JP3732252B2 - Manufacturing method of light control functional sheet for liquid crystal display device - Google Patents
Manufacturing method of light control functional sheet for liquid crystal display device Download PDFInfo
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- JP3732252B2 JP3732252B2 JP14243395A JP14243395A JP3732252B2 JP 3732252 B2 JP3732252 B2 JP 3732252B2 JP 14243395 A JP14243395 A JP 14243395A JP 14243395 A JP14243395 A JP 14243395A JP 3732252 B2 JP3732252 B2 JP 3732252B2
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- crystal display
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- 239000004973 liquid crystal related substance Substances 0.000 title claims description 17
- 238000004519 manufacturing process Methods 0.000 title claims description 17
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Images
Classifications
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
- B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00278—Lenticular sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0073—Optical laminates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
- G02B5/0215—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures the surface having a regular structure
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/02—Diffusing elements; Afocal elements
- G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
- G02B5/0236—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
- G02B5/0242—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element by means of dispersed particles
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
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- G—PHYSICS
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- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
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- G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/04—Prisms
- G02B5/045—Prism arrays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/44—Compression means for making articles of indefinite length
- B29C43/46—Rollers
- B29C2043/461—Rollers the rollers having specific surface features
- B29C2043/463—Rollers the rollers having specific surface features corrugated, patterned or embossed surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0016—Lenses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Health & Medical Sciences (AREA)
- Ophthalmology & Optometry (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Optical Elements Other Than Lenses (AREA)
- Liquid Crystal (AREA)
Description
【０００１】
【産業上の利用分野】
本発明は液晶表示装置用バックライトシステムに用いられる光制御機能性シートの製造方法に関する。本発明において光制御機能性シートとは、液晶表示装置用レンズシートや液晶表示装置用光拡散シート兼レンズシートのことである。
【０００２】
【従来の技術】
従来、液晶表示装置用バックライトにはエッジライト方式が多く用いられている。エッジライト型バックライトは一般に、透光性材料からなる導光板と、その側面端部に設けられた冷陰極管等からなる線光源と、導光板の下面と線光源を覆うように配置された光反射フィルムと、出光面となる導光板の上面に配置された光拡散フィルムやレンズシートで構成される。
近年、輝度の向上及び消費電力の低下を目的として、特にカラー液晶表示装置においては、光拡散フィルムの上面もしくは光拡散フィルムと導光板の間に表面にプリズム形状を有するレンズシートを１枚もしくは２枚配置することが多くなった。
また、光源からの距離により出光量の不均一を改善するため、導光板の裏面には光拡散インキからなるドット状のパターンが、光源から離れるにしたがって大きくなるように印刷されている。
光拡散フィルムは、光を均一に拡散し、導光板の裏面に印刷されたドット状パターンを見えなくすることを主目的として配置され、レンズシートは導光板から出射した光を効率良く液晶パネルの正面方向に集光するために、光拡散フィルムの上面もしくは光拡散フィルムと導光板の間に１枚もしくは２枚配される。
【０００３】
【発明が解決しようとする課題】
しかし、従来、これらのレンズシートは熱可塑性シートのエンボス加工や電離放射線硬化型樹脂を利用したプリズム形状の転写などにより製造されていた。しかしこれら従来のレンズシートは製造コストが高く、ひいてはバックライトシステムが高価となる主要因とされてきた。また、従来のレンズシートはその製造方法より、プリズム形状が形成される層の材質の選択範囲が狭いという問題もあった。
さらに、レンズシートは光拡散効果を有しないため、必ず光拡散フィルムと組み合わせて使用しなければならず、バックライトの組み立て工程が煩雑になるという問題もあった。
【０００４】
【課題を解決するための手段】
そこで、このような問題を解決するためになされた本発明は、以下の２つである。すなわち、
（請求項１） 熱可塑性樹脂フィルムからなる基材上に、光拡散層、プリズムが、順次積層されて成る液晶表示装置用光制御機能性シートの製造方法であって、
熱可塑性樹脂フィルムからなる基材の片面に光拡散層を積層後、前記基材の該光拡散層側の表面に、押し出しラミネート法により、熱可塑性樹脂を押し出しコーティングすると同時に表面にプリズム形状を有する冷却ロールに押圧して、押し出しコーティングされた熱可塑性樹脂の表面にプリズム形状を転写、形成することを特徴とする液晶表示装置用光制御機能性シートの製造方法。
（請求項２） 熱可塑性樹脂フィルムからなる基材の、前記プリズムが積層される側とは反対側の面にマット層を形成する工程を、更に含む、ことを特徴とする請求項１記載の液晶表示装置用光制御機能性シートの製造方法。である。
【０００５】
本発明の熱可塑性樹脂フィルムからなる基材（押し出しラミネート用基材）は、単層もしくは複合フィルムもしくはシートでその厚みとしては通常５〜２００μｍが好ましく、さらに好ましくは１０〜１２５μｍのものを使用できる。この基材の素材の具体例を示すと、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンテレフタレート・イソフタレート共重合体等によるポリエステル系樹脂、ポリエチレン、ポリプロピレン、ポリメチルペンテン等のポリオレフィン系樹脂、ポリフッ化塩化ビニル、ポリフッ化ビニリデン、ポリ４フッ化エチレン、エチレン・４フッ化エチレン共重合体等によるポリフッ化エチレン系樹脂、ナイロン６ナイロン６６等によるポリアミド系樹脂、ポリ塩化ビニル、塩化ビニル・酢酸ビニル共重合体、エチレン・ビニルアルコール共重合体、ポリビニルアルコール等のビニル系樹脂、三酢酸セルロース、セロファン等によるセルロース系樹脂、ポリメタクリル酸メチル、ポリメタクリル酸エチル、ポリアクリル酸ブチル等のアクリル系樹脂、耐衝撃性ポリスチレン、ポリカーボネート、ポリアリレート、ポリイミド等があげられる。
【０００６】
本発明において基材に光拡散層を形成して光拡散フィルムを製造する方法としては、例えば
▲１▼ 基材に光拡散剤を練り込んだ樹脂を押し出しラミネーションにより積層する方法
▲２▼ 基材に光拡散剤をバインダー樹脂に分散した光拡散層用コーティング剤を塗工形成する方法
▲３▼ 光拡散剤を練り込んだフィルムを基材とドライラミする方法
が利用される。
光拡散剤としては、アクリル樹脂、メラミン樹脂、ポリエチレン、ポリスチレン、有機シリコーン樹脂、アクリル−スチレン共重合体等の有機質微粒子及び炭酸カルシウム、シリカ、酸化アルミニウム、炭酸バリウム、硫酸バリウム、ガラス等の無機質微粒子で平均粒子径１〜４０μｍの単体もしくは混合体である。
【０００７】
本発明において光拡散フィルムとは、前記した基材と光拡散層とからなるものと図２に示したように、さらにマット層を形成したものとの２種類がある。
そして、本発明において基材にマット層を形成する方法としては、
▲１▼ 基材にマット剤を練り込んだ樹脂を押し出しラミネーションにより積層する方法
▲２▼ 基材にマット剤をバインダー樹脂に分散したコーティング剤を塗工形成する方法
が利用される。
マット層用マット剤としては、アクリル樹脂、メラミン樹脂、ポリエチレン、ポリスチレン、有機シリコーン樹脂、アクリル−スチレン共重合体等の有機質微粒子及び炭酸カルシウム、シリカ、酸化アルミニウム、炭酸バリウム、硫酸バリウム、ガラス等の無機質微粒子で平均粒子径３〜２０μｍの単体もしくは混合体である。
【０００８】
本発明の光拡散層用コーティング剤及びマット層用コーティング剤のバインダー樹脂としては、ポリウレタン，ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンテレフタレート・イソフタレート共重合体等によるポリエステル系樹脂、ポリエチレン、ポリプロピレン、ポリメチルペンテン等のポリオレフィン系樹脂、ポリフッ化塩化ビニル、ポリフッ化ビニリデン、ポリ４フッ化エチレン、エチレン・４フッ化エチレン共重合体等によるポリフッ化エチレン系樹脂、ナイロン６ナイロン６６等によるポリアミド系樹脂、ポリ塩化ビニル、塩化ビニル・酢酸ビニル共重合体、ポリビニルブチラール、エチレン・ビニルアルコール共重合体、ポリビニルアルコール等のビニル系樹脂、三酢酸セルロース、セロファン等によるセルロース系樹脂、ポリメタクリル酸メチル、ポリメタクリル酸エチル、ポリアクリル酸ブチル等のアクリル系樹脂、アクリロニトリル−ブタジエン共重合体、ポリスチレン、ポリカーボネート、ポリアリレート、ポリイミド等の単独もしくは混合物やさらにイソシアネート等の架橋剤を配合しても良い。
【０００９】
本発明の押し出しコーティングする熱可塑性樹脂（プリズム用押し出し樹脂）としては、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンテレフタレート・イソフタレート共重合体等によるポリエステル系樹脂、ポリエチレン、ポリプロピレン、ポリメチルペンテン等のポリオレフィン系樹脂、ポリフッ化塩化ビニル、ポリフッ化ビニリデン、ポリ４フッ化エチレン、エチレン・４フッ化エチレン共重合体等によるポリフッ化エチレン系樹脂、ナイロン６ナイロン６６等によるポリアミド系樹脂、ポリ塩化ビニル、塩化ビニル・酢酸ビニル共重合体、エチレン・ビニルアルコール共重合体、ポリビニルアルコール等のビニル系樹脂、三酢酸セルロース、セロファン等によるセルロース系樹脂、ポリメタクリル酸メチル、ポリメタクリル酸エチル、ポリアクリル酸ブチル等のアクリル系樹脂、ポリスチレン、ポリカーボネート、ポリアリレート、ポリイミド等の単独もしくは混合体もしくは共重合体があげられる。
【００１０】
次に、本発明において光制御機能性シートの一方の表面に図４〜図８に示したような形状のプリズムを形成するには、少なくとも光拡散層を積層した熱可塑性樹脂フィルムからなる基材の前記光拡散層の表面に、押し出しラミネート法により、熱可塑性樹脂を押し出しコーティングすると同時に表面にプリズム形状を有する冷却ロールに押圧し冷却する方法がある。形状としては、導光板からの出射光を法線方向に集光できる形状、例えば図４の様な三角プリズムを多数平行に配置した形状などが好ましい。前記プリズム形状を有する冷却ロールの製造方法としては、冷却ロールの表面に直接、彫刻あるいは腐食等の方法でプリズム形状を形成しても良いし、プリズム形状を形成した金属あるいは樹脂などからなるスタンパなどを冷却ロール表面に形成しても良い。
【００１１】
【作用】
光拡散層の役目は、導光板から出た光を均一に拡散し、導光板裏面のドット状パターンを見えなくすることである。
マット層は必ずしも必要ではないが、その役目は、導光板とのスティッキング防止のためである。
本発明の光制御機能性シートは押し出しラミネート法により冷却ロールの表面に形成されたプリズム形状を溶融押し出しされた熱可塑性樹脂シートの表面に転写するものであり、従来に比較して、低コストで大量生産に適した液晶表示装置用レンズシートおよびその製造方法を提供するものである。
さらに、押し出しラミネートする基材として光拡散層が形成されている光拡散フィルムを使用することによりレンズシートと光拡散フィルムを一体化でき、液晶表示装置用バックライトの組み立て工程を簡略化することができる。
【００１２】
【実施例】
本発明の実施例を図面により説明する。
図１は本発明による光制御機能性シートの製造方法の一実施例を示す断面図である。
図２は本発明による光制御機能性シートに使用される光拡散フィルムの一実施例を示した断面図である。
図３は本発明による光制御機能性シート（光拡散フィルム兼レンズシート）の一実施例を示した断面図である。
図４〜図８は本発明による光制御機能性シートの表面に形成されたプリズム形状の実施例を示した斜視図である。
【００１３】
実施例１
図２において、基材６として厚さ２５μｍのポリエステルフィルム〔帝人（株）製 ＨＳタイプ〕の片面に、下記組成の光拡散層用コーティング剤をコンマコート法により塗布後、乾燥し、厚さ１５μの光拡散層５を形成した。次いでポリエステルフィルムのもう一方の面に、下記組成のマット層用コーティング剤を塗布前に主剤と硬化剤を１００／３（重量比）の割合で混合し、グラビアリバースコート法（グラビア版版深２０μ、２３０線／ｉｎｃｈ）により塗布後乾燥し、厚さ５μｍのマット層７を形成して、押し出しラミネート基材となる図１や図２の光拡散フィルム４を得た。
【００１４】
【発明の効果】
本発明の光制御機能性シートは押し出しラミネート法により冷却ロールの表面に形成されたプリズム形状を溶融押し出しされた熱可塑性樹脂シートの表面に転写するものであり、従来に比較して、低コストで大量生産に適した液晶表示装置用光制御機能性シートの製造方法を提供することができる。また、溶融押し出し可能な樹脂であればいずれの樹脂も光制御機能性シート（レンズシート）材料として使用できる。さらに、押し出しラミネートする基材として光拡散層が形成されている光拡散フィルムを使用することによりレンズシートと光拡散フィルムを一体化でき、液晶表示装置用バックライトの組み立て工程を簡略化することができる。
【図面の簡単な説明】
【図１】本発明による光制御機能性シートの製造方法の一実施例を示す断面図
【図２】本発明による光制御機能性シートに使用される光拡散フィルムの一実施例を示した断面図である。
【図３】本発明による光制御機能性シート（光拡散フィルム兼レンズシート）の一実施例を示した断面図である。
【図４】本発明による光制御機能性シートの表面に形成されたプリズム形状の実施例を示した斜視図である。
【図５】本発明による光制御機能性シートの表面に形成されたかまぼこ型プリズム形状の実施例を示した斜視図
【図６】本発明による光制御機能性シートの表面に形成されたプリズム形状の実施例を示した斜視図である。
【図７】本発明による光制御機能性シートの表面に形成されたプリズム形状の実施例を示した斜視図である。
【図８】本発明による光制御機能性シートの表面に形成されたプリズム形状の実施例を示した斜視図である。
【符号の説明】
１ 表面にプリズム形状を有する冷却ロール
２ ニップロール
３ Ｔダイ
４ 光拡散フィルム
５ 光拡散層
６ 基材
７ マット層
８ 光拡散シート兼レンズシート
９ プリズム[0001]
[Industrial application fields]
The present invention relates to a process for producing a light control functionality sheet used in the backlight system for a liquid crystal display device. In the present invention, the light control functional sheet means a lens sheet for a liquid crystal display device or a light diffusion sheet / lens sheet for a liquid crystal display device.
[0002]
[Prior art]
Conventionally, an edge light system is often used for a backlight for a liquid crystal display device. The edge-light type backlight is generally arranged so as to cover the light guide plate made of a light-transmitting material, a line light source made of a cold cathode tube or the like provided at the side edge, and the lower surface of the light guide plate and the line light source. It is comprised with the light-diffusion film and the light-diffusion film arrange | positioned on the upper surface of the light-guide plate used as a light emission surface, and a lens sheet.
In recent years, for the purpose of improving luminance and reducing power consumption, particularly in a color liquid crystal display device, one or two lens sheets having a prism shape on the upper surface of the light diffusion film or between the light diffusion film and the light guide plate are used. Increased placement.
Further, in order to improve the unevenness of the emitted light quantity depending on the distance from the light source, a dot-like pattern made of light diffusing ink is printed on the back surface of the light guide plate so as to increase as the distance from the light source increases.
The light diffusion film is disposed mainly for the purpose of diffusing light uniformly and making the dot pattern printed on the back surface of the light guide plate invisible, and the lens sheet efficiently transmits the light emitted from the light guide plate. In order to condense in the front direction, one or two sheets are arranged on the upper surface of the light diffusion film or between the light diffusion film and the light guide plate.
[0003]
[Problems to be solved by the invention]
However, conventionally, these lens sheets have been manufactured by embossing a thermoplastic sheet or transferring a prism shape using an ionizing radiation curable resin. However, these conventional lens sheets have been considered to be the main factor that the manufacturing cost is high and the backlight system is expensive. Further, the conventional lens sheet has a problem that the selection range of the material of the layer on which the prism shape is formed is narrower than the manufacturing method thereof.
Furthermore, since the lens sheet does not have a light diffusion effect, it must be used in combination with a light diffusion film, and there is a problem that the assembly process of the backlight becomes complicated.
[0004]
[Means for Solving the Problems]
Therefore, the present invention made to solve such problems is the following two . That is,
(Claim 1 ) A method for producing a light control functional sheet for a liquid crystal display device, in which a light diffusion layer and a prism are sequentially laminated on a base material made of a thermoplastic resin film,
After laminating a light diffusion layer on one side of a base material made of a thermoplastic resin film, the surface of the base material on the light diffusion layer side is extruded and coated with a thermoplastic resin by an extrusion laminating method, and at the same time has a prism shape on the surface. A method for producing a light control functional sheet for a liquid crystal display device, which comprises pressing a cooling roll to transfer and form a prism shape on the surface of an extrusion-coated thermoplastic resin.
(Claim 2) The method according to claim 1, further comprising a step of forming a matte layer on a surface of a base material made of a thermoplastic resin film on a side opposite to the side on which the prism is laminated. Manufacturing method of light control functional sheet for liquid crystal display device. It is.
[0005]
The base material (extrusion laminating base material) made of the thermoplastic resin film of the present invention is preferably a single layer, a composite film or a sheet with a thickness of usually 5 to 200 μm, more preferably 10 to 125 μm. . Specific examples of the material of the base material include: polyethylene terephthalate, polybutylene terephthalate, polyester resins such as polyethylene terephthalate / isophthalate copolymer, polyolefin resins such as polyethylene, polypropylene, polymethylpentene, and polyvinyl fluoride chloride. Polyvinylidene fluoride, polytetrafluoroethylene, polyfluorinated ethylene resin such as ethylene / tetrafluoroethylene copolymer, polyamide resin such as nylon 6 nylon 66, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer , Ethylene-vinyl alcohol copolymers, vinyl resins such as polyvinyl alcohol, cellulose resins such as cellulose triacetate, cellophane, polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate Acrylic resins, high impact polystyrene, polycarbonate, polyarylate, polyimide and the like.
[0006]
In the present invention, a method for producing a light diffusing film by forming a light diffusing layer on a substrate includes, for example, (1) a method of laminating a resin in which a light diffusing agent is kneaded on the substrate by extrusion lamination, and (2) a substrate. (3) A method in which a film containing a light diffusing agent is kneaded with a base material is used.
Examples of the light diffusing agent include organic fine particles such as acrylic resin, melamine resin, polyethylene, polystyrene, organic silicone resin, and acrylic-styrene copolymer, and inorganic fine particles such as calcium carbonate, silica, aluminum oxide, barium carbonate, barium sulfate, and glass. And a simple substance or a mixture having an average particle diameter of 1 to 40 μm.
[0007]
In the present invention, there are two types of light diffusing films: those composed of the above-mentioned base material and light diffusing layer and those further formed with a mat layer as shown in FIG.
And as a method of forming a mat layer on a substrate in the present invention,
(1) A method of laminating a resin in which a matting agent is kneaded on a base material by extrusion lamination (2) A method of coating and forming a coating agent in which a matting agent is dispersed in a binder resin is used on the base material.
Matting agents for matting layer include organic fine particles such as acrylic resin, melamine resin, polyethylene, polystyrene, organic silicone resin, acrylic-styrene copolymer, and calcium carbonate, silica, aluminum oxide, barium carbonate, barium sulfate, glass, etc. A simple substance or a mixture of inorganic fine particles having an average particle diameter of 3 to 20 μm.
[0008]
As the binder resin for the light diffusion layer coating agent and mat layer coating agent of the present invention, polyester resins such as polyurethane, polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate / isophthalate copolymer, polyethylene, polypropylene, polymethyl, etc. Polyolefin resins such as pentene, polyfluorinated vinyl chloride, polyvinylidene fluoride, polytetrafluoroethylene, polyfluorinated ethylene resins such as ethylene / tetrafluoroethylene copolymer, polyamide resins such as nylon 6 nylon 66, poly For vinyl chloride, vinyl chloride / vinyl acetate copolymer, polyvinyl butyral, ethylene / vinyl alcohol copolymer, polyvinyl resins such as polyvinyl alcohol, cellulose triacetate, cellophane, etc. Cellulose resins, polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate and other acrylic resins, acrylonitrile-butadiene copolymers, polystyrene, polycarbonate, polyarylate, polyimide, etc. You may mix | blend a crosslinking agent.
[0009]
Examples of the thermoplastic resin (extruded resin for prism) for extrusion coating of the present invention include polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate / isophthalate copolymer, and polyolefins such as polyethylene, polypropylene, and polymethylpentene. Resin, polyvinyl fluoride chloride, polyvinylidene fluoride, polytetrafluoroethylene, polyfluorinated ethylene resin such as ethylene / tetrafluoroethylene copolymer, polyamide resin such as nylon 6 nylon 66, polyvinyl chloride, vinyl chloride・ Vinyl acetate copolymers, ethylene / vinyl alcohol copolymers, vinyl resins such as polyvinyl alcohol, cellulose resins using cellulose triacetate, cellophane, etc., polymethacrylate , Polyethyl methacrylate, acrylic resins such as polybutyl acrylate, polystyrene, polycarbonate, polyarylate, alone or in combination or copolymer of polyimide and the like.
[0010]
Next, in order to form a prism having a shape as shown in FIGS. 4 to 8 on one surface of the light control functional sheet in the present invention, a base material made of a thermoplastic resin film on which at least a light diffusion layer is laminated. There is a method in which a thermoplastic resin is extruded and coated on the surface of the light diffusion layer by an extrusion laminating method, and at the same time, it is pressed against a cooling roll having a prism shape on the surface and cooled. The shape is preferably a shape that allows light emitted from the light guide plate to be condensed in the normal direction, for example, a shape in which a large number of triangular prisms as shown in FIG. 4 are arranged in parallel. As a manufacturing method of the cooling roll having the prism shape, the prism shape may be formed directly on the surface of the cooling roll by a method such as engraving or corrosion, or a stamper made of metal or resin having the prism shape, etc. May be formed on the surface of the cooling roll.
[0011]
[Action]
The role of the light diffusion layer is to uniformly diffuse the light emitted from the light guide plate and to make the dot pattern on the back surface of the light guide plate invisible.
The mat layer is not always necessary, but its role is to prevent sticking with the light guide plate.
The light control functional sheet of the present invention transfers the prism shape formed on the surface of the cooling roll to the surface of the melt-extruded thermoplastic resin sheet by an extrusion laminating method. A lens sheet for a liquid crystal display device suitable for mass production and a method for manufacturing the same are provided.
Furthermore, by using a light diffusion film on which a light diffusion layer is formed as a base material for extrusion lamination, the lens sheet and the light diffusion film can be integrated, and the assembly process of the backlight for the liquid crystal display device can be simplified. it can.
[0012]
【Example】
Embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a cross-sectional view showing an embodiment of a method for producing a light control functional sheet according to the present invention.
FIG. 2 is a cross-sectional view showing an embodiment of a light diffusion film used in the light control functional sheet according to the present invention.
FIG. 3 is a cross-sectional view showing an embodiment of a light control functional sheet (light diffusion film / lens sheet) according to the present invention.
4 to 8 are perspective views showing examples of prism shapes formed on the surface of the light control functional sheet according to the present invention.
[0013]
Example 1
In FIG. 2, a light diffusion layer coating agent having the following composition is applied to one side of a 25 μm thick polyester film (HS type, manufactured by Teijin Ltd.) as a base material 6 by a comma coating method, and then dried to a thickness of 15 μm. The
[0014]
【The invention's effect】
The light control functional sheet of the present invention transfers the prism shape formed on the surface of the cooling roll to the surface of the melt-extruded thermoplastic resin sheet by an extrusion laminating method. mass liquid crystal display device manufacturing method for a light control functionality sheet suitable for the production can be provided. Any resin that can be melt extruded can be used as a light control functional sheet (lens sheet) material. Furthermore, by using a light diffusion film on which a light diffusion layer is formed as a base material for extrusion lamination, the lens sheet and the light diffusion film can be integrated, and the assembly process of the backlight for the liquid crystal display device can be simplified. it can.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a method for producing a light control functional sheet according to the present invention. FIG. 2 is a cross section showing an embodiment of a light diffusion film used in the light control functional sheet according to the present invention. FIG.
FIG. 3 is a cross-sectional view showing an example of a light control functional sheet (light diffusion film / lens sheet) according to the present invention.
FIG. 4 is a perspective view showing an example of a prism shape formed on the surface of a light control functional sheet according to the present invention.
FIG. 5 is a perspective view showing an example of a kamaboko-type prism shape formed on the surface of the light control functional sheet according to the present invention. FIG. 6 is a prism shape formed on the surface of the light control functional sheet according to the present invention. It is the perspective view which showed the Example.
FIG. 7 is a perspective view showing an example of a prism shape formed on the surface of the light control functional sheet according to the present invention.
FIG. 8 is a perspective view showing an example of a prism shape formed on the surface of the light control functional sheet according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Cooling roll which has prism shape on the surface 2 Nip roll 3 T die 4
Claims (2)
熱可塑性樹脂フィルムからなる基材の片面に光拡散層を積層後、前記基材の該光拡散層側の表面に、押し出しラミネート法により、熱可塑性樹脂を押し出しコーティングすると同時に表面にプリズム形状を有する冷却ロールに押圧して、押し出しコーティングされた熱可塑性樹脂の表面にプリズム形状を転写、形成することを特徴とする液晶表示装置用光制御機能性シートの製造方法。 After laminating a light diffusing layer on one side of a base material made of a thermoplastic resin film, the surface of the base material on the light diffusing layer side is extruded and coated with a thermoplastic resin by an extrusion laminating method and at the same time has a prism shape on the surface. A method for producing a light control functional sheet for a liquid crystal display device, wherein the prism shape is transferred to and formed on a surface of an extrusion-coated thermoplastic resin by pressing against a cooling roll.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP14243395A JP3732252B2 (en) | 1995-05-18 | 1995-05-18 | Manufacturing method of light control functional sheet for liquid crystal display device |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP14243395A JP3732252B2 (en) | 1995-05-18 | 1995-05-18 | Manufacturing method of light control functional sheet for liquid crystal display device |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH08313707A JPH08313707A (en) | 1996-11-29 |
| JP3732252B2 true JP3732252B2 (en) | 2006-01-05 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP14243395A Expired - Lifetime JP3732252B2 (en) | 1995-05-18 | 1995-05-18 | Manufacturing method of light control functional sheet for liquid crystal display device |
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| JP (1) | JP3732252B2 (en) |
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| JP2002258018A (en) * | 2001-03-02 | 2002-09-11 | Keiwa Inc | Light diffusion sheet and backlight unit using the same |
| JP4763143B2 (en) * | 2001-03-19 | 2011-08-31 | 恵和株式会社 | Optical sheet |
| JP2007114587A (en) * | 2005-10-21 | 2007-05-10 | Takiron Co Ltd | Light diffusion sheet |
| TWI358575B (en) * | 2006-03-17 | 2012-02-21 | Light diffusion reflection sheet with buffering ef | |
| DE102006037999A1 (en) * | 2006-08-14 | 2008-02-21 | Schreiner Group Gmbh & Co. Kg | Three-dimensional component and method for producing the same |
| DE102006037997A1 (en) * | 2006-08-14 | 2008-02-21 | Schreiner Group Gmbh & Co. Kg | Three-dimensional component and method for producing the same |
| DE102007056587A1 (en) | 2007-11-23 | 2009-05-28 | Sortech Ag | Functional composite material |
| KR100886206B1 (en) * | 2008-09-01 | 2009-02-27 | 바이엘쉬트코리아 주식회사 | Optical sheet and optical sheet manufacturing method |
-
1995
- 1995-05-18 JP JP14243395A patent/JP3732252B2/en not_active Expired - Lifetime
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8088325B2 (en) | 2007-11-19 | 2012-01-03 | 3M Innovative Properties Company | Articles and methods of making articles having a concavity or convexity |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH08313707A (en) | 1996-11-29 |
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