JP3732253B2 - Manufacturing method of lens sheet for liquid crystal display device - Google Patents

Manufacturing method of lens sheet for liquid crystal display device Download PDF

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Publication number
JP3732253B2
JP3732253B2 JP14243495A JP14243495A JP3732253B2 JP 3732253 B2 JP3732253 B2 JP 3732253B2 JP 14243495 A JP14243495 A JP 14243495A JP 14243495 A JP14243495 A JP 14243495A JP 3732253 B2 JP3732253 B2 JP 3732253B2
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thermoplastic resin
light diffusing
kneaded
diffusing agent
resin layer
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JPH08313708A (en
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泰樹 鈴浦
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Dai Nippon Printing Co Ltd
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Dai Nippon Printing Co Ltd
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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
    • B29C43/22—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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/9155—Pressure rollers
    • 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
    • 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
    • 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
    • G02B5/021—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
    • 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
    • G02B5/021—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
    • G02B5/0231—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 microprismatic or micropyramidal shape
    • 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
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0273—Diffusing elements; Afocal elements characterized by the use
    • G02B5/0278—Diffusing elements; Afocal elements characterized by the use used in transmission
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/04—Prisms
    • G02B5/045—Prism arrays
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/307—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets specially adapted for bringing together components, e.g. melts within the die
    • 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
    • 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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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Liquid Crystal (AREA)
  • Planar Illumination Modules (AREA)
  • Optical Elements Other Than Lenses (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拡散効果を併せ持つレンズシートの製造方法に関する。
【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、
（１）光拡散剤を混練した熱可塑性樹脂層から成る光拡散層と、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状が形成されたプリズム形状形成層の少なくとも２層を積層して成る液晶表示装置用レンズシートの製造方法であって、光拡散剤を混練した熱可塑性樹脂層と光拡散剤を混練し無い熱可塑性樹脂層とから成る少なくとも２層の熱可塑性樹脂層を、共押し出し法により積層した状態で、溶融押し出しし、該溶融押し出しした少なくとも２層の熱可塑性樹脂層を、表面にプリズム形状を有する冷却ロール上に、前記光拡散剤を混練し無い熱可塑性樹脂層側が該冷却ロール側に向くようにして供給し、該冷却ロールで押圧し、光拡散剤を混練し無い熱可塑性樹脂層側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レンズシートの製造方法。
（２）熱可塑性樹脂フィルムからなる基材の表面に、光拡散剤を混練した熱可塑性樹脂層から成る光拡散層と、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状が形成されたプリズム形状形成層の少なくとも２層を積層して成る液晶表示装置用レンズ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表面に、共押し出しラミネート法により、光拡散剤を混練した熱可塑性樹脂層と光拡散剤を混練し無い熱可塑性樹脂層とから成る少なくとも２層の熱可塑性樹脂層を、該光拡散剤を混練した熱可塑性樹脂層側が該基材側を向くようにして、共押し出しコーティングにより溶融押し出しして積層させ、積層と同時に前記溶融押し出しした少なくとも２層の熱可塑性樹脂層のうち、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状を有する冷却ロールを押圧し、これ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レンズシートの製造方法。である。
【０００５】
本発明のプリズム形状形成層用の押し出しする樹脂としては、アクリル樹脂、ポリカーボネート、ポリ塩化ビニル、ポリスチレン、ポリエチレン、ポリプロピレン、ポリエステル、環状ポリオレフィン等の単独もしくは混合体もしくは共重合体が特に有効である。
この他、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、ポリエチレンナフタレート・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、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も使用される。
【０００６】
本発明の光拡散層用の押し出しする樹脂としては、光拡散剤が混練されたアクリル樹脂、ポリカーボネート、ポリ塩化ビニル、ポリスチレン、ポリエチレン、ポリプロピレン、ポリエステル、環状ポリオレフィン等の単独もしくは混合体もしくは共重合体が特に有効である。
この他、光拡散剤が混練された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、ポリエチレンナフタレート・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、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も使用される。
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が利用される。
【０００７】
本発明の熱可塑性樹脂フィルムからなる基材（共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、ポリエチレンナフタレート・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、ポリイミド等があげられる。
【０００８】
本発明の基材には前記した光拡散剤を練り混んでおくと、光拡散層も兼ねることができる。
また、本発明の基材にはマット層を形成してもよい。形成方法としては、
▲１▼基材にマット剤をバインダー樹脂に分散したマット層用コーティング剤を塗工形成する方法
▲２▼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
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。
【０００９】
上記の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樹脂等の架橋剤を配合しても良い。
【００１０】
次に、本発明のレンズシートの一方の表面の図５〜図９に示したような形状のプリズムを形成するには、『共押し出し法により積層した少なくとも２層の熱可塑性樹脂層の一方の表面層に図５〜図９に示したプリズム形状を有する冷却ロールに押圧する方法』と『熱可塑性樹脂フィルムからなる基材の表面に、共押し出しラミネート法により、少なくとも２層の熱可塑性樹脂層を共押し出しコーティングにより積層させ、前記熱可塑性樹脂層の表面に図５〜図６に示したプリズム形状を有する冷却ロールに押圧する方法。』とがある。
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５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】
本発明によれば、溶融押し出し可能な樹脂であればいずれの樹脂もレンズシート用材料として使用できるため、樹脂特有の屈折率等の光学特性や熱的特性、物理的特性等の選択範囲が極めて広くなる。
さらに本発明のレンズシートは、光拡散効果を併せ持つため、バックライトの組み立て工程で別途光拡散フィルムを入れる必要がなく、組み立て工程を簡略化することができる。さらには従来のレンズシートのように熱可塑性シートを製造したのちにさらにエンボス工程が必要になる等の製造コストアップの要因がなく、一体化する光拡散層も同時に形成できるため、別途光拡散フィルム成形工程やコーティング工程等の製造工程が必要ない。従って、本発明のレンズシートは、極めて低コストで大量生産できる。
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。
マット層の役目は、導光板とのスティッキング防止のためである。
【００１２】
【実施例】
本発明の実施例を図面により説明する。
図１は本発明によるレンズシートの製造方法の一実施例を示す断面図である。図２は本発明によるレンズシートの製造方法の一実施例を示す断面図である。
図３は本発明によるレンズシートの一実施例を示した断面図である。
図４は本発明によるレンズシートの一実施例を示した断面図である。
図５〜図９は本発明によるレンズ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１に示した共押し出し装置を用いて、プリズム形状形成層として環状ポリオレフィン系樹脂（三井石油化学工業製アペル）、光拡散層として光拡散剤になるポリメチルメタクリレートビーズ（積水化成品品工業製平均粒径２μ）を２０重量％分散したアペルをシリンダー温度２５０°Ｃ、ダイス温度２２０°Ｃの加工条件で、表面に図５のプリズム形状を有する冷却ロール上に押し出し、ニップロールで押し圧し冷却することにより、表面にプリズム形状が転写されたプリズム形状形成層８０μ、光拡散層３０μの本発明のレンズシートを得た。
実施例２
厚さ２５μｍのポリエステルフィルム〔帝人（株）製 ＳＰ8 〕の非処理面に、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）により塗布した後に乾燥し、厚さ５μｍのマット層を形成して、共押し出しラミネート用基材４を得た。

Figure 0003732253
次いで、図２に示した共押し出しラミネート装置を用いて、プリズム形状を形成する層としてアクリル（三菱レーヨン製アクリペット）、光拡散層として光拡散剤になるシリカ中空ビーズ（旭硝子製セルスター平均粒径４０μ）を５重量％分散したアクリル樹脂をシリンダー温度２５０°Ｃ、ダイス温度２３０°Ｃの加工条件で、裏面にマット層を形成した共押し出しラミネート用基材の表面に共押し出しラミネートすると同時に表面に図９のプリズム形状を有する冷却ロールにニップロールで押し圧し冷却することにより、表面にプリズム形状が転写されたプリズム形状形成層６０μ、光拡散層８０μ、共押し出しラミネート用基材２５μ、裏面マット層５μの本発明のレンズシートを得た。
【００１４】
【発明の効果】
本発明によるレンズシートは押し出しラミネート法もしくは共押し出しコーティング法により、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、プリズム形状が形成される層とは異なる熱可塑性樹脂層に光拡散剤を添加することにより光拡散層を形成し、光拡散フィルムを一体化したものであるので、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の製造方法を提供するものである上に、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】本発明によるレンズシートの製造方法の一実施例を示した断面図である。
【図２】本発明によるレンズシートの製造方法の一実施例を示した断面図である。
【図３】本発明によるレンズシートの一実施例を示した断面図である。
【図４】本発明によるレンズシートの一実施例を示した断面図である。
【図５】本発明によるレンズ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
【図６】本発明によるレンズ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である。
【図７】本発明によるレンズ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】本発明によるレンズ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９】本発明によるレンズ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 共押し出しラミネート用基材
５ レンズシート
６ 光拡散層
７ プリズム形状形成層[0001]
[Industrial application fields]
The present invention relates to a process for producing a lens sheet having both light diffusing effect used in the backlight system 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,
(1) Laminating at least two layers of a light diffusing layer comprising a thermoplastic resin layer kneaded with a light diffusing agent and a prism shape forming layer having a prism shape formed on the surface of a thermoplastic resin layer not kneading the light diffusing agent. A method for producing a lens sheet for a liquid crystal display device comprising: a thermoplastic resin layer kneaded with a light diffusing agent; and a thermoplastic resin layer comprising at least two thermoplastic resin layers not kneaded with a light diffusing agent. A thermoplastic resin in which the light diffusing agent is not kneaded on a cooling roll having a prism shape on the surface of the thermoplastic resin layer melt-extruded in a state of being laminated by a co-extrusion method. The liquid crystal surface is characterized in that the layer shape is supplied so that the layer side faces the cooling roll side, is pressed by the cooling roll, and the prism shape is transferred and formed on the thermoplastic resin layer side not kneaded with the light diffusing agent. Method for manufacturing a device for the lens sheet.
(2) A prism shape is formed on the surface of a base material made of a thermoplastic resin film, a light diffusion layer made of a thermoplastic resin layer kneaded with a light diffusing agent, and a surface of a thermoplastic resin layer not kneaded with the light diffusing agent. A method for producing a lens sheet for a liquid crystal display device, comprising a laminate of at least two prism shape forming layers, wherein a light diffusing agent is applied to a surface of a substrate made of a thermoplastic resin film by a coextrusion laminating method. At least two thermoplastic resin layers composed of a kneaded thermoplastic resin layer and a thermoplastic resin layer not kneaded with the light diffusing agent are arranged so that the thermoplastic resin layer side kneaded with the light diffusing agent faces the substrate side. A thermoplastic resin layer in which a light diffusing agent is not kneaded out of at least two thermoplastic resin layers that have been melt-extruded by coextrusion coating and laminated and simultaneously melt-extruded. Surface presses the cooling roll having a prism shape, which the transfer of the prism shape to form a liquid crystal display device for a lens sheet manufacturing method, characterized in that. It is.
[0005]
As the resin to be extruded for the prism shape forming layer of the present invention, an acrylic resin, polycarbonate, polyvinyl chloride, polystyrene, polyethylene, polypropylene, polyester, cyclic polyolefin or the like alone or a mixture or a copolymer is particularly effective.
In addition, polyethylene terephthalate, polybutylene terephthalate, polyester resins using polyethylene naphthalate / isophthalate copolymer, polyolefin resins such as polymethylpentene, polyvinyl fluoride chloride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene・ Polyfluorinated ethylene resin such as tetrafluoroethylene copolymer, polyamide resin such as nylon 6 nylon 66, vinyl resin such as vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer, polyvinyl alcohol Cellulose resin with cellulose triacetate, cellophane, etc., acrylic resin such as polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate, polyarylate, polyimide, etc. alone or as a mixture The copolymers are also used.
[0006]
As the resin to be extruded for the light diffusion layer of the present invention, acrylic resin, polycarbonate, polyvinyl chloride, polystyrene, polyethylene, polypropylene, polyester, cyclic polyolefin, etc., which are kneaded with a light diffusion agent, are used alone or as a mixture or copolymer Is particularly effective.
In addition, polyethylene terephthalate kneaded with a light diffusing agent, polybutylene terephthalate, polyester resin such as polyethylene naphthalate / isophthalate copolymer, polyolefin resin such as polymethylpentene, polyvinyl fluoride chloride, polyvinylidene fluoride, Polytetrafluoroethylene, polyfluorinated ethylene resin such as ethylene / tetrafluoroethylene copolymer, polyamide resin such as nylon 6 nylon 66, vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer, Vinyl resins such as polyvinyl alcohol, cellulose resins using cellulose triacetate, cellophane, etc., acrylic resins such as polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate, polyarylate, polyimide, etc. Or mixtures or copolymers are also used.
Examples of the light diffusing agent include organic fine particles such as acrylic resin, melamine resin, polyethylene, polystyrene, organic silicone resin, acrylic-styrene copolymer, and inorganic fine particles such as calcium carbonate, silica, aluminum oxide, barium carbonate, barium sulfate, and glass. A simple substance or a mixture having an average particle diameter of 1 to 40 μm is used.
[0007]
The base material (coextrusion laminating base material) made of the thermoplastic resin film of the present invention is a single layer or composite film or sheet, and preferably has a thickness of preferably 5 to 200 μm, more preferably 10 to 125 μm. it can. Specific examples of the material of this base material include: polyethylene terephthalate, polybutylene terephthalate, polyester resin by polyethylene naphthalate / isophthalate copolymer, polyolefin resin such as polyethylene, polypropylene, polymethylpentene, polyfluorinated chloride Vinyl, 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 Polymers, ethylene / vinyl alcohol copolymers, vinyl resins such as polyvinyl alcohol, cellulose resins such as cellulose triacetate and cellophane, polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate, etc. Acrylic resins, polystyrene, polycarbonate, polyarylate, polyimide and the like.
[0008]
When the above-described light diffusing agent is mixed in the base material of the present invention, it can also serve as a light diffusing layer.
Further, a mat layer may be formed on the substrate of the present invention. As a formation method,
(1) A method of coating and forming a matting layer coating agent in which a matting agent is dispersed in a binder resin on a base material (2) A method of laminating a resin in which a matting agent is kneaded into a base material by lamination is used.
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. It is a simple substance or a mixture of inorganic fine particles having an average particle diameter of 3 to 20 μm.
[0009]
Examples of the binder resin for the matting layer coating agent include polyester resins such as polyurethane, polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate / isophthalate copolymer, polyolefin resins such as polyethylene, polypropylene, and polymethylpentene, and polyfluorine. Polyvinyl chloride, polyvinylidene fluoride, polytetrafluoroethylene, polytetrafluoroethylene resin with ethylene / tetrafluoroethylene copolymer, etc., polyamide resin with nylon 6 nylon 66, etc., polyvinyl chloride, vinyl chloride / vinyl acetate Copolymers, polyvinyl butyral, ethylene / vinyl alcohol copolymers, vinyl resins such as polyvinyl alcohol, cellulose resins such as cellulose triacetate and cellophane, polymeta Blended with acrylic resins such as methyl laurate, polyethyl methacrylate, and polybutyl acrylate, acrylonitrile-butadiene copolymer, polystyrene, polycarbonate, polyarylate, polyimide alone or a mixture, and also with a crosslinking agent such as isocyanate resin. May be.
[0010]
Next, in order to form a prism having a shape as shown in FIGS. 5 to 9 on one surface of the lens sheet of the present invention, “one of at least two thermoplastic resin layers laminated by the coextrusion method” is used. The method of pressing the cooling roll having the prism shape shown in FIGS. 5 to 9 on the surface layer ”and“ the surface of the base material made of the thermoplastic resin film on the surface of the thermoplastic resin layer by coextrusion laminating method. Are laminated by coextrusion coating, and pressed onto the surface of the thermoplastic resin layer against a cooling roll having the prism shape shown in FIGS. There is.
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. 5 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]
According to the present invention, any resin that can be melt-extruded can be used as a lens sheet material. Therefore, the selection range of optical characteristics such as refractive index, thermal characteristics, physical characteristics, etc. specific to the resin is extremely high. Become wider.
Furthermore, since the lens sheet of the present invention also has a light diffusion effect, it is not necessary to put a separate light diffusion film in the backlight assembly process, and the assembly process can be simplified. Furthermore, after manufacturing a thermoplastic sheet like a conventional lens sheet, there is no factor in increasing the manufacturing cost such as requiring an embossing process, and an integrated light diffusion layer can be formed at the same time, so a separate light diffusion film Manufacturing processes such as a molding process and a coating process are not required. Therefore, the lens sheet of the present invention can be mass-produced at a very low cost.
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 role of the mat layer is to prevent sticking with the light guide plate.
[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 lens sheet according to the present invention. FIG. 2 is a cross-sectional view showing an embodiment of a method for manufacturing a lens sheet according to the present invention.
FIG. 3 is a sectional view showing an embodiment of a lens sheet according to the present invention.
FIG. 4 is a sectional view showing an embodiment of a lens sheet according to the present invention.
5 to 9 are perspective views showing examples of prism shapes formed on the surface of the lens sheet according to the present invention.
[0013]
Example 1
Using the co-extrusion apparatus shown in FIG. 1, a cyclic polyolefin-based resin (Apel manufactured by Mitsui Petrochemical Industries) as a prism shape forming layer, and polymethyl methacrylate beads (manufactured by Sekisui Plastics Industries) as a light diffusing agent as a light diffusion layer An appel in which 20% by weight of an average particle diameter of 2 μ) is dispersed is extruded onto a cooling roll having the prism shape of FIG. 5 on the surface under processing conditions of a cylinder temperature of 250 ° C. and a die temperature of 220 ° C., and is cooled by pressing with a nip roll. As a result, a lens sheet of the present invention having a prism shape forming layer 80 μ having a prism shape transferred to the surface and a light diffusion layer 30 μ was obtained.
Example 2
Before coating a matting layer coating agent of the following composition on a non-treated surface of a 25 μm thick polyester film [SP 8 manufactured by Teijin Ltd.], mix the main agent and curing agent in a ratio of 100/3 (weight ratio). Then, after applying by a gravure reverse coating method (gravure plate depth 20 μ, 230 lines / inch) and drying, a mat layer having a thickness of 5 μm was formed to obtain a coextrusion laminate base 4.
Figure 0003732253
Next, using the coextrusion laminator shown in FIG. 2, acrylic (Mitsubishi Rayon Acrypet) is used as a layer for forming a prism shape, and silica hollow beads (Asahi Glass Cellstar average particle size) are used as a light diffusion agent as a light diffusion layer. 40μ) is dispersed on the surface of the coextrusion laminate base material with a mat layer formed on the back surface under the processing conditions of cylinder temperature 250 ° C and die temperature 230 ° C. The cooling roll having the prism shape shown in FIG. 9 is pressed and cooled by a nip roll to cool the prism shape forming layer 60 μ, the light diffusion layer 80 μ having the prism shape transferred to the surface, the coextrusion laminating base material 25 μ, and the back surface mat layer 5 μm. The lens sheet of the present invention was obtained.
[0014]
【The invention's effect】
The lens sheet according to 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 extrusion lamination or coextrusion coating, and the prism shape is formed. A light diffusion layer is formed by adding a light diffusing agent to a thermoplastic resin layer different from the layer, and the light diffusion film is integrated. Therefore, it is suitable for mass production at a lower cost than in the past. on is to provide a method of manufacturing a liquid crystal display device lens sheet, it is possible to simplify the assembling process of the backlight for a liquid crystal display device.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a method for producing a lens sheet according to the present invention.
FIG. 2 is a cross-sectional view showing an embodiment of a method for manufacturing a lens sheet according to the present invention.
FIG. 3 is a cross-sectional view showing an embodiment of a lens sheet according to the present invention.
FIG. 4 is a cross-sectional view showing an embodiment of a lens sheet according to the present invention.
FIG. 5 is a perspective view showing an example of a prism shape formed on the surface of a lens sheet according to the present invention. FIG. 6 shows an example of a kamaboko type prism shape formed on the surface of a lens sheet according to the present invention. It is a perspective view.
FIG. 7 is a perspective view showing an embodiment of a prism shape formed on the surface of a lens sheet according to the present invention.
FIG. 8 is a perspective view showing an embodiment of a prism shape formed on the surface of a lens sheet according to the present invention.
FIG. 9 is a perspective view showing an embodiment of a prism shape formed on the surface of a lens 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 Coextrusion lamination base material 5 Lens sheet 6 Light diffusion layer 7 Prism shape formation layer

Claims (2)

光拡散剤を混練した熱可塑性樹脂層から成る光拡散層と、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状が形成されたプリズム形状形成層の少なくとも２層を積層して成る液晶表示装置用レンズシートの製造方法であって、At least two layers, a light diffusing layer composed of a thermoplastic resin layer kneaded with a light diffusing agent and a prism shape forming layer in which a prism shape is formed on the surface of a thermoplastic resin layer not kneaded with the light diffusing agent, are laminated. A method of manufacturing a lens sheet for a liquid crystal display device,
光拡散剤を混練した熱可塑性樹脂層と光拡散剤を混練し無い熱可塑性樹脂層とから成る少なくとも２層の熱可塑性樹脂層を、共押し出し法により積層した状態で、溶融押し出しし、  At least two thermoplastic resin layers composed of a thermoplastic resin layer kneaded with a light diffusing agent and a thermoplastic resin layer not kneaded with a light diffusing agent are melt-extruded in a state of being laminated by a coextrusion method,
該溶融押し出しした少なくとも２層の熱可塑性樹脂層を、表面にプリズム形状を有する冷却ロール上に、前記光拡散剤を混練し無い熱可塑性樹脂層側が該冷却ロール側に向くようにして供給し、該冷却ロールで押圧し、光拡散剤を混練し無い熱可塑性樹脂層側にプリズム形状を転写、形成する、  The melt-extruded at least two thermoplastic resin layers are supplied on a cooling roll having a prism shape on the surface so that the thermoplastic resin layer side on which the light diffusing agent is not kneaded faces the cooling roll side, The prism shape is transferred and formed on the thermoplastic resin layer side which is pressed with the cooling roll and does not knead the light diffusing agent.
ことを特徴とする液晶表示装置用レンズシートの製造方法。  A method for producing a lens sheet for a liquid crystal display device. 熱可塑性樹脂フィルムからなる基材の表面に、光拡散剤を混練した熱可塑性樹脂層から成る光拡散層と、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状が形成されたプリズム形状形成層の少なくとも２層を積層して成る液晶表示装置用レンズシートの製造方法であって、A prism having a light diffusing layer composed of a thermoplastic resin layer kneaded with a light diffusing agent on the surface of a base material made of a thermoplastic resin film, and a prism shape formed on the surface of a thermoplastic resin layer not kneaded with the light diffusing agent. A method for producing a lens sheet for a liquid crystal display device comprising a laminate of at least two shape forming layers,
熱可塑性樹脂フィルムからなる基材の表面に、共押し出しラミネート法により、光拡散剤を混練した熱可塑性樹脂層と光拡散剤を混練し無い熱可塑性樹脂層とから成る少なくとも２層の熱可塑性樹脂層を、該光拡散剤を混練した熱可塑性樹脂層側が該基材側を向くようにして、共押し出しコーティングにより溶融押し出しして積層させ、  At least two thermoplastic resins comprising a thermoplastic resin layer kneaded with a light diffusing agent and a thermoplastic resin layer not kneaded with a light diffusing agent on the surface of a substrate made of a thermoplastic resin film by a coextrusion laminating method. The layers are laminated by melt extrusion by coextrusion coating, with the thermoplastic resin layer side kneaded with the light diffusing agent facing the substrate side,
積層と同時に前記溶融押し出しした少なくとも２層の熱可塑性樹脂層のうち、光拡散剤を混練し無い熱可塑性樹脂層の表面にプリズム形状を有する冷却ロールを押圧し、これにプリズム形状を転写、形成する、  Of the at least two thermoplastic resin layers melt-extruded at the same time as the lamination, a cooling roll having a prism shape is pressed onto the surface of the thermoplastic resin layer not kneaded with the light diffusing agent, and the prism shape is transferred and formed thereon. To
ことを特徴とする液晶表示装置用レンズシートの製造方法。  A method for producing a lens sheet for a liquid crystal display device.
JP14243495A 1995-05-18 1995-05-18 Manufacturing method of lens sheet for liquid crystal display device Expired - Lifetime JP3732253B2 (en)

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