JP4849263B2 - LIGHTING DEVICE MANUFACTURING METHOD AND LIGHTING DEVICE - Google Patents

Description

  The present invention relates to a method for manufacturing a lighting device and a lighting device, and more particularly to a method for manufacturing a lighting device that can easily manufacture a lighting device that can increase the brightness in the front direction and a lighting device manufactured by the method.

  Conventionally, from the viewpoint of reduction in thickness and weight, it has been studied to use, for example, an electroluminescence element (EL element) for a lighting device. A general EL element includes a transparent base layer having a light emitting surface on one side, a first electrode provided on the other side of the transparent base layer, and the other side of the first electrode. A light emitting layer provided on the side surface and a second electrode provided on the other side surface of the light emitting layer are provided. In such an EL element, various improvements have been made to further increase the luminance in the front direction on the light exit surface. For example, in Patent Document 1, a lens array sheet in which a plurality of quadrangular pyramidal protrusions or depressions (light output direction changing portions) is formed on the surface of a transparent base film is provided on the light output surface of the transparent base layer of the EL element. Disposition techniques are disclosed.

International Publication WO2004 / 017106

  However, in the technique shown in Patent Document 1, it is necessary to attach a separate lens array sheet to the light emitting surface of the EL element via an adhesive or the like, for example. For this reason, a lens array sheet has to be prepared in advance, and the manufacture of the lighting device has not always been simple. For this reason, the technique which can manufacture simply the illuminating device which can further raise the brightness | luminance of a front direction is calculated | required. Such a problem is not limited to the case where the above-described EL element is used as a light source, and similarly occurs in an aspect in which a backlight for a liquid crystal display device or the like is used as a light source.

  The objective of this invention is providing the manufacturing method of the illuminating device which can manufacture simply the illuminating device which can further raise the brightness | luminance of a front direction, and its illuminating device.

  The present invention is a lighting device comprising: a light source having a light emission surface that emits light; and a light emission direction conversion unit that is provided on the light emission side of the light emission surface and converts the direction of light emitted from the light source. A method for preparing a mold having a pattern surface having a fine concavo-convex structure, and an uncured photocurable composition in a state where the light emitting surface and the pattern surface are opposed to each other. A mold disposing step of placing the light source and the mold in contact with each other, a curing step of curing the photocurable composition by light irradiation to obtain a photocured product after the mold disposing step, and the curing step And a mold release step of forming the light exit direction changing portion having a shape to which the pattern surface has been transferred by peeling the mold from the photocured product.

  Here, the light source may be a backlight for a liquid crystal display device or an electroluminescence element. The light source may be a hot cathode tube (HCFL), a cold cathode tube (CCFL), or a light emitting diode (LED). The uncured photocurable composition includes a semi-cured photocurable composition in addition to the uncured photocurable composition.

  In addition, “the light source and the mold are placed in contact with each other through the uncured photocurable composition in a state where the light emitting surface and the pattern surface are opposed” means that the mold and the light source A mode in which a photocurable composition is injected between them in a state where they are opposed to each other, a mode in which a photocurable composition is previously provided on a pattern surface, and a mold and a light source are arranged to face each other, and light An example in which a curable composition is provided in advance on the light emitting surface and the light source and the mold are arranged to face each other can be exemplified.

  According to the present invention, a mold is disposed on the light exit surface of a light source via the photocurable composition, and then the photocurable composition is cured by emitting light from the light source or from the outside to obtain a photocured product. After that, by removing the mold from the photocured product, it is possible to form a light output direction changing portion having a predetermined shape. Therefore, the step of forming the light exit direction changing portion and the step of providing the light exit direction changing portion on the light exit surface of the light source can be performed simultaneously. For this reason, the number of processes is reduced as compared with a case where a sheet on which a light exit direction changing portion having a predetermined shape is formed in advance and the created sheet is attached to the light emitting surface of the light source to manufacture the lighting device. For this reason, it is possible to easily manufacture an illuminating device with improved brightness in the front direction.

  Here, the light irradiation in the curing step can be performed by external light irradiation and / or light emission of the light source, but it is preferable to cure the photocurable composition by light emission of the light source. According to this, since it is the structure which arrange | positions a type | mold on the light-projection surface of a light source through a photocurable composition, and hardens the said photocurable composition by light emission of the light source, a light source light-emits correctly. In the case of confirmation (inspection) of whether or not, the curing step can also be carried out, and a lighting device with improved brightness in the front direction can be more easily manufactured.

  By the way, when an organic material is used as the material of the light emitting layer of the EL element, there is a problem that the material deteriorates due to external light or the like, and the life of the EL element and thus the lighting device cannot be extended. there were. However, according to this configuration, since the photocurable composition is cured by light emission from the light source itself, the problem of deterioration of the light emitting layer does not occur, and the lifetime of the EL element and the lighting device can be extended. Moreover, since heat is generated as the EL element emits light, the photocurable composition is also cured by this heat, which can contribute to improvement in productivity of the lighting device.

  Moreover, this invention has a transparent base material layer, a 1st electrode, a light emitting layer, and a 2nd electrode in this order, and the surface on the opposite side to the said 1st electrode in the said transparent base material layer light-emits. A manufacturing method of an illuminating device comprising: an electroluminescence element serving as a light emission surface to emit; and a light emission direction conversion unit that is provided on a light emission side of the light emission surface and converts a direction of light emitted from the electroluminescence element. A step of providing a first electrode on a surface of the transparent base material layer opposite to the light emitting surface, and a provision of a light emitting layer on a surface of the first electrode opposite to the transparent base material layer. A step of providing a second electrode on the surface of the light emitting layer opposite to the first electrode, a mold preparing step of preparing a mold having a pattern surface having a fine concavo-convex structure, the light emitting surface, Pair with pattern surface A mold placement step of placing the transparent substrate layer and the mold in contact with each other through the uncured photocurable composition, and curing the photocurable composition by light irradiation to produce light. A curing step for obtaining a cured product, and a mold release step for forming the light output direction changing portion having a shape to which the pattern surface is transferred by peeling the mold from the photocured product after the curing step. Prepare.

  In this invention, after manufacturing an EL element previously, it is good also as an aspect which manufactures a light emission direction conversion part in the light-projection surface, and a type | mold is set | placed on the light-projection surface of a transparent base material layer through a photocurable composition. It is good also as an aspect which prepares the arrange | positioned member and implements the step which manufactures an EL element, and the step which manufactures a light output direction change part using the member.

  According to the present invention, as described above, the photocurable composition is cured by emitting light from the EL element itself or from the outside, and then the mold is peeled off, whereby the light emitting surface of the EL element has a predetermined shape. It is possible to form a light exit direction changing portion having Therefore, since the step of forming the light output direction conversion unit and the step of providing the light output direction conversion unit on the light exit surface of the light source can be performed at the same time, a sheet on which the light output direction conversion unit of a predetermined shape has been formed in advance. Since the number of processes is reduced as compared with the case where the lighting device is manufactured by sticking the prepared sheet to the light emission surface of the light source, it is possible to easily manufacture the lighting device with improved brightness in the front direction.

  Here, the light irradiation in the curing step can be performed by external light irradiation and / or light emission of the EL element, but it is preferable to cure the photocurable composition by light emission of the EL element. . According to such a configuration, since the photocurable composition is cured by light emission of the EL element itself, the problem of deterioration of the light emitting layer constituting the EL element does not occur, and the life of the EL element and the lighting device is extended. be able to.

  Moreover, in the manufacturing method of the illuminating device of the aspect which light-emits light source itself (EL element itself), and hardens a photocurable composition, the said type | mold is formed with transparent resin, and before the said curing | hardening step, It is preferable to include a light reflecting portion forming step of providing a light reflecting portion that reflects light from the light source on at least a part of the back surface of the outer surface on which the pattern surface is formed. At this time, the light reflecting portion may be a metal sheet or a layer formed on the surface of the mold by vapor deposition of metal or the like. According to such a configuration, since the light emitted from the light source can be reflected by the light reflecting portion and returned to the photocurable composition side, curing of the photocurable composition can be promoted, and the illumination device Can improve productivity.

  In the manufacturing method of the above illuminating device, the peeling sheet installation step which provides a peeling sheet via the photocurable composition on the pattern surface in the mold, and the photocurable composition is left on the mold side. It is good also as a structure further equipped with the peeling step which peels the said peeling sheet from the said mold | die in a state before the said mold arrangement | positioning step. According to such a configuration, a member in which the release sheet and the mold are placed in contact with each other with the photocurable composition interposed therebetween is prepared, and the release sheet is simply peeled off just before being installed on the light emitting surface of the light source. The lighting device can be manufactured by a relatively simple procedure.

  In the method for manufacturing the lighting device, the light source may be a backlight device for a liquid crystal display device or an electroluminescence element.

  According to the present invention, a mold is disposed on the light exit surface of a light source via the photocurable composition, and then the photocurable composition is cured by emitting light from the light source or from the outside to obtain a photocured product. Then, the mold is peeled off from the photocured product, whereby a light emission direction changing portion having a predetermined shape can be formed. Therefore, since the step of forming the light output direction conversion unit and the step of providing the light output direction conversion unit on the light exit surface of the light source can be performed at the same time, a sheet on which the light output direction conversion unit of a predetermined shape has been formed in advance. Compared to the case where the lighting device is manufactured by sticking the prepared sheet to the light emitting surface of the light source, the lighting device with improved brightness in the front direction can be easily manufactured.

  Hereinafter, the lighting device obtained by the manufacturing method of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view schematically showing a configuration of a lighting device obtained by the manufacturing method of the present invention. As shown in FIG. 1, the illumination device 1 includes an organic EL element 10 as a light source having a light emitting surface 12B that emits light, and light emitted from the organic EL element 10 provided on the light emitting side of the light emitting surface 12B. And a light output direction conversion unit 20 that converts the direction of the light.

  The organic EL element 10 includes a transparent base layer 12 and a first electrode provided on a surface 12A which is one side of the transparent base layer 12 in FIG. 1 and which is the back side of the light emitting surface 12B. The transparent electrode 14, the light emitting layer 16 provided on the transparent electrode 14, and the back electrode 18 as the second electrode provided on the light emitting layer 16.

  The transparent base material layer 12 is a member formed in a film shape, a sheet shape, or a plate shape, and its outer shape is, for example, a rectangular shape. The transparent substrate layer 12 is made of, for example, glass or a transparent resin material. In the transparent base material layer 12 using a transparent resin material, the total light transmittance is preferably 90% or more when the thickness is 0.1 mm. As the transparent resin material, those added with various additives may be used as necessary. In addition, the transparent base material layer 12 of this embodiment is made of glass.

  In providing a layer made of a photocurable composition on the surface of the transparent substrate layer 12, the surface of the transparent substrate layer 12 is subjected to a surface treatment with a surfactant (such as hexamethylene disilazane (HMDS)), and the like. You may improve the adhesiveness of the transparent base material layer 12 and the hardened | cured material of a photocurable composition.

  Transparent resin materials include chain polyolefin resins such as polyethylene, polypropylene, and polymethylpentene; aromatic vinyl resins such as polystyrene; norbornene polymers, vinyl alicyclic hydrocarbon polymers, monocyclic olefin polymers, and cyclic diolefins Polymers and other alicyclic olefin resins; Polycarbonate resins such as polycarbonate, polyethylene phthalate, polybutylene phthalate, and liquid crystal polyester; Acrylic resins such as polymethyl methacrylate; Acrylonitrile resins such as acrylonitrile styrene resin and acrylonitrile styrene butadiene resin; Polysulfone, Poly Polyether resins such as ether sulfone, polyphenylene sulfide and polyphenylene ether; ketone resins such as polyether ether ketone It can gel. Among these, alicyclic olefin resins are preferred because they absorb little visible light and have low water absorption.

  The transparent electrode 14 is made of, for example, ITO (Indium Tin Oxide), zinc oxide (ZnO), or the like. The back electrode 18 is made of, for example, a vapor deposition film such as aluminum or a magnesium silver alloy. A voltage can be applied between the transparent electrode 14 and the back electrode 18.

For the light emitting layer 16, various organic materials and inorganic materials that have been generally used can be used. For example, JP 2002-164170 A, JP 2006-135101 A, and JP 2006-40856 A. The material shown in the gazette etc. can be used. For example, the light-emitting layer 16 has a blue light-emitting material (bis (2-methyl-8-quinolinolato) -4-phenylphenolato-aluminum complex (BAlq), benzoxazole zinc complex (Zn (box) ₂ ), 4,4. -Bis (diphenylvinylene) -biphenyl (ADS082) etc.), yellow light emitting material (bis (8-quinolato) zinc complex (Znq ₂ ) etc.), green light emitting material (bis (benzoquinolinolato) beryllium complex (Bebq ₂ )) , Tris (8-quinolinolato) aluminum complex (Alq ₃ ), etc.), red light emitting material (4- (dicyanomethylene) -2-t-butyl-6- (1,1,7,7-tetramethyljulolidyl- 9-enyl) -4H-pyran (DCJTB) and other DCMs, rubrene and other polycyclic aromatic ring systems) and hole transport materials (N, N′-di (1 Naphthyl) -N, N′-diphenylbenzidine (NPD), triphenyldiamine derivative (TPD), 4,4 ′, 4 ″ -tris (N- (3-methylphenyl) N-phenylamino) triphenylamine (m -MTDATA), N, N'-di (naphthalen-1-yl) -N, N'-diphenyl-benzidine (NPB), etc.), electron transport materials (Alq ₃ , oxadiazole derivatives (PBD, BND), 1 2,4-triazole derivatives (TAZ) and the like.

  The organic EL element 10 is preferably an element that emits white light. In this case, the organic EL element 10 preferably has an emission spectrum peak in a wavelength range of 500 nm or less, particularly in a wavelength range of 400 nm to 500 nm.

  The light exit direction changing unit 20 is a fine concavo-convex structure made of a photocured product obtained by curing an uncured photocurable composition. As this photocurable composition, it is preferable to use a composition that is sensitive to the peak wavelength of the emission spectrum in the wavelength range of 500 nm or less of the organic EL element 10. For example, when the organic EL element 10 having an emission spectrum peak at 440 nm is used, the photocurable composition is preferably one that is particularly sensitive in the wavelength range of 440 nm ± 50 nm. By using such a photocurable composition, the light emission direction changing part 20 can be formed in a relatively short time, and the lighting device 1 can be manufactured efficiently.

  Here, the photocurable composition is in an uncured state by irradiation with ionizing radiation such as α rays, β rays, γ rays, X rays, and electron beams, ultraviolet rays, and energy rays such as visible rays. It is a composition having a property of curing by inducing molecular chain growth and a crosslinking reaction of the photocurable composition. This photocurable resin composition contains a photocurable material as a main component and a photopolymerizable initiator. Moreover, the photocurable resin composition contains additives such as a thermal polymerization initiator and the like when used in combination with a photosensitizer, a polymerization accelerator, a stabilizer, a filler, and thermal polymerization as necessary. There may be.

Examples of the photocurable material include a photocurable oligomer and a photocurable monomer. Examples of the photocurable oligomer include acrylates such as polyester acrylate, epoxy acrylate, urethane acrylate, polyether acrylate, polybutadiene acrylate, and silicone acrylate, epoxy, vinyl ether, and polyene thiol. Examples of the photocurable monomer include monofunctional acrylates and polyfunctional acrylates.
Examples of the photopolymerizable initiator include benzophenone series, acetophenone series, benzoin series, and thioxanthone series.

FIG. 2 is a perspective view schematically showing the light exit direction changing unit 20.
As shown in FIG. 2, the light output direction conversion unit 20 includes a plurality of concave or convex cones 21. Here, examples of the cone 21 include a pyramid shape such as a triangular pyramid and a quadrangular pyramid, a truncated pyramid shape, a conical shape, and a truncated cone shape. Among these, the pyramid is preferably a quadrangular pyramid because it can improve the luminance in the front direction and can be easily molded. In addition, the cone 21 of this embodiment is a quadrangular pyramid. Further, the light output direction changing section 20 can be concave from the viewpoint of preventing chipping and the like, and can be convex from the viewpoint of easily removing foreign matters such as dust. The surface of the cone 21 may be a mirror surface or a rough surface having fine irregularities.

  When the pyramid is a quadrangular pyramid, the bottom surface of the quadrangular pyramid can be a square or a rectangle. When the bottom surface is rectangular, it is preferable that the relationship of a ≦ b ≦ 5a is satisfied, where a is the short side length and b is the long side length, and a ≦ b ≦ 1.5a. It is more preferable to satisfy the relationship. The length a of one side can be 0.1 μm to 500 μm, preferably 0.1 μm to 100 μm, more preferably 0.1 μm to 50 μm, and more preferably from the viewpoint of preventing the occurrence of moire. Is 0.1 μm to 50 μm.

  Here, the apex angle of the cone 21 is preferably 20 degrees to 140 degrees, and more preferably 30 degrees to 120 degrees. Moreover, the length of the width dimension of the bottom face part which comprises the cone 21 can be made into 1 micrometer-100 micrometers, it is preferable that they are 10 micrometers-80 micrometers, and it is more preferable that they are 20 micrometers-50 micrometers. By setting it as such a dimension, the brightness | luminance of a front direction can be raised. Here, the length of the width of the bottom surface portion constituting the cone indicates the diameter of the circular bottom surface when the cone is conical, and when the cone is an elliptical cone, The average value of the major axis and minor axis of the bottom surface of the ellipse is shown. Moreover, when a cone is a pyramid shape, the average value of the length of the one side which comprises a polygonal bottom face part is shown.

  The light output direction conversion unit 20 may be configured to include a plurality of cones having substantially the same shape, or may be configured to include a plurality of types of cones having different shapes. Further, the plurality of cones may be arranged in a regular lattice shape, a staggered lattice shape, or a random lattice shape. However, it is preferable to arrange in a regular grid pattern or a staggered grid pattern in terms of higher brightness. Furthermore, the adjacent cones may be arranged so as to be adjacent to each other or may be arranged apart from each other.

Next, the manufacturing method of the illuminating device concerning this invention is demonstrated.
FIG. 3 is a schematic diagram for explaining a procedure for manufacturing the lighting device 1 by the manufacturing method according to the present embodiment. As shown in FIG. 3A, first, an organic EL element 10 as a light source is prepared in advance. Specifically, first, the transparent electrode 14 is formed of ITO or the like on the surface 12A opposite to the light emission surface 12B in the transparent substrate layer 12 made of glass, and then the light emitting layer 16 is formed on the transparent electrode 14. The back electrode 18 is formed in this order by vacuum deposition or the like. In this way, the organic EL element 10 is produced.

  Further, separately from the organic EL element 10, a mold member 30 for manufacturing the light output direction changing unit 20 is prepared and prepared in advance (mold preparation step). The mold member 30 includes a mold 32 having a pattern surface 32A having a fine concavo-convex structure, an uncured photocurable composition 34 provided on the pattern surface 32A of the mold 32, and a photocurable composition 34. And a metal sheet 38 as a light reflecting portion provided on a surface 32B of the mold 32 opposite to the pattern surface 32A.

The mold 32 having the pattern surface 32A can be formed of metal, resin, or the like.
When the mold 32 is formed of metal, it can be formed using, for example, a cutting technique or a general photolithographic technique. When using the cutting technique, for example, a metal flat plate is prepared and the surface thereof is prepared. A die 32 having a pattern surface 32 can be formed by providing a plating layer or the like on the substrate and cutting the plating layer with a cutting tool. However, the plating layer may not be provided. At this time, a release treatment may be performed on the surface of the pattern surface 32A of the mold 32 so that the cured photocurable composition 34 and the mold 32 can be easily released. Examples of such mold release treatment include an aspect in which the surface is coated with a fluorine-based material or the surface is treated with a fluorine-based gas.

  Further, when the mold 32 is formed of a resin, a known thermoplastic resin can be used as the resin. As the thermoplastic resin, for example, alicyclic structure-containing resin, polycarbonate, polymethacrylate, polyimide, polyamide, polysulfone, polyvinyl chloride, polyvinylidene chloride, or polyolefin resin such as polypropylene, polyethylene, polymethylpentene-1, etc. are transparent. Among them, alicyclic structure-containing resins are preferable. By molding the mold with an alicyclic structure-containing resin, the surface pattern can be molded with high accuracy, excellent in durability (anti-hygroscopic deformation, reusability), and released from the light-curing exit direction changing section. A mold having excellent properties can be obtained. In particular, as the area of the light exit direction changing portion increases, these features are emphasized and are suitable. Moreover, what added the additive as needed can also be used for the said resin.

  Next, as shown in FIG. 3B, in the mold member 30, the release sheet 36 is peeled from the mold 32 provided with the photocurable composition 34 (peeling step). It is preferable that the photocurable composition 34 has a certain degree of viscosity so that the photocurable composition 34 does not hang from the mold 32 when the release sheet 36 is peeled off. In order to ensure such a viscosity, it is preferable that the photocurable composition 34 is semi-cured before the release sheet 36 is peeled from the mold 32.

  Next, the light emitting surface 12B of the transparent base material layer 12 of the organic EL element 10 is surface-treated with, for example, hexamethylene disilazane (HMDS). Thereby, the adhesiveness of the transparent base material layer 12 and the hardened | cured material of the photocurable composition 34 can be improved.

  Next, as shown in FIG. 3 (C), in a state where the light emitting surface 12B of the transparent base material layer 12 and the pattern surface 32A of the mold 32 face each other, the uncured photocurable composition 34 is formed. The transparent base material layer 12 and the mold 32 are placed in contact with each other (mold placement step).

  Next, as shown in FIG. 3D, a voltage is applied between the transparent electrode 14 and the back electrode 18 to cause the light emitting layer 16 to emit light. Thereby, the light L emitted from the light emitting layer 16 reaches the photocurable composition 34 via the light emitting surface 12B of the transparent base material layer 12, and a part of the light L1 is made of the metal sheet 38. And reaches the photocurable composition 34 again. At this time, a sufficient amount of irradiation energy is applied to cure the photocurable composition 34. Thereby, the curable composition 34 is cured in response to the direct light L from the organic EL element 10 or the reflected light L2 to be a photocured product. In this way, the photocurable composition 34 is cured (curing step).

  Finally, as shown in FIG. 3 (E), the mold 32 and the metal sheet 38 are peeled from the photocured product 34 to form the light output direction changing portion 20 having a shape obtained by transferring the shape of the pattern surface 32A. (Release step)

The lighting device 1 is manufactured as described above.
The used mold 32 and the metal sheet 38 can be reused by providing the photocurable composition 34 on the pattern surface 32 again.

According to the present embodiment, there are the following effects.
(1) Since the light output direction conversion unit 20 including the plurality of quadrangular pyramids 21 is formed on the surface of the transparent base material layer 12, the light from the light emitting layer 16 is condensed by the light output direction conversion unit 20. And the light extraction efficiency can be increased. For this reason, it is possible to provide an electroluminescence element having higher brightness in the front direction. Therefore, by using such a high-luminance element, a lighting device with higher luminance can be provided. In addition, by providing a liquid crystal panel on the light emission side of the illumination device, it is possible to provide a higher-brightness liquid crystal display device including a liquid crystal panel disposed on the light emission side of the illumination device.

  (2) Since the light exit direction changing unit 20 is composed of a plurality of pyramids 21 having a quadrangular pyramid shape, the light extraction efficiency can be further enhanced as compared with other shapes.

  (3) The mold member 30 is disposed on the light emitting surface 12B of the organic EL element 10 through the photocurable composition 34, and the organic EL element 10 is caused to emit light to cure the photocurable composition 34. The light-cured product 34 is formed, and then the mold member 30 is peeled off from the photo-cured product 34, whereby the light output direction changing portion 20 having a predetermined shape can be formed. Accordingly, since the step of forming the light exit direction changing unit 20 and the step of providing the light exit direction changing unit 20 on the light exit surface 12B can be performed simultaneously, a sheet on which the light exit direction changing unit having a predetermined shape is formed in advance. Since the number of steps is reduced as compared with the case where the lighting device is manufactured by sticking the created sheet to the light emitting surface of the light source, the lighting device with improved brightness in the front direction can be easily manufactured.

  (4) Since the photocurable composition 34 is cured by the light emission of the organic EL element 10 itself, the curing step is also included when confirming whether or not the organic EL element 10 emits light correctly (inspection). It is possible to implement a lighting device with improved brightness in the front direction.

  (5) Since the photocurable composition 34 is cured by the light emission of the light emitting layer 16 itself, the problem of deterioration of the light emitting layer 16 made of an organic material does not occur as in the case of irradiating light from the outside. 10 and the lighting device 10 can be extended in service life.

  (6) Heat generation occurs with the light emission of the organic EL element 10, and the curing of the photocurable composition 34 proceeds with this heat, which can contribute to the improvement of the productivity of the lighting device 1.

  (7) By using the metal sheet 38, light emitted from the organic EL element 10 can be reflected by the metal sheet 38 and returned to the photocurable composition 34 side. Curing can be accelerated. For this reason, the productivity of the lighting device 1 can be further improved.

  (8) A member in which the release sheet 36 and the mold 32 are disposed in contact with each other with the photocurable composition 34 interposed therebetween is prepared, and the release sheet 36 is peeled in a state where the photocurable composition 34 is left on the mold 32 side. Since it was set as the structure, the illumination apparatus 1 can be manufactured comparatively easily only by peeling off the peeling sheet 36 just before installing in the light-projection surface 12B.

  (9) Since the light emitting direction changing portion 20 is formed on the light emitting surface 12B after the organic EL element 10 which is a light source is formed, it is easy even when the members 10 and 20 are manufactured in different places. It can correspond to.

The present invention is not limited to the above embodiment.
In the said embodiment, it was set as the procedure which forms the light emission direction conversion part 20 after manufacturing the organic EL element 10 previously, For example, as a procedure which forms the light emission direction conversion part 20 with manufacture of the organic EL element which is a light source, for example. Good. Specifically, the mold 32 and the metal sheet 38 are disposed on the light emitting surface 12B of the transparent base material layer 12 so that the light emitting surface 12B and the pattern surface 32A face each other with the photocurable composition 34 interposed therebetween. To. Next, using the transparent substrate layer 12 in which the mold 32 and the metal sheet 38 are installed on the light emitting surface 12B, the transparent substrate 12 is transparent on the surface 12A opposite to the light emitting surface 12B. The electrode 14, the light emitting layer 16, and the back electrode 18 are formed in this order. Thereby, the member by which the type | mold 32 and the metal sheet | seats 38 were installed on the light-projection surface 12B of the organic EL element 10 via the photocurable composition 34 is created. In this state, the organic EL element 10 is caused to emit light to cure the photocurable composition 34, and then the mold 32 and the metal sheet 38 are peeled off, thereby forming the light output direction changing portion 20. The lighting device 1 can be manufactured as described above.

  In the above embodiment, the release sheet 36 is peeled from the mold member 30 to expose the photocurable composition 34. However, the release sheet 36 may not be provided. In this case, for example, a member composed of the mold 32 and the metal sheet 38 is facilitated, and the photocurable composition 34 is provided on the pattern surface 32A of the mold 32 by coating or the like. The lighting device 1 can be manufactured by the procedure of arranging 12. Moreover, you may manufacture the illuminating device 1 in the procedure which provides the photocurable composition 34 on the transparent base material layer 12 by application | coating etc., and arrange | positions the type | mold 32 on it.

  In the said embodiment, although the organic EL element was light-emitted and the photocurable composition was hardened, it is good also as a structure which hardens a photocurable composition using an external light source. However, since an organic EL element is used as a light source and a light emitting layer made of an organic material may be deteriorated by light irradiation from the outside, an embodiment in which the organic EL element itself emits light is preferable.

  In the above embodiment, the light source is an organic EL element, but an inorganic EL element or a backlight for a liquid crystal display device may be used.

Further, for example, in the above-described embodiment, the transparent base layer 12 and the transparent electrode 14 are directly laminated. However, from the viewpoint of increasing the light emission efficiency, for example, sputtering is performed between the members 12 and 14 by sputtering SiO ₂ or the like. A gas barrier layer formed as a film may be laminated.

  Next, the present invention will be described in more detail using Examples and Comparative Examples 1 and 2 with reference to FIG.

<Example 1>
(1) Creation of mold member First, a rectangular plate made of 50 mm × 50 mm stainless steel SUS430 was prepared, and nickel-phosphorous electroless plating with a thickness of 100 μm was applied to the entire surface. Next, nickel-phosphorus electroless plating is performed using a tool on which a single crystal diamond tip having a vertex angle of 90 degrees (manufactured by Contool Fine Tooling) is attached to a machine tool for fine processing (Nano Gruber AMG71P, manufactured by Fujikoshi). A plurality of linear parts having an isosceles triangular cross section having a width of 20 μm, a height of 10 μm, a pitch of 20 μm, and an apex angle of 90 degrees were cut along the short side direction of the plate. Next, a plurality of linear portions were cut at the same pitch as described above along the long side direction of the plate material. As a result, a metal stamper having a concavo-convex structure in which a plurality of convex quadrangular pyramids are arranged in a regular lattice shape on the surface of a rectangular plate material was produced.

  Next, a resin pellet of a ring-opening polymer hydride of a norbornene-based monomer that is an alicyclic structure-containing resin (“ZEONOR 1060R” manufactured by ZEON CORPORATION) is used as a raw material by an injection molding machine equipped with the metal stamper. Then, an alicyclic structure-containing resin mold 32 having a pattern surface 32A in which a plurality of concave quadrangular pyramids are arranged, to which the concavo-convex structure was transferred, was molded.

  In this example, a resinous mold was formed by injection molding. For example, a film made of an alicyclic structure-containing resin (manufactured by Nippon Zeon Co., Ltd., “ZEONOR FILM”) was prepared, and the metal A mold made of resin having a pattern surface on which a plurality of concave quadrangular pyramids are arranged may be formed by embossing (nanoimprinting) using a mold having the same configuration as the stamper.

  Next, an aluminum sheet 38 was attached to the surface 32B of the mold 32 opposite to the pattern surface 32A. Further, a photocurable composition (“PAK01” manufactured by Toyo Gosei Co., Ltd.) was applied on the pattern surface 32A with the pattern surface 32A of the mold 32 facing upward. The mold member 30 was produced as described above. In this example, no release sheet was provided.

(2) Preparation of white organic EL element First, ITO was vapor-deposited on a transparent glass substrate (transparent substrate layer) to form an anode (first electrode). Next, NPB was deposited on the anode to form a hole transport layer (light emitting layer). A blue light emitting layer (light emitting layer) was formed by vapor-depositing ADS082 which is a blue light emitting material on the hole transport layer. A red light emitting layer (light emitting layer) was formed on the blue light emitting layer by depositing DCJTB as a red light emitting material. Alq ₃ was vapor-deposited on the red light emitting layer to form a green light emitting layer (light emitting layer) and an electron transport layer. LiF was deposited on the electron transport layer to form a buffer layer, and then aluminum was deposited to form a cathode (second electrode). A white organic EL device was produced as described above.

(3) Manufacture of illuminating device Next, the mold member 30 was placed on the surface (light emitting surface) of the glass substrate of the obtained white organic EL element so that the photocurable composition was in contact with it. Next, the white organic EL device was allowed to emit light at 3000 cd / m ² for 2 minutes to cure the photocurable composition to obtain a photocured product. Finally, the mold member 30 was peeled off from the photocured product and released from the mold, and an illuminating device having a light output direction changing portion made of the photocured product on the light emitting surface of the organic EL element was manufactured.

<Example 2>
In this example, an illuminating device was obtained in the same manner as in Example 1 except that the aluminum sheet was not used and that the white organic EL element emitted light at 3000 cd / m ² for 3 minutes.

<Example 3>
In this example, instead of the resin mold used in Example 1, the following metal mold having the same configuration as the metal stamper obtained in Example 1 was used as the mold. The lighting device was obtained. The metal mold was obtained by applying a mold release agent (“OPTOOL” manufactured by Daikin Co., Ltd.) on the surface of the metal stamper on which the concavo-convex structure was formed (corresponding to the pattern surface) and drying for 10 minutes.

<Example 4>
In this example, first, a PET mold having a pattern surface on which a plurality of concave quadrangular pyramids are arranged by embossing (nanoimprint processing) using a mold having the same configuration as the metal stamper on the surface of the PET film. Was molded. Next, a mold release agent (“OPTOOL” manufactured by Daikin Co., Ltd.) was applied to the surface (corresponding to the pattern surface) on which the uneven structure of this type was formed, and dried for 10 minutes. In this example, the PET mold was used in place of the alicyclic structure-containing resin stamper used in Example 1, and the emission of the white organic EL element was 3000 cd / m ² for 3 minutes. Except for the points, an illumination device was obtained in the same manner as in Example 1.

<Example 5>
In this example, it was carried out except that the light-curable composition was not cured by light emission from the white organic EL element, but the photocurable composition was cured by external light irradiation using an exposure apparatus ("TME-150R", manufactured by TOPCON). A lighting device was obtained in the same manner as in Example 1.

  For each lighting device manufactured as described above, after confirming that the light output conversion portion is formed in a desired shape with an optical microscope, the luminance efficiency was determined using a spectrophotometer. 1 to 4 had a luminous efficiency of 18.5 (lm / W). On the other hand, Example 5 had a luminous efficiency of 15.3 (lm / W). Therefore, it turned out that Examples 1-4 are 17% efficient compared with Example 5. FIG.

It is sectional drawing which shows typically the structure of the illuminating device obtained by the manufacturing method of this invention. It is a perspective view which shows typically the light emission direction conversion part which comprises the said illuminating device. It is a schematic diagram for demonstrating the procedure which manufactures an illuminating device with the manufacturing method which concerns on embodiment of this invention.

Explanation of symbols

1 Illumination device 10 Organic EL element (light source)
DESCRIPTION OF SYMBOLS 12 Transparent base material layer 12A Surface 12B Light emission surface 14 Transparent electrode 16 Light emitting layer 18 Back surface electrode 20 Light emission direction conversion part 21 Cone 30 Type | mold member 32 Type | mold 32A Pattern surface 32B Surface 34 Photocurable composition (photocured material)
36 Release sheet 38 Metal sheet (light reflection part)

Claims (6)

An electroluminescence element which is a light source having a light emitting surface for emitting light;
A light output direction conversion unit that is provided on the light output side of the light output surface and converts the direction of light emitted from the light source, and a manufacturing method of an illumination device,
A mold preparation step of preparing a mold having a pattern surface made of a fine concavo-convex structure;
A mold placement step of placing the light source and the mold in contact with each other through an uncured photocurable composition with the light emitting surface and the pattern surface facing each other,
After this mold placement step, a curing step of curing the photocurable composition by light irradiation by light emission of the light source to obtain a photocured product,
After this curing step, a mold release step for forming the light exit direction changing portion having a shape to which the pattern surface is transferred by peeling the mold from the photocured product;
A method for manufacturing a lighting device comprising: It has a transparent base material layer, a first electrode, a light emitting layer, and a second electrode in this order, and the surface opposite to the first electrode in the transparent base material layer is a light emitting surface that emits light. An electroluminescence element;
A light emitting direction conversion unit that is provided on a light emitting side of the light emitting surface and converts a direction of light emitted from the electroluminescence element, and a manufacturing method of an illumination device,
Providing a first electrode on a surface of the transparent substrate layer opposite to the light emitting surface;
Providing a light emitting layer on a surface of the first electrode opposite to the transparent substrate layer;
Providing a second electrode on a surface of the light emitting layer opposite to the first electrode;
A mold preparation step of preparing a mold having a pattern surface made of a fine concavo-convex structure;
A mold placement step of placing the transparent base material layer and the mold in contact with each other through the uncured photocurable composition with the light emitting surface and the pattern surface facing each other,
A curing step of curing the photocurable composition by light irradiation by light emission of the electroluminescence element to obtain a photocured product;
After this curing step, a mold release step for forming the light exit direction changing portion having a shape to which the pattern surface is transferred by peeling the mold from the photohard material;
A method for manufacturing a lighting device comprising: In the manufacturing method of the illuminating device of Claim 1 or 2,
The mold is formed of a transparent resin,
Before the curing step, a light reflecting portion forming step of providing a light reflecting portion that reflects light from the light source on at least a part of the back surface of the outer surface of the mold on which the pattern surface is formed. The manufacturing method of the illuminating device further provided. In the manufacturing method of the illuminating device of Claim 3,
The manufacturing method of the illuminating device whose said light reflection part is a metal sheet | seat. In the manufacturing method of the illuminating device in any one of Claims 1-4,
A release sheet installation step in which a release sheet is provided on the pattern surface of the mold via the photocurable composition, and the release sheet is removed from the mold in a state where the photocurable composition is left on the mold side. The manufacturing method of the illuminating device further provided with the peeling step to peel before the said mold | positioning step. The illuminating device manufactured by the manufacturing method of the illuminating device in any one of Claims 1-5.

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