tips of the protrusion 22, the tip of the protrusion 22 is sputtered. Many of the optical functional films 30 are formed on the irradiation source side.
Further, as shown in FIG. 5, the optical functional film 30 may be in a formed state so as to cover not only the tip of the protrusion 22 of the grid structure 20 but also a part of the side surface.

The optical functional film 30 is formed on a part of the tip and a side surface of the protrusion 22 of the grid structure 20, as shown in FIGS. 5 and 26, from the viewpoint of obtaining better contrast. Is preferable. By covering not only the tip of the protrusion 22 but also the side surface of the optical functional film 30, the absorption performance and / or the reflection performance of the polarizing element is enhanced, and as a result, a better contrast can be obtained.
As a condition for forming the optical functional film 30, for example, as shown in FIG. 26, the optical is formed by alternately performing sputtering or vapor deposition on the protrusions 22 of the grid structure 20 from a plurality of directions. The functional film 30 can be formed on the tip and a part of the side surface of the protrusion 22 of the grid structure 20.

When the optical functional film 30 is formed on the tip and side surfaces of the protrusion 22, it is preferable that the optical functional film 30 is not formed on the base 21 of the grid structure 20. This is to maintain excellent transparency. Further, as shown in FIG. 4, the optical functional film 30 may be formed only on one side surface of the protrusion 22 when viewed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element. However, from the viewpoint that more excellent polarization characteristics can be obtained regardless of the direction of the incident light, it is preferable that the projection portion 22 is formed so as to cover both side surfaces thereof.

Further, as shown in FIG. 26, the optical functional film 30 formed on a part of the side surface of the protrusion 22 is formed in a range covering 10% or more of the height H of the protrusion 22 ( HX: Height range in which the optical functional film covers the protrusions ÷ H: Height of the protrusions × 100% ≧ 10%) is more preferable. This is because the optical functional film 30 covers 10% or more of the height H of the protrusions, so that even more excellent contrast can be realized.

The thickness of the optical functional film 30 is not particularly limited, and can be appropriately changed depending on the shape of the grid structure 20, the performance required for the optical functional film 30, and the like.
For example, when the optical functional film 30 is an absorbing film, it can be 5 to 100 nm. Further, when the optical functional film 30 is a reflective film, it can be set to 5 to 200 nm. Further, when the optical functional film 30 is a multilayer film, it can be set to 10 to 400 nm.

(Other parts)
In the first embodiment of the polarizing element of the present invention, members other than the substrate 10, the grid structure 20, and the optical functional film 30 described above may be further provided.

For example, in the first embodiment of the polarizing element of the present invention, as shown in FIGS. 6A and 6B, a protective film 40 formed so as to cover at least the surface of the optical functional film 30 is further provided. Is preferable.
By forming the protective film 40, it is possible to further improve the flaw resistance, stain resistance, and waterproofness of the polarizing element.

Further, it is more preferable that the protective film 40 further includes a water-repellent coating or an oil-repellent coating. This is because the antifouling property and the waterproof property of the polarizing element can be further improved.

The material constituting the protective film 40 is not particularly limited as long as it can improve the flaw resistance, antifouling property, and waterproof property of the polarizing element.
For example, a film made of a dielectric material can be mentioned, and more specifically, an inorganic oxide, a silane-based water repellent material, and the like can be mentioned. Examples of the inorganic oxide include Si oxide and Hf oxide, and the silane-based water-repellent material may contain a fluorine-based silane compound such as perfluorodecyltriethoxysilane (FDTS). , Octadecyltrichlorosilane (OTS) and other non-fluorinated silane compounds may be contained.
Among these materials, it is more preferable to contain at least one of the inorganic oxide and the fluorine-based water repellent material. When the protective film 40 contains the inorganic oxide, the flaw resistance of the polarizing element can be further enhanced, and when the protective film 40 contains the fluorine-based water repellent material, the antifouling property and waterproof property of the polarizing element can be improved. Can be enhanced.

The protective film 40 may be formed so as to cover at least the surface of the optical functional film 30, and as shown in FIG. 6A, the surfaces of the grid structure 20 and the optical functional film 30. It is more preferable that it is formed so as to cover the above. Further, as shown in FIG. 6B, it may be formed so as to cover the entire polarizing element 1.

Further, in the first embodiment of the polarizing element of the present invention, as shown in FIG. 7, it is preferable that the heat radiating member 50 is provided so as to cover the substrate 10. This is because the heat from the substrate 10 can be released more efficiently.
Here, the heat radiating member 50 is not particularly limited as long as it is a member having a high heat radiating effect. Examples thereof include radiators, heat sinks, heat spreaders, die pads, heat pipes, metal covers, housings and the like.

Here, FIG. 8 is an enlarged photograph of the actually produced polarizing element of the present invention using a scanning electron microscope (SEM).
From FIG. 8A, it can be seen that the grid structure 20 having the grid-like protrusions 22 is formed on the substrate 10. Further, from FIGS. 8 (b) and 8 (c), the grid structure 20 is formed with a base portion 21 provided along the surface of the substrate 10 and a protrusion 22 protruding from the base portion 21. You can see that. Further, from FIG. 8D, it can be seen that the optical functional film 30 made of an absorbing film is formed at the tip of the protrusion 22.

<Manufacturing method of polarizing element>
Next, a method for manufacturing the polarizing element of the present invention will be described.
In the method for manufacturing a polarizing element of the present invention, as shown in FIGS. 9A to 9D, a grid structure material 23 made of a transparent material is formed on a substrate 10 made of an inorganic material (FIG. 9A). )) Process and
By applying nanoimprint to the grid structure material 23 (FIG. 9B), it has a base portion 21 provided along the surface of the substrate 10 and a protrusion 22 protruding from the base portion 21 in a grid pattern. The step of forming the grid structure 20 (FIG. 9 (c)) and
An optical functional film 30 formed of an absorbing film that absorbs light, a reflective film that reflects light, or a multilayer film having at least the absorbing film and the reflective film is formed on the protrusion 22 (FIG. 9 (d)). )) It is characterized by including a process.
By going through the above-mentioned steps, it is possible to manufacture the polarizing element 1 having excellent polarization characteristics and heat dissipation without causing an increase in cost and complexity of manufacturing.

On the other hand, in the conventional method for manufacturing a wire grid polarizing element, as shown in FIGS. 10A to 10E, in order to produce a convex grit shape, a substrate 10 made of an inorganic material such as glass is made of aluminum or the like. The metal film 80 is formed into a film by sputtering or vapor deposition, and the optical functional film material layer 31 made of a material or the like that absorbs light in the used band is formed by lamination on the metal film 80 by sputtering or thin film deposition. (Fig. 10 (a)). Then, the resist mask 70 is patterned using a photolithography technique (FIG. 10 (b)). After that, the optical functional film material layer 31 and the metal film 80 are etched by a vacuum dry etching apparatus or the like to form a convex shape composed of the metal film 80 and the optical functional film 30 (FIG. 10 (c)). For example, at this time, if the etching selectivity of the resist mask 70 and the optical functional film material layer 31 / metal film 80 cannot be obtained, an oxide film such as _{SiO 2 is further sputtered on the optical functional film material layer 31.} A film is formed, and a resist mask 70 is formed on the film by a photolithography technique. Then, after the resist mask 70 is peeled off (FIG. 10 (d)), a SiO ₂ film or the like is formed as a protective film 40 by CVD or the like, and water-repellent / oil-repellent coating treatment is also performed as necessary.
Incidentally, although the process of making the absorptive wire grid polarizer of FIG. 10 (a) ~ (e) in basic configuration, or via a dielectric film of SiO ₂ or the like between the metal film and the absorbing layer, Considering the case where the absorbing layer is a multilayer film, a more complicated process is required. Therefore, it can be inferred that the conventional wire grid polarizing element manufactured by the process as shown in FIGS. 10A to 10E increases the cost and time required for manufacturing and becomes expensive. In addition, when mass-producing polarizing elements, it is necessary to prepare a plurality of high-precision and expensive etching devices and photolithography devices for forming a convex shape smaller than the wavelength of light according to the production volume. , Capital investment is also expected to be higher.

As the substrate 10 made of an inorganic material used in the method for manufacturing a polarizing element of the present invention, the same substrate 10 as described in the above-described polarizing element of the present invention can be used.

Further, in the method for manufacturing a polarizing element of the present invention, the grid structure material 23 formed on the substrate 10 is a material used in the grid structure 20 described in the above-described polarizing element of the present invention. The same as the above can be used.

Further, the film thickness of the grid structure material 23 can be appropriately adjusted according to the dimensions of the base portion 21 and the protrusion portion 22 of the grid structure 20 formed by nanoimprint.

In the method for manufacturing a polarizing element of the present invention, nanoimprint is applied to the grid structure material 23 (FIG. 9B), but the conditions for nanoimprint are not particularly limited.
For example, as shown in FIG. 9B, imprinting is performed by subjecting the grid structure material 23 to UV irradiation, heating, or the like while performing nanoimprinting using a replica master (or this type master). By releasing the replica master after curing in this state, the grit structure 20 on which the base portion 21 and the protrusion 22 are formed can be transfer-molded.

The master used for the nanoimprint can be manufactured by a photolithography technique, for example, as shown in FIGS. 11A to 11E.
First, a metal film 62 for the master is formed on the base material 61 for the master (FIG. 11 (a)), a resist mask 70 is formed (FIG. 11 (b)), and the metal film 62 for the master is etched. (Fig. 11 (c)). By peeling off the resist mask 70 after etching, a master 60 having a master base material 61 and a master convex portion 63 can be obtained (FIG. 11 (d)).
Further, the master 60 may further include a release film coat 64, if necessary (FIG. 11 (e)). By providing the release film coat 64, the release can be performed more easily after nanoimprinting is applied to the grid structure material 23 (FIG. 9 (b)).

Further, in the method for manufacturing a polarizing element of the present invention, the aspect of the optical functional film 30 formed on the protrusion 22 is the same as that of the optical functional film 30 described in the above-described polarizing element of the present invention. Can be.

As shown in FIG. 9D, the method for manufacturing a polarizing element of the present invention is a protective film 40 formed so as to cover the surfaces of the grid structure 20 and the optical functional film 30 as needed. Can be further formed.
The mode of the protective film can be the same as that of the protective film 40 described in the above-described polarizing element of the present invention.

<Head-up display device>
Next, an embodiment of the head-up display device of the present invention will be described.
As shown in FIG. 12, embodiment 100 of the head-up display device of the present invention includes the above-described polarizing element 1 of the present invention.
By providing the polarizing element 1 of the present invention in the head-up display device 100, the polarization characteristics and heat resistance can be improved. Since the head-up display incorporating the conventional polarizing element is inferior in heat dissipation, it is considered that the heat resistance is not sufficient in consideration of long-term use and future high-brightness / enlarged display.

Further, in the 100th embodiment of the head-up display device of the present invention, the arrangement position of the polarizing element 1 is not particularly limited. For example, as shown in FIG. 12, a light source 2, a display element 3 that emits a display image, and a reflector 4 that reflects the display image onto a display surface 5 are provided, and the polarizing element 1 is converted into the display element. It can be provided between 3 and the reflector 4.
By using the polarizing element 1 of the present invention as a pre-polarizing plate placed in front of the display element 3, the display image emitted from the display element 3 is transmitted, and sunlight is suppressed from being incident on the display element 3. Therefore, the heat resistance and durability of the head-up display can be further improved.

In the 100th embodiment of the head-up display device of the present invention, as shown in FIG. 12, the display element 3 is, for example, a transmissive liquid crystal panel in which a liquid crystal is sealed in a pair of substrates transparent to light in the used band. There are polarizing elements (not shown) attached before and after this. The polarization axes of the polarizing elements before and after the bonding are orthogonal to each other. A display image can be emitted by arranging a light source 2 such as an LED behind the display element 3 (on the side opposite to the emission direction of the display image) and illuminating the display element 3.
The polarizing element 1 arranged on the front side of the display element 3 (front of the emission direction of the display image) is arranged so that the polarizing element attached to the front side of the display element 3 and the polarizing axis are in the same direction for display. The display image emitted from the element 3 is transmitted. The display image transmitted through the polarizing element 1 is reflected by a mirror (reflector 4) arranged at an angle of about 45 ° with respect to the display element 3, and is emitted to the windshield surface (display surface 5) to display the display image. Is visually recognized as a virtual image by the driver (person). Each member constituting these head-up display devices is housed in a housing.

Further, in the 100th embodiment of the head-up display device of the present invention, as shown in FIG. 13, it is preferable that the heat radiating member 50 is provided around the polarizing element 1. This is because the heat of the polarizing element 1 can be released more efficiently and the heat resistance of the apparatus can be further improved.
Here, the heat radiating member 50 is the same as the heat radiating member 50 described in the polarizing element 1 of the present invention described above.

The configuration of the head-up display device 100 shown in FIGS. 12 and 13 is a minimum and basic configuration, and each member constituting the head-up display device of the present invention is limited to FIGS. 12 and 13. Other members may be provided as appropriate according to the required performance and the like.

In addition, in the head-up display device of the present invention, as described above, the arrangement position of the polarizing element 1 is not particularly limited, and depending on the configuration of the head-up display device and the required performance. It can be selected as appropriate.
For example, although not shown, the polarizing element 1 can be provided between the display element 3 and the light source 2.
Further, although not shown, the polarizing element 1 can be incorporated in the reflector 4.
Further, the cover portion 6 provided in the head-up display device may be composed of the polarizing element 1.

Next, the present invention will be specifically described based on examples. However, the present invention is not limited to the following examples.

<Example 1>
As shown in FIG. 6B, a substrate 10 made of glass, a base portion 21 made of an ultraviolet curable resin (acrylic resin), and a base portion 21 and a base portion 21 provided along the surface of the substrate 10. An optical functional film 30 made of a grid structure 20 having protrusions 22 protruding in a grid pattern from the above, an optical functional film 30 formed on the protrusions 22 and a Ge absorbing film that absorbs light, and a protective film made of _{SiO 2.} A model of the polarizing element 1 provided with 40 and 40 was produced.
Then, with respect to the produced model of the polarizing element 1, the conditions of the grid structure 20 and the optical functional film 30 are changed as shown in (1) to (9) below, and the optical characteristics for light having a wavelength of 430 to 680 nm ( Transmission axis transmittance: Tp, absorption axis transmittance: Ts, transmission axis reflectance: Rp, absorption axis reflectance: Rs, contrast: CR) were evaluated.
The optical characteristics of the prepared model were verified by electromagnetic field simulation by the RCWA (Rigorous Coupled Wave Analysis) method. For the simulation, a grating simulator Gsolver manufactured by Grating Solver Development was used.

(1) Types of materials for the grid structure Regarding the model of the polarizing element 1, the material of the grid structure 20 is _{the case where SiO 2} made of SOG is used, and the case where the UV curable resin is polymethyl methacrylate resin (PMMA). The average values of the optical characteristics (Tp, Rp, Ts, Rs, CR) for wavelengths of 430 to 680 nm were plotted and compared. The comparison result is shown in FIG.

From the results of FIG. 14, it was confirmed that the same characteristics can be obtained regardless of whether the _{grid structure 20 is formed of SiO 2 or PMMA.} From this result, by forming the grid structure 20 with a material that is transparent to the light in the band used, the same characteristics can be obtained for both inorganic and organic materials, so the required characteristics, reliability, and mass productivity are taken into consideration. It can be seen that the material can be appropriately selected.

(2) Thickness of base portion of grid structure For the model of the polarizing element 1, optical characteristics (Tp, Rp, Ts,) for wavelengths of 430 to 680 nm when the thickness TB of the base portion 21 of the grid structure 20 is changed. The average values of Rs and CR) were plotted and compared. The comparison result is shown in FIG.

From the results of FIG. 15, it was confirmed that the thickness TB of the base portion 21 was changed from 0 nm to 30,000 nm at regular intervals, but even if the thickness of the base portion 21 was changed, the effect on the polarization characteristics was small. However, it was found that when the thickness of the base portion 21 exceeds 30,000 nm (30 μm), the characteristics of Tp and Ts change. From this result, it is necessary that the thickness of the base portion 21 can be appropriately adjusted within a certain range according to the reliability including adhesion, and that severe process control such as control of the base layer in the mass production process is required. It can be seen that the cost merit can be obtained.

(3) Height of Protrusions of Grid Structure For the model of the polarizing element 1, optical characteristics for wavelengths of 430 to 680 nm when the height H protruding from the base 21 of the protrusions 22 of the grid structure 20 is changed. The average values of (Tp, Rp, Ts, Rs, CR) were plotted and compared. The comparison result is shown in FIG.

From the result of FIG. 16, it was confirmed that the height of the protrusion 22 was changed from 20 nm to 400 nm at a certain interval, but there was almost no effect on the polarization characteristics. From this result, by forming the protrusion 22 with a material that is transparent to the light in the band used, it is not necessary to perform severe process control such as controlling the height H of the protrusion 22, and the protrusion is considered in consideration of mass productivity. It can be seen that the lower the height H of the portion 22, the easier it is to manufacture, and the greater the merit even when the yield and reliability are taken into consideration.

(4) Thickness of Absorption Film For the model of the polarizing element 1, when the thickness of the absorption film as the optical functional film 30 (the thickness of the thickest part of the absorption film adhering to the protrusion 22) is changed. , The average values of the optical characteristics (Tp, Rp, Ts, Rs, CR) for wavelengths of 430 to 680 nm were plotted and compared. The comparison result is shown in FIG.

From the results of FIG. 17, it was confirmed that when the thickness of the absorbing film was changed from 10 nm to 50 nm at a certain interval, the polarization characteristics changed. Therefore, after forming the grid structure 20 with a material transparent to the light in the used band, an absorbing film is formed and the thickness of the absorbing film is controlled to control the optical characteristics, particularly Rs and Ts. It can be seen that it is possible to optimize the polarization characteristics according to the customer's needs by controlling only the thickness of the absorption film.

(5) Types of Absorbent Film Material For the model of the polarizing element 1, the optical characteristics of the absorbent film material as the optical functional film 30 for wavelengths of 430 to 680 nm when Ge is used and when FeSi is used. The average values of Tp, Rp, Ts, Rs, and CR) were plotted and compared. The comparison result is shown in FIG.

From the results shown in FIG. 18, it was confirmed that the polarization characteristics were changed by changing the type of the material of the absorbing film. Therefore, after forming the grid structure 20 with a material transparent to the light in the used band, an absorbing film is formed, and the optical characteristics, particularly Rs and Ts, are controlled by changing the type of the absorbing film. It can be seen that it is possible to optimize the polarization characteristics according to the customer's needs by selecting the material of the absorption film. Further, it can be inferred that the interference effect can be utilized and the polarization characteristics can be further optimized by forming a multilayer structure in which a metal, a semiconductor, and a dielectric are combined.

(6) Width of Absorption Film For the model of the polarizing element 1, the width parallel to the transmission axis of the incident light of the optical functional film 30 formed on each protrusion 21 of the grid structure 20 (that is, the longitudinal direction of the grid structure). The average values of the optical characteristics (Tp, Rp, Ts, Rs, CR) when the width in the direction orthogonal to the above was changed were plotted and compared. The comparison result is shown in FIG.

From the results of FIG. 19, it was confirmed that the polarization characteristics were changed by changing the width of the absorbing film. Therefore, after forming the grid structure 20 with a material transparent to the light in the used band, an absorption film is formed, and the film formation width of the absorption film is changed to change the optical characteristics, particularly Rs, Rp and Tp. It can be seen that it is possible to optimize the polarization characteristics according to the customer's needs by selecting the material of the absorption film.

(7) Forming State of Absorption Film When the absorption film as shown in FIG. 3 is formed only at the tip of the protrusion 22 in the model of the polarizing element 1, the absorption film as shown in FIG. 4 is formed at the tip of the protrusion 22. Optical characteristics (Tp, Rp, Ts, Rs) when the absorption film is thickly formed on one side, when the absorption film as shown in FIG. 5 is thickly formed on both sides of the tip of the protrusion 22, and when the formation state is changed. , CR) were plotted and compared. The comparison results are shown in FIG.

From the results of FIG. 20, it was confirmed that the polarization characteristics changed by changing the way the absorbing film was attached to each protrusion 21 of the grid structure 20. Therefore, the optical characteristics, especially Rs and Ts, can be controlled by changing the angle θ of sputtering in the oblique direction or by performing sputtering from both sides, and optimization can be performed according to the polarization characteristics of the customer's needs. It can be seen that it is.

Then, from the results of FIGS. 17 to 20, the grid structure 20 is formed of a material transparent to the light in the band used, and an absorption film is formed on the grid structure 20 to form an absorption film (material, thickness). , The film formation width, the state of formation at the tip of the protrusion, etc.), it can be seen that the polarization characteristics can be adjusted according to the customer's needs. Similarly, it can be seen that desired polarization characteristics can be obtained by forming and controlling a reflective film or a multilayer film.

(8) Thickness of Reflective Film For the model of the polarizing element 1, when the thickness of the reflective film as the optical functional film 30 (the thickness of the thickest part of the reflective film attached to the protrusion 22) is changed. , The average values of the optical characteristics (Tp, Rp, Ts, Rs, CR) for wavelengths of 430 to 680 nm were plotted and compared. The comparison result is shown in FIG.

From the results of FIG. 21, it was confirmed that when the thickness of the reflective film was changed from 30 nm to 100 nm at a certain interval, the polarization characteristics changed. Therefore, after forming the grid structure 20 with a material transparent to the light in the used band, a reflective film is formed and the thickness of the reflective film is controlled to control the optical characteristics, particularly Rs and Ts. It can be seen that it is possible to optimize the polarization characteristics according to the customer's needs by controlling only the thickness of the reflective film.

(9) Height range in which the reflective film covers the protrusions With respect to the model of the polarizing element 1, the range of the reflective film formed on the tip and side surfaces of the protrusions 22 as the optical functional film 30 (of the protrusions). Plot the average value of the optical characteristics (Tp, Rp, Ts, Rs, CR) for wavelengths of 430 to 680 nm when the ratio (%) of the height range HX covered with the optical functional film to the height H is changed. And compared. Among the comparison results, Tp, Rp, Ts, and Rs are shown in FIG. 27 (a), and the contrast is shown in FIG. 27 (b).
From the results of FIG. 27, it was found that when the ratio (HX / H) of the reflective film covering the side surface of the protrusion 22 is increased, the contrast characteristic can be improved while maintaining good optical characteristics. In FIG. 27 (b), the ratio of the reflective film covering the side surface of the protrusion 22 is as large as 60%, 76%, and 92%, so that the CR characteristics are further improved. Therefore, after forming the grid structure 20 with a material transparent to the light in the band used, the optical functional film 30 is formed, and the optical functional film 30 is formed on the side surface of the protrusion 22 of the grit structure 20. It can be seen that by controlling the range, it is possible to control the optical characteristics, particularly the contrast, and it is possible to realize the polarization characteristics that meet the needs of the customer.
(If even a part of the optical functional film 30 is formed on the base portion 21, which is not formed on the base portion 21, the Tp characteristics deteriorate.)

(10) Types of Optical Functional Films For the model of the polarizing element 1, the optical characteristics (Tp, Rp, The average values of Ts, Rs, and CR) were plotted and compared. The comparison result is shown in FIG. 22 (a). In FIG. 22A, "Ge" indicates that the optical functional film 30 is composed of an absorption film of Ge, and "Al100" is derived from an Al reflective film in which the optical functional film 30 has a film thickness of 100 nm. "Ge / Al" indicates that the optical functional film 30 is a laminate of an absorption film of Ge and an antireflection film of Al having a film thickness of 100 nm, and "Ge / SiO ₂ _10 / Al50". ”Indicates that the optical functional film 30 is _{a laminate of a Ge absorption film, a dielectric film made of SiO 2} having a film thickness of 10 nm, and an Al reflective film having a film thickness of 50 nm. .. Further, FIG. 22 (b) shows only the CR result among the optical characteristics shown in FIG. 22 (a).

From the results shown in FIG. 22 (a), it is possible to control Rs by selecting and forming a film on the absorbent film (Ge) or the reflective film (Al) according to the purpose, and it is possible to control the absorption type polarized light. It can be seen that it is possible to make different elements and reflective polarizing elements. Further, it can be seen that it is possible to provide an absorption type polarizing element in which Rs is further reduced as compared with the absorption film alone by laminating the reflection film (Al) and the absorption film (Ge).
Furthermore, from the results of FIGS. 22 (a) and 22 (b), _{the combination of the reflective film (Al) / dielectric film (SiO 2} ) / absorbing film (Ge) is equivalent to the two-layer structure of the reflective film and the absorbing film. From the results shown in FIG. 22B, it can be seen that the contrast can be improved while maintaining the polarization characteristics.
In this way, it is possible to optimize the polarization characteristics according to the customer's needs by configuring the optical functional film.

<Example 2>
A base portion 21 and a base portion 21 made of a substrate 10 made of glass and an ultraviolet curable resin (acrylic resin) as shown in FIG. 6B and provided along the surface of the substrate 10. It is composed of a grid structure 20 having protrusions 22 protruding from the protrusions 22 in a grid pattern, an optical functional film 30 formed on the protrusions 22 and made of a Ge absorbing film that absorbs light, and Al ₂ O _3. A sample of the polarizing element 1 provided with the protective film 40 was actually produced.
The following tests (1) and (2) were performed on the prepared sample of the polarizing element 1.

(1) Observation of the grid structure of the prepared sample Here, FIGS. 23 (a) and 23 (b) are magnified by using a scanning electron microscope (SEM) with respect to the cross section of the actually produced polarizing element of the present invention. This is a picture taken.
From the photographs of FIGS. 23 (a) and 23 (b), the grid structure 20 is formed with a base portion 21 provided along the surface of the substrate 10 and a protrusion 22 protruding from the base portion 21. You can see that. Further, from FIG. 23B, it can be seen that the optical functional film 30 made of an absorbing film is formed at the tip of the protrusion 22. Further, the base portion 21, the protrusion 22 protruding from the base portion 21, the optical functional film 30 made of an absorbing film at the tip of the protrusion 22, and the protective film 40 are formed so as to cover the whole. I also understand. The protective film 40 was formed by using the ALD (Atomic Layer Deposition) film forming method this time, and is formed with a thickness of 8 nm using _{Al 2} O _{3 as a material.}

(2) Heat resistance of the prepared sample A high temperature test was carried out on the prepared sample of the polarizing element 1. The high temperature test was carried out under the condition of leaving at 150 ° C. for 800 hours.
FIG. 24 shows the average values of the optical characteristics (Tp, Rp, Ts, Rs, CR) for wavelengths of 430 to 680 nm before the high temperature test was applied, and the optics for the wavelengths of 430 to 680 nm in the high temperature test (150 ° C. after 800 hours of application). The average values of the characteristics (Tp, Rp, Ts, Rs, CR) were plotted and compared.

From the results of FIG. 24, it was confirmed that the polarizing element of the present invention did not significantly change its polarization characteristics even when left in a high temperature environment of 150 ° C. for 800 hours. Therefore, it can be seen that it can be used with confidence even in the temperature environment required for the equipment used in the vehicle, and it is possible to provide a polarizing element that meets the needs of the customer.

According to the present invention, it is possible to provide a polarizing element and a method for manufacturing a polarizing element, which have good polarization characteristics and are excellent in heat dissipation and manufacturing cost. Further, according to the present invention, it is possible to provide a head-up display device having excellent polarization characteristics and heat resistance.

1 Polarizing element 2 Light source 3 Display element 4 Reflector 5 Display surface 6 Cover part 10 Substrate 20 Grid structure 21 Base part 22 Projection part 23 Grid structure material 30 Optical functional film 31 Optical functional film Material layer 40 Protective film 50 Heat dissipation member 60 Master 61 Base material for master 62 Metal film for master 63 Convex part for master 64 Release film coat 70 Resist mask 80 Metal film 100 Head-up display device

Claims (16)

A substrate made of transparent inorganic material and
A grid structure made of a transparent material and having a base portion provided along the surface of the substrate and protrusions protruding in a grid pattern from the base portion.
An optical functional film formed on the protrusions, which is an absorption film that absorbs light, a reflection film that reflects light, or a multilayer film having at least the absorption film and the reflection film.
A polarizing element, characterized in that it is provided with. The polarizing element according to claim 1, wherein the thickness of the base portion is 1 nm or more. According to claim 1 or 2, the shape of the protrusion when viewed in a cross section orthogonal to the absorption axis direction or the reflection axis direction of the polarizing element is rectangular, trapezoidal, polygonal or elliptical. The polarizing element according to the description. The polarizing element according to any one of claims 1 to 3, wherein the optical functional film is formed at least at the tip of the protrusion. The polarizing element according to any one of claims 1 to 4, wherein the optical functional film is not formed on the base portion. The polarizing element according to claim 4 or 5, wherein the optical functional film is formed on a tip end of the protrusion and a part of a side surface of the protrusion. The polarizing element according to claim 6, wherein the optical functional film formed on a part of the side surface of the protrusion is formed in a range covering 10% or more of the height of the protrusion. The polarizing element according to any one of claims 1 to 7, wherein the inorganic material constituting the substrate is different from the material constituting the grid structure. The polarizing element according to any one of claims 1 to 8, further comprising a protective film formed so as to cover at least the surface of the optical functional film. The polarizing element according to claim 9, wherein the protective film includes a water-repellent coating or an oil-repellent coating. The polarizing element according to claim 1, wherein the optical functional film is composed of a multilayer film having at least the absorption film and the reflection film. The polarizing element according to claim 11, wherein the optical functional film further has a dielectric film between the reflective film and the absorbing film. The process of forming a grid structure material made of a transparent material on a substrate made of an inorganic material, and
A step of forming a grid structure having a base portion provided along the surface of the substrate and protrusions protruding in a grid pattern from the base portion by applying nanoimprint to the grid structure material.
A step of forming an absorption film that absorbs light, a reflection film that reflects light, or an optical functional film composed of a multilayer film having at least the absorption film and the reflection film is provided on the protrusion. A characteristic method for manufacturing a polarizing element. The method for manufacturing a polarizing element according to claim 13, wherein the step of forming the optical functional film is characterized by alternately forming a film on the protrusions from a plurality of directions by a sputtering or a thin-film deposition method. A head-up display device comprising the polarizing element according to any one of claims 1 to 14. The head-up display device according to claim 15, wherein a heat radiating member is provided around the polarizing element.

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