JP5693182B2 - Method for manufacturing display device member and display device - Google Patents

Description

  The present invention relates to a method for manufacturing a member for a display device, and more particularly to a method for manufacturing a member constituting a display device.

  Moreover, this invention relates to the display apparatus containing the member for display apparatuses manufactured by the manufacturing method of such a member for display apparatuses.

  As a three-dimensional display device capable of displaying an image three-dimensionally, a three-dimensional display device including a micro-pattern polarizing element is known (for example, by Non-Patent Document 1 (Sadeg M. Faris) , “Micro-Polarizer Arrays to a New Class of Stereoscopic Imaging”, SID 91 DIGEST, 1991, p.840- 843).) In addition, as such a micro-pattern polarizing element, a resist is coated on a stretched dichroic polyvinyl alcohol film, patterned, and then the film is dissolved (removed) with an aqueous caustic soda solution to obtain a patterned polarizing element. A polarizing element produced by superposing two patterned polarizing elements having orthogonal polarization axes is known. Also, a method of manufacturing a display device that functions as a stereoscopic display device by bonding such a polarizing element to a substrate on which a display element is formed (a plurality of pixels arrayed along the main surface of the substrate). It has been known.

Sadeg M. Faris, “Micro-Polarizer Arrays to a New Class of Stereoscopic Imaging”, S.D. 91 Digest ( SID 91 DIGEST), 1991, p.840-843

  In the conventional method for manufacturing a display device, there is a problem that misalignment is likely to occur between the pattern of the polarizing element and the pixels of the display device.

  Here, as a display device, as a member constituting the display device, a substrate having a plurality of color filters arranged along the main surface on the back side of two main surfaces (this is appropriately referred to as “color”). Some have a filter substrate. Each of the plurality of color filters constitutes a pixel and defines an area occupied by the pixel. In such a display device, the positional deviation between the polarizing element pattern and the pixels of the display device is a positional deviation between the polarizing element pattern and a plurality of color filters arranged on the color filter substrate. It can be said that it is equivalent.

  Accordingly, an object of the present invention is to provide a substrate having a plurality of color filters arranged along the main surface on the back side of the two main surfaces, and the main surface on the light emitting side of the substrate. A member for a display device having a retardation layer having a plurality of regions (referred to as “retardation regions”) having different slow axis directions from each other can be easily produced, and To provide a method for manufacturing a member for a display device capable of reducing a positional deviation between the plurality of retardation regions of the retardation layer and the plurality of color filters (and thus pixels) arranged on the substrate. is there.

  Moreover, the subject of this invention is providing the display apparatus containing the member for display apparatuses manufactured by the manufacturing method of such a member for display apparatuses.

In order to solve the above problems, a method for manufacturing a member for a display device according to the present invention includes:
A substrate having a plurality of color filters arranged along the main surface on the back side of the two main surfaces, and a transmission axis in a specific direction along the main surface, arranged on the light emitting side of the substrate And a retardation layer disposed on the light exit side of the polarizing layer and having a plurality of retardation regions having slow axes that intersect the transmission axis at different angles along the principal surface. A display device member manufacturing method for manufacturing a display device member comprising a layer,
It includes the following steps (1) to (4).
(1) A step of forming the polarizing layer along the main surface on the light emitting side of the substrate on which the color filter is formed (2) On the polarizing layer formed in the step (1), A function of arranging liquid crystal components of a liquid crystal composition, which is a material of the retardation layer, in positions corresponding to the arrangement of the plurality of color filters on the substrate in different alignment directions according to the direction of the slow axis; A step (3) of forming an alignment film having a plurality of pattern regions, and applying a liquid crystal composition containing a polymerizable liquid crystal compound on the alignment film formed in the step (2) to form a coating film; The coating film is held at a temperature at which the liquid crystal component of the liquid crystal composition exhibits a liquid crystal phase, and the liquid crystal component is aligned in different alignment directions for each region corresponding to the plurality of pattern regions of the alignment film. Step (4) The above step (3) In the polymerizable liquid crystal compound forming the formed liquid crystal component, by polymerizing while maintaining the oriented direction, the step of forming the retardation layer having the plurality of retardation region

  According to the method for manufacturing a member for a display device of the present invention, the positional deviation between the plurality of retardation regions of the retardation layer and the plurality of color filters (and thus pixels) arranged on the substrate is reduced. be able to. In addition, it is possible to suppress misalignment caused by thermal expansion of the substrate. By these, the member for display apparatuses which can display the outstanding stereo image can be obtained.

  In this specification, the “main surface” of the substrate means a surface (a surface different from the end surface) having a spread of the substrate.

  The “light emitting side” of the substrate refers to the side where light should be emitted from the substrate in the manufactured display device. Which is the “light emitting side” is determined according to the configuration of the substrate before the step (1) is performed.

  The “rear surface” of the two main surfaces refers to a main surface on the opposite side of the main surface on the light emitting side of the substrate.

  “Color filter” refers to a filter that selectively transmits light in a specific wavelength region such as red, green, and blue.

  A plurality of “pixels” means elements that can be turned on / off for light transmission, reflection, or light emission by being driven by electrical signals. As such display elements having a plurality of pixels, display elements having a light emitting layer such as liquid crystal display elements, organic electroluminescence (EL) display elements, plasma display elements, field emission display elements, and surface-conduction electron emission elements. Can be mentioned.

  The “polarizing layer” refers to an object having a function of selectively transmitting linearly polarized light in one direction (direction of the transmission axis) from natural light.

  The “retardation layer” refers to an object that transmits light and has birefringence. The phase difference layer is used for converting linearly polarized light into circularly polarized light or elliptically polarized light, or conversely converting circularly polarized light or elliptically polarized light into linearly polarized light by combining with a polarizing layer.

  In the method for manufacturing a member for a display device according to an embodiment, the shape and size of the plurality of retardation regions of the retardation layer in the direction along the main surface are each an arrangement of a plurality of color filters on the substrate. It is characterized by the fact that it coincides with the shape and size.

  According to the method for manufacturing a member for a display device of this embodiment, the plurality of color filters arranged on the substrate and the plurality of retardation regions of the retardation layer according to the arrangement of the plurality of color filters. Therefore, the positional deviation between the pixel and the pixel can be reduced.

In the method for manufacturing a member for a display device according to one embodiment, the step (2) includes the following steps (2a) to (2c).
(2a) A step of applying a solution containing a photoalignable polymer on the polarizing layer to form a photoalignable polymer film (2b) The plurality of the photoalignable polymer films formed in the step (2a) Of the first pattern region by irradiating the first polarized light having the first polarization direction through a first mask having a gap corresponding to the first pattern region of the first pattern region. Step (2c) of causing the direction of regulation force to correspond to the first polarization direction In a second pattern region different from the first pattern region of the photo-alignment polymer film irradiated with the first polarization The second polarized light having a second polarization direction different from the first polarization direction is irradiated through the second mask having a gap corresponding to the second pattern region, and the second The direction of the orientation regulating force in the pattern area of Step to correspond to the second polarization direction

  According to the method for manufacturing a member for a display device according to this embodiment, the member for a display device including a retardation layer having a plurality of retardation regions having different slow axis directions along the main surface of the substrate. It can be easily manufactured.

In the method for manufacturing a member for a display device according to one embodiment, the step (2) includes the following steps (2f) to (2h).
(2f) A step of applying a solution containing an orientation polymer on the polarizing layer to form an orientation polymer film (2g) The orientation polymer film formed in the step (2f) on the light emitting side Performing a first rubbing process on the surface along the first rubbing process direction so that the direction of the orientation regulating force of the surface on the light emitting side corresponds to the first rubbing process direction (2h) The first rubbing treatment is performed on the oriented polymer film that has been subjected to the first rubbing treatment according to (2g) through a mask having a void corresponding to the second pattern region other than the first pattern region. Performing a second rubbing process along a second rubbing process direction different from the direction, and changing a direction of the orientation regulating force of the second pattern region to correspond to the second rubbing process direction.

  According to the method for manufacturing a member for a display device according to this embodiment, the member for a display device including a retardation layer having a plurality of retardation regions having different slow axis directions along the main surface of the substrate. It can be easily manufactured.

  The method for manufacturing a display device member according to an embodiment further includes a step of forming an antireflection layer for preventing reflection of external light on the light emitting side of the retardation layer.

  According to the method for manufacturing a member for a display device according to this embodiment, the antireflection layer in the manufactured display device can reduce the generation of reflected light derived from external light. Interference between the emitted light for display and the reflected light can also be suppressed. As a result, display characteristics can be improved. Furthermore, the retardation layer can be protected by the antireflection layer.

  Moreover, the display apparatus of this invention is equipped with the member for display apparatuses manufactured by the manufacturing method of the said member for display apparatuses.

  According to the display device of the present invention, an excellent stereoscopic image can be displayed thanks to the display device member.

  According to the method for manufacturing a member for a display device of the present invention, a substrate having a plurality of color filters arranged along the main surface is provided on the back side of the two main surfaces, and the light emission of the substrate On the side, a member for a display device having a retardation layer having a plurality of retardation regions having different slow axis directions from each other along the principal surface can be easily produced, and the retardation layer The positional deviation between the plurality of phase difference regions and the plurality of color filters (and thus pixels) arranged on the substrate can be reduced. In addition, it is possible to suppress misalignment caused by thermal expansion of the substrate. Thus, a display device capable of displaying an excellent stereoscopic image can be obtained.

It is a figure which shows the structure of the mask used with the manufacturing method of the member for display apparatuses of one Embodiment of this invention. It is a figure which shows the aspect of the alignment film obtained using the mask of FIG. It is a figure which shows schematic structure of the member for liquid crystal display devices which should be produced by the said manufacturing method. It is a figure which shows schematic structure of another member for liquid crystal display devices which should be produced by the said manufacturing method. In a liquid crystal display device configured using the liquid crystal display device member, a correspondence relationship between a plurality of color filters (and thus pixels) arranged on a substrate, a polarizing layer, and a retardation layer is schematically shown. FIG. It is a figure which shows schematic structure of the liquid crystal display device comprised using the said member for liquid crystal display devices.

  Hereinafter, the present invention will be described in detail with reference to the illustrated embodiments.

  FIG. 3 shows a schematic cross-sectional configuration of a liquid crystal display device member (shown as a whole by reference numeral 51A) as an example of a display device member to be manufactured by the manufacturing method of one embodiment of the present invention.

  The liquid crystal display device member 51A includes a transparent glass substrate 53 as a substrate. The color filter layer 52 is disposed on the side of the two main surfaces 53a and 53b of the substrate 53 that becomes the back surface 53b. On the other hand, the polarizing layer 54, the alignment film 55, and the retardation layer 56 are arranged in order on the light emitting side of the substrate 53 (the side of the main surface 53a opposite to the back surface 53b).

  As schematically shown in FIG. 5, the color filter layer 52 has a plurality of rectangular color filters A1, A2,...; B1, B2,... Arranged in a matrix along the back surface 53b. . In this example, the color filters A1, A2,... Selectively transmit light in the red (R), green (G),. The color filters B1, B2,... Selectively transmit light in the wavelength ranges of green (G), blue (B),. These color filters are separated from each other by a black lattice-shaped black matrix BM and are shielded from light.

  The plurality of color filters A1, A2,..., B1, B2,. Note that various variations are allowed in the arrangement (arrangement) of the red (R), green (G), and blue (B) color filters.

  A known transparent electrode (counter electrode, not shown) common to a plurality of pixels is provided on the back surface 53b of the glass substrate 53 (between the glass substrate 53 and the color filter layer 52) along the back surface 53b. Is provided.

The polarizing layer 54 has a transmission axis 70a in a specific direction along the main surfaces 53a and 53b (which is inclined at an angle of 45 degrees with respect to the horizontal direction as schematically shown in FIG. 5). . The polarizing layer 54 transmits the component of the light transmitted through the substrate 53 along the direction of the transmission axis 70 a to the light emitting side F.

The retardation layer 56 includes a plurality of regions (retardation regions) 71A and 71B having slow axes 71a and 71b that intersect with the transmission axis 70a at different angles along the main surfaces 53a and 53b. Have. As schematically shown in FIG. 5, the slow axis 71a of the phase difference region 71A is oriented in the vertical direction, while the slow axis 71b of the phase difference region 71B is oriented in the horizontal direction. That is, when viewed from the light emitting side F, the slow axis 71a of the phase difference region 71A intersects at 45 degrees with respect to the direction of the transmission axis 70a of the polarizing layer 54 (this is 0 degree). The slow axis 71b of the phase difference region 71B intersects at 135 degrees. With such an arrangement, the phase difference regions 71A and 71B convert the linearly polarized light from the polarizing layer 54 into circularly polarized light rotating in the opposite directions, and respectively output to the light emitting side F. As a result, stereoscopic display is possible as will be described later.

In this example, the shape and size of the phase difference regions 71A and 71B of the phase difference layer 56 in the direction along the main surfaces 53a and 53b are respectively the plurality of color filters (and thus pixels) A1, A2,. It matches the shape and size of the array of B1, B2,.

  This liquid crystal display device 51A is manufactured by the following steps (1) to (4).

  The manufacturing method of the present invention includes, as step (1), a step of forming a polarizing layer 54 on the light emitting side of the substrate 53 on which the color filters A1, A2,..., B1, B2,.

  Examples of the polarizing layer 54 include a layer obtained by applying a liquid crystal composition containing a dichroic dye and a layer obtained by bonding a film-like polarizing plate with an adhesive.

  As a polarizing plate used when the polarizing layer 54 is formed by bonding, for example, an iodine polarizing plate in which iodine is adsorbed and oriented on a polyvinyl alcohol film, or a dichroic dye is adsorbed on a polyvinyl alcohol film. -An oriented dye-type polarizing plate, a coating type polarizing plate coated with a dichroic dye in a lyotropic liquid crystal state, oriented and fixed, and the like. Among these, an iodine polarizing plate is preferable because of its excellent polarization degree and transmittance. Examples of the iodine-based polarizing plate include polarizing plates described in Japanese Patent No. 3770862 and Japanese Patent No. 4432487.

  Examples of the adhesive used for the bonding include an adhesive having, as an adhesive component, a polyvinyl alcohol resin, an epoxy resin, a urethane resin, a cyanoacrylate resin, an acrylamide resin, and the like. The material described in -77224 gazette is mentioned. In addition, as a method of bonding a polarizing plate, you may bond after providing an adhesive bond layer in the polarizing plate side, and you may bond after providing an adhesive bond layer in the board | substrate 53 side. Moreover, as a method of bonding a polarizing plate, you may carry out by the method as described in Unexamined-Japanese-Patent No. 2010-276754 or Unexamined-Japanese-Patent No. 2010-276755. In the present specification, the adhesive includes an adhesive.

  When the polarizing layer 54 is formed of a liquid crystal composition containing a dichroic dye, the liquid crystal composition containing a dichroic dye includes a liquid crystal composition containing a dichroic dye having liquid crystallinity, a liquid crystal compound, and two colors. Liquid crystal composition containing a functional dye. The polarizing layer 54 can be formed by applying the liquid crystal composition to the substrate 53 and drying it. When the liquid crystal compound and / or dichroic dye is a compound having a polymerizable group, the film after drying is irradiated with light or heated to polymerize the compound having the polymerizable group in the film, It is preferable in terms of durability of the polarizing layer 54. Examples of the method for forming the polarizing layer 54 using a liquid crystal composition containing a dichroic dye include the methods described in JP-T-2007-510946 and Japanese Patent No. 3492669.

  The manufacturing method of the present invention corresponds to the arrangement of a plurality of color filters A1, A2,...; B1, B2,... On the substrate 53 on the polarizing layer 54 formed in the step (1) as the step (2). A step of forming an alignment film 55 (hereinafter sometimes referred to as “patterned alignment film”) 55 having a plurality of pattern regions 13 and 12 (see FIG. 2) at the position.

  The plurality of pattern regions 13 and 12 have different alignment directions (corresponding to the hatching directions given in FIG. 2) of the liquid crystalline components of the liquid crystal composition, which will be the material of the retardation layer 56 formed in a later step. It has the function of aligning (alignment regulating force).

In this example, the shape and size of the plurality of pattern regions 13 and 12 of the patterned alignment film 55 in the direction along the main surfaces 53a and 53b are the same as those of the retardation layer 56 to be formed on the alignment film 55, respectively. The shape and size of the phase difference regions 71A and 71B coincide with each other. Therefore, the shape and size of the plurality of color filters A1, A2,...; B1, B2,.

  As a method of forming the alignment film 55, a method using an alignment polymer to which an alignment regulating force is imparted by rubbing (hereinafter sometimes referred to as “rubbing method”), an alignment regulating force is imparted by irradiating polarized light. A method using a photo-alignable polymer (hereinafter sometimes referred to as “photo-alignment method”), a method of obliquely depositing silicon oxide on a substrate surface, and a long-chain alkyl group using a Langmuir-Blodgett method (LB method). Examples thereof include a method for forming a monomolecular film. Among these, from the viewpoint of alignment uniformity of the liquid crystal composition, processing time, and processing cost, a rubbing method and a photo-alignment method are preferable, and a photo-alignment method is more preferable. As the alignment film 55, solvent resistance to the extent that it does not dissolve in the solvent contained in the liquid crystal composition (which will be the material of the retardation layer 56 formed in the subsequent process) applied in the subsequent process thereon, removal of the solvent It preferably has heat resistance to heat treatment such as liquid crystal alignment and adhesion to the substrate.

  When the alignment film 55 is formed by the rubbing method, the alignment polymer used in the rubbing method is, for example, polyamide or gelatin having an amide bond in the molecule, polyimide having an imide bond in the molecule, or a hydrolyzate thereof. A polymer such as a certain polyamic acid, polyvinyl alcohol, alkyl-modified polyvinyl alcohol, polyacrylamide, polyoxazole, polyethyleneimine, polystyrene, polyvinylpyrrolidone, polyacrylic acid or polyacrylic acid esters can be mentioned. Commercial products such as Sunever (registered trademark, manufactured by Nissan Chemical Industries, Ltd.) or Optmer (registered trademark, manufactured by JSR Corporation) may be used.

  When the alignment film 55 is formed by a photo-alignment method, examples of the photo-alignment polymer used in the photo-alignment method include a polymer having a photosensitive structure. When a polymer having a photosensitive structure is irradiated with polarized light, the photosensitive structure in the irradiated portion is isomerized or cross-linked so that the photo-alignable polymer is aligned, and an alignment regulating force is imparted to the film made of the photo-alignable polymer. The Examples of the photosensitive structure include an azobenzene structure, a maleimide structure, a chalcone structure, a cinnamic acid structure, a 1,2-vinylene structure, a 1,2-acetylene structure, a spiropyran structure, a spirobenzopyran structure, and a fulgide structure. . These polymers may be used alone or in combination of two or more. These polymers are obtained by using a monomer having a photosensitive structure by polycondensation such as dehydration or deamination, chain polymerization such as radical polymerization, anionic polymerization, or cationic polymerization, coordination polymerization, or ring-opening polymerization. be able to. Moreover, the copolymer which consists of multiple types of monomer which has a different photosensitive structure may be sufficient. Examples of such photo-alignable polymers include Japanese Patent No. 4450261, Japanese Patent No. 4011652, Japanese Patent Application Laid-Open No. 2010-49230, Japanese Patent No. 444090, Japanese Patent Application Laid-Open No. 2007-156439, and Japanese Patent Application Laid-Open No. 2007-232934. Mention may be made of the photoalignable polymers described.

  The orientation polymer and photo-alignment polymer can be applied after being dissolved in a solvent. The solvent is not particularly limited, and specifically, alcohol solvents such as water, methanol, ethanol, ethylene glycol, isopropyl alcohol, propylene glycol, ethylene glycol methyl ether, ethylene glycol butyl ether or propylene glycol monomethyl ether; ethyl acetate, Ester solvents such as butyl acetate, ethylene glycol methyl ether acetate, γ-butyrolactone, propylene glycol methyl ether acetate or ethyl lactate; ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, 2-heptanone or methyl isobutyl ketone; Aliphatic hydrocarbon solvents such as hexane or heptane; aromatic hydrocarbon solvents such as toluene or xylene; Le solvent; chlorinated solvents chloroform or chlorobenzene; ethers solvent such as tetrahydrofuran or dimethoxyethane, and the like. These organic solvents may be used alone or in combination.

  In order to form the alignment film 55, first, the alignment polymer or photo-alignment polymer solution is applied onto the polarizing layer 54 formed in the step (1). Application methods include, for example, extrusion coating method, direct gravure coating method, reverse gravure coating method, CAP (cap) coating method, die coating method, ink jet method, dip coating method, slit coating method, spin coating method, and bar coater. Application etc. are mentioned. Among these, application by a CAP coating method, an inkjet method, a dip coating method, a slit coating method, and a bar coater is preferable in that damage to the display element can be suppressed.

  After applying the alignment polymer or photoalignment polymer solution, the solution is dried to remove low-boiling components such as a solvent from the applied film.

  Examples of the drying method include natural drying, ventilation drying, and reduced pressure drying. The specific drying temperature is preferably 10 to 250 ° C, and more preferably 25 to 200 ° C. Further, the drying time is preferably 5 seconds to 60 minutes, more preferably 10 seconds to 30 minutes. When the drying temperature and the drying time are within the above ranges, damage to the substrate 53 and the polarizing layer 54 on which the color filter is formed can be suppressed.

  Next, when the alignment film 55 is aligned by laminating the liquid crystal composition, the dried alignment polymer film or photoalignment property is divided so as to be divided into a plurality of pattern regions 13 and 12 having different directions of alignment regulating force. Applies orientation regulating force to the polymer film. As a method for imparting the alignment regulating force, it is preferable to apply a rubbing method and a photo-alignment method to the orientation polymer film after drying.

  In order to apply the alignment regulating force by the rubbing method, for example, a rubbing cloth is wound, and a rotating rubbing roll is placed on the stage and brought into contact with the dried oriented polymer film.

  In order to form the patterned alignment film 55 by the rubbing method, first, the first rubbing process is performed on the surface (light emission side) of the oriented polymer film after drying without using a mask. By this first rubbing treatment, the direction of the alignment regulating force over the entire surface is made to correspond to the first rubbing treatment direction. Next, for example, the mask 1 shown in FIG. 1 (having the void portion 2 corresponding to the second pattern region 12 in FIG. 2) is laminated on the oriented polymer film after the first rubbing treatment, The second rubbing process is performed along a second rubbing process direction (in this example, a direction perpendicular to the first rubbing process direction) different from the first rubbing process direction. By this second rubbing process, the direction of the orientation regulating force of the second pattern region 12 is changed to correspond to the second rubbing process direction. Even if the second rubbing treatment is performed, the region covered with the real part 3 of the mask 1 in the surface of the oriented polymer film is not subjected to rubbing, and thus the alignment regulating force is maintained. Therefore, the direction of the orientation regulating force in the region covered with the real part 3 of the mask 1 is maintained in the first rubbing treatment direction. As a result, an alignment film 55 having a plurality of pattern regions 13 and 12 having different alignment regulating forces can be obtained.

  A first mask having a void corresponding to the first pattern region 13 in FIG. 2 (the remaining region is a real part) is laminated on the orientation polymer film after drying. A first rubbing process is performed, and then a second mask having a gap 2 corresponding to the second pattern region 12 in FIG. 2 (the remaining region is a real part) is laminated, The patterned alignment film 55 can also be formed by performing the rubbing process 2. Furthermore, by repeatedly performing the rubbing process through three or more types of masks, a patterned alignment film having three or more pattern regions having different directions of alignment regulating force can be produced.

  As shown in FIG. 1, the mask 1 has a pattern in which stripe-shaped real portions 3 and stripe-shaped gap portions 2 are alternately arranged with the same width. The width of the real part 3 and the gap part 2 is equal to the pitch of the arrangement of the plurality of color filters (and therefore pixels) A1, A2,...; B1, B2,. Has been. Mask materials include metal plates such as SUS (stainless steel) plates, iron plates, and aluminum plates, PMMA (polymethyl methacrylate), PET (polyethylene terephthalate), PP (polypropylene), PE (polyethylene), and PC (polycarbonate). For example, any material that does not crush by rubbing may be used. Moreover, 20 micrometers-5 mm are preferable and, as for the film thickness of a mask, 30 micrometers-1 mm are more preferable.

  In order to impart the alignment regulating force by the photo-alignment method, polarized light irradiation (for example, linearly polarized ultraviolet light) is performed on the photo-alignable polymer film after drying. The polarized light irradiation can be performed using, for example, an apparatus described in JP-A-2006-323060. For example, on the photo-alignable polymer film after drying, for example, a region corresponding to the arrangement of the plurality of color filters A1, A2,... And a region corresponding to the arrangement of the color filters B1, B2,. The patterned alignment film 55 can be formed by repeatedly performing polarized light irradiation (for example, linearly polarized ultraviolet light) through a photomask for each region. Examples of the photomask include those in which a light shielding pattern (corresponding to the real part 3 of the mask 1 shown in FIG. 1) is provided on a film such as quartz glass, soda lime glass, or polyester. The exposed light is blocked in the portion covered with the light shielding pattern, and the exposed light is transmitted through the uncovered gap. Since the influence of thermal expansion is small, quartz glass is preferable as the substrate used for the photomask.

  In order to form the patterned alignment film 55 by the photo-alignment method, first, a first mask having a void corresponding to the first pattern region 13 in FIG. Is irradiated with a first polarized light having a first polarization direction (first polarized light irradiation). By this first polarized light irradiation, the direction of the orientation regulating force of the first pattern region 13 is made to correspond to the first polarized light direction. Next, a second different from the first polarization direction is passed through a first mask having a gap corresponding to the second pattern region 12 in FIG. 2 (the remaining region is a light shielding pattern). The second polarized light having a polarization direction (in this example, a direction perpendicular to the first polarization direction) is irradiated (second polarized light irradiation). By this second polarized light irradiation, the direction of the orientation regulating force of the second pattern region 12 is made to correspond to the second polarized light direction. As a result, an alignment film 55 having a plurality of pattern regions 13 and 12 having different alignment regulating forces can be obtained. Furthermore, a patterned alignment film having three or more pattern regions in which the directions of the alignment regulating force are different from each other can be created by repeatedly performing polarized light irradiation through three or more types of masks. In view of the reactivity of the photo-alignment polymer, it is preferable that the irradiated light is ultraviolet light for each irradiation with polarized light.

  The film thickness of the patterned alignment film 55 is, for example, 10 nm to 10000 nm, preferably 10 nm to 1000 nm. If it is set as such a range, the liquid crystalline component contained in a liquid-crystal composition can be orientated to a desired angle by a post process.

  In the production method of the present invention, as step (3), a liquid crystal composition containing a polymerizable liquid crystal compound is applied on the alignment film 55 formed in the step (2) to form a coating film. Is maintained at a temperature at which the liquid crystal component of the liquid crystal composition exhibits a liquid crystal phase, and the liquid crystal component is aligned in different alignment directions for each of the regions corresponding to the plurality of pattern regions 13 and 12 of the alignment film 55. Arranging.

  The liquid crystal composition preferably contains a polymerization initiator, a solvent and the like in addition to the polymerizable liquid crystal compound. In such a case, in this step (3), a film from which the solvent has been removed is formed from the coating film obtained by applying the liquid crystal composition, and then the liquid crystal contained in the film from which the solvent has been removed. The sex component is oriented.

  As the polymerizable liquid crystal compound contained in the liquid crystal composition, chapter 3 of the liquid crystal handbook (edited by the Liquid Crystal Handbook Editorial Committee, published by Maruzen Co., Ltd., October 30, 2000) 3.2 of the molecular structure and liquid crystallinity. Non-chiral rod-like liquid crystal molecules, 3.3 Compounds having a polymerizable group among the compounds described in Chiral rod-like liquid crystal molecules, polymerizable liquid crystal compounds disclosed in JP 2010-31223 A, and the like. These polymerizable liquid crystal compounds may be used alone or in combination.

  As described above, the liquid crystal composition used in the production method of the present invention preferably contains a solvent.

  The solvent may be any solvent that dissolves the components contained in the liquid crystal composition and is inert to the polymerization reaction of the polymerizable liquid crystal compound. Specifically, methanol, ethanol, ethylene glycol, isopropyl alcohol, propylene glycol Alcohol solvents such as ethylene glycol methyl ether, ethylene glycol butyl ether, propylene glycol monomethyl ether or phenol; ester solvents such as ethyl acetate, butyl acetate, ethylene glycol methyl ether acetate, γ-butyrolactone, propylene glycol methyl ether acetate or ethyl lactate; Ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, 2-heptanone or methyl isobutyl ketone; pentane, hexane, heptane, etc. Aliphatic hydrocarbon solvents: toluene, or an aromatic hydrocarbon solvent such as xylene, nitrile solvents such as acetonitrile; ethers solvent such as tetrahydrofuran or dimethoxyethane; chlorinated solvents chloroform or chlorobenzene; and the like. These solvents may be used alone or in combination.

  The amount of the solvent used is preferably 50 to 95% by mass with respect to the liquid crystal composition. Conversely, the solid content in the liquid crystal composition is preferably 5 to 50% by mass. When the solid content concentration is 5% by mass or more, the thickness of the obtained retardation layer 56 does not become too thin, and a birefringence necessary for polarization conversion tends to be provided. Moreover, since the viscosity of a liquid crystal composition is low as it is 50 mass% or less, there exists a tendency for nonuniformity to become difficult to produce in the film thickness of the phase difference layer 56. FIG. Here, solid content is content of the component remove | excluding the solvent from the composition with respect to the composition whole quantity.

  The viscosity of the liquid crystal composition is preferably adjusted to 10 mPa · s or less, more preferably 0.1 to 7 mPa · s so that it can be easily applied.

  As described above, the liquid crystal composition used in the production method of the present invention preferably contains a polymerization initiator.

  Examples of the polymerization initiator include a thermal polymerization initiator, a photopolymerization initiator, and the like. Since there is a tendency that a polymerizable liquid crystal compound can be polymerized at a low temperature, a photopolymerization initiator is preferable.

  Examples of the photopolymerization initiator include benzoin compounds, benzophenone compounds, alkylphenone compounds, acylphosphine oxide compounds, triazine compounds, iodonium salts, and sulfonium salts.

  As photopolymerization initiators, Irgacure 907, Irgacure 184, Irgacure 651, Irgacure 819, Irgacure 250, Irgacure 369 (all are manufactured by Ciba Japan Co., Ltd.), Sake All BZ, Sequol Z, Sequol BEE (and above) All manufactured by Seiko Chemical Co., Ltd.), kayacure BP100 (manufactured by Nippon Kayaku Co., Ltd.), Kayacure UVI-6992 (manufactured by Dow), Adekaoptomer SP-152, Adekaoptomer SP-170 (above Commercially available photopolymerization initiators such as TAZ-A, TAZ-PP (manufactured by Nippon Shibel Hegner) or TAZ-104 (manufactured by Sanwa Chemical Co., Ltd.) can also be used.

  The liquid crystal composition used in the production method of the present invention may contain additives such as a chiral agent, a polymerization inhibitor, a photosensitizer, and a leveling agent as necessary.

  As the chiral agent, “Liquid Crystal Device Handbook” (Chapter 3, Section 4-3, TN, Chiral Agent for STN, 199 pages, edited by the 142th Committee of the Japan Society for the Promotion of Science, 1989), JP 2007-269640 A, JP-A 2007-269639, JP-A 2007-176870, JP-A 2003-137879, JP-T 2000-51596, JP-A 2007-169178, JP-A 9-506088, etc. The compounds described are mentioned.

  Examples of the polymerization inhibitor include hydroquinones having a substituent such as hydroquinone or alkyl ether, catechols having a substituent such as alkyl ether such as butylcatechol, pyrogallols, 2,2,6,6-tetramethyl-1 -Radical scavengers such as piperidinyloxy radicals, thiophenols, β-naphthylamines or β-naphthols.

  Examples of the photosensitizer include xanthones such as xanthone and thioxanthone, anthracene having a substituent such as anthracene and alkyl ether, phenothiazine, and rubrene.

  As a leveling agent, for example, an additive for radiation-curing coatings (BYK-352, BYK-353, BYK-361N manufactured by BYK Japan), a coating additive (manufactured by Toray Dow Corning: SH28PA, DC11PA, ST80PA). Paint additives (Shin-Etsu Chemical Co., Ltd .: KP321, KP323, X22-161A, KF6001) or fluorine-based additives (DIC Corporation: F-445, F-470, F-479), etc. be able to.

  In the step (3), the method for applying the liquid crystal composition includes the same method as the method for applying the alignment film 55. Among these, application by a CAP coating method, an inkjet method, a dip coating method, a slit coating method, and a bar coater is preferable in that damage to the display element can be suppressed.

  After applying the liquid crystal composition, it is preferable to remove the solvent contained in the liquid crystal composition as described above.

  The coating film obtained by applying the liquid crystal composition (preferably the film from which the solvent has been removed from the coating film) is maintained at a temperature at which the liquid crystalline component of the liquid crystal composition exhibits a liquid crystal phase. By maintaining the temperature at which the coating film exhibits a liquid crystal phase, the liquid crystalline component contained in the coating film can be aligned and birefringence can be imparted. As temperature to orientate, 0-250 degreeC is preferable and 10-150 degreeC is more preferable.

  In this way, the liquid crystal components are aligned differently for each of the regions corresponding to the plurality of pattern regions 13 and 12 of the patterned alignment film 55 according to the direction of the alignment regulating force of each of the pattern regions 13 and 12. Arrange in the direction.

  In each of the retardation regions 71A and 71B, the liquid crystalline component is preferably monodomain aligned.

  In the production method of the present invention, as the step (4), the polymerizable liquid crystal compound forming the liquid crystalline component formed in the step (3) is polymerized while maintaining the alignment direction, thereby the plurality of positions. This includes a step of forming the retardation layer 56 having the retardation regions 71A and 71B.

  When the polymerizable liquid crystal compound contained in the liquid crystal composition is a polymerizable liquid crystal compound having a photopolymerizable group, it is preferably polymerized by a photopolymerization method. Moreover, when the polymerizable liquid crystal compound contained in the liquid crystal composition is a polymerizable liquid crystal compound having a thermally polymerizable group, it is preferably polymerized by a thermal polymerization method. Here, the photopolymerizable group means a group capable of polymerizing a compound by light irradiation or a group capable of polymerizing a compound by an active radical or an active acid generated from a polymerization initiator by light irradiation. The thermopolymerizable group refers to a group capable of polymerizing a compound by the action of heat, or a group capable of polymerizing a compound by an active radical or an active acid generated from a polymerization initiator by the action of heat. By performing the polymerization in a state where the components included in the film are aligned, that is, in a state where the components included in the film exhibit a liquid crystal phase, the retardation layer 56 is formed as a cured film that retains the liquid crystal phase (that is, the alignment direction). Can be obtained.

  In the production method of the present invention, the polymerizable liquid crystal compound is preferably polymerized by a photopolymerization method. According to the photopolymerization method, polymerization can be performed without heating to a high temperature, so that the polarizing layer (polarizing plate) 54 can be prevented from being deformed by heat. In addition, it is easy to manufacture industrially. The photopolymerization method is also preferable from the viewpoint of film formability. Examples of the light source used in the photopolymerization method include visible light, ultraviolet light, and laser light. From the viewpoint of handling, ultraviolet light is preferable. The light irradiation may be performed at a temperature at which the component contained in the film exhibits a liquid crystal phase. At this time, the retardation layer 56 patterned into more regions by masking or the like can be obtained.

  When the retardation layer 56 formed in the step (4) is a λ / 4 plate (quarter wavelength plate), in any of the plurality of retardation regions 71A, 71B having different slow axis directions. The thickness of the retardation layer 56 is adjusted so that the retardation value (retardation value) Re (550 nm) is 113 to 163 nm, preferably 135 to 140 nm, particularly preferably about 137.5 nm. Further, when the retardation layer 56 formed in the step (4) is a λ / 2 plate (a half-wave plate), any of the plurality of retardation regions 71A and 71B having different slow axis directions. The thickness of the retardation layer 56 is adjusted so that the retardation value Re (550 nm) is 250 to 300 nm, preferably 273 to 277 nm, and particularly preferably about 275 nm.

The retardation value Re (λ) in the retardation layer 56 can be adjusted by appropriately changing the coating amount of the liquid crystal composition and the content of the polymerizable liquid crystal compound in the liquid crystal composition. Further, since the retardation value Re (λ) of the obtained retardation layer 56 is determined as in the following equation (X), in order to obtain a desired retardation value Re (λ), the retardation value The film thickness d of the layer 56 may be adjusted.
Re (λ) = d × Δn (λ) (X)
(In the formula, Re (λ) represents a retardation value at a wavelength λ (nm), d represents a film thickness, and Δn (λ) represents a birefringence at a wavelength λ (nm).)

  However, the film thickness of the retardation layer 56 to be adjusted is preferably 0.1 to 10 μm, and more preferably 0.5 to 3 μm.

  As a result of the steps (1) to (4), the polarizing layer 54 and the retardation layer 56 are provided in this order on the light emitting side of the substrate 53.

  The manufacturing method of the present invention preferably further includes a step of forming an antireflection layer for preventing reflection of external light on the light emitting side of the retardation layer 56 formed in the step (4). FIG. 4 shows a schematic cross-sectional configuration of a liquid crystal display member (the whole is denoted by reference numeral 51 </ b> B) provided with such an antireflection layer 57. In FIG. 4, the same components as those in FIG. 3 are denoted by the same reference numerals, and redundant description is omitted.

  The material constituting the antireflection layer 57 is not particularly limited, and for example, a layer composed of at least one selected from the group consisting of metals, metal oxides, metal fluorides, fine particles, polymer materials, and the like, and publicly known Antireflection (AR) film, low reflection (LR) film, moth-eye type antireflection film, antireflection layer of these, and the like.

  Examples of the metal include silver. Examples of the metal oxide include silicon oxide, aluminum oxide, titanium oxide, tantalum oxide, yttrium oxide, and zirconium oxide. Examples of the metal fluoride include: Examples thereof include calcium fluoride and magnesium fluoride.

  As fine particles, inorganic fine particles such as barium sulfate, talc, kaolin, calcium sulfate, silica gel, silica gel containing metal fine particles; polymethacrylate methyl acrylate resin fine particles, acrylic styrene resin fine particles, polymethyl methacrylate resin fine particles, silicon resin fine particles, polystyrene Organic fine particles such as resin fine particles, polycarbonate resin fine particles, benzoguanamine resin fine particles, melamine resin fine particles, polyolefin resin fine particles, polyester resin fine particles, polyamide resin fine particles, polyimide resin fine particles, or polyfluoroethylene resin fine particles; JP 2010-84018 A And hollow organic-inorganic hybrid fine particles described in the above.

  Polymer materials include siloxane polymer, bis (4-methacryloylthiophenyl) sulfide, vinyl naphthalene, vinyl phenyl sulfide and 4-methacryloxyphenyl-4′-methoxyphenyl thioether, fluorine-containing (meth) acrylate, fluorine-containing itaconic acid Polymers such as esters, fluorine-containing maleates, fluorine-containing silicon compounds, polyvinyl alcohol resins, polyvinyl acetal resins such as polyvinyl butyral and polyvinyl formal, cellulose resins such as cellulose acetate butyrate, (meth) acrylic resins such as butyl acrylate , Urethane resin, polyester resin, epoxy resin and the like. A thin film is formed from a polymer material to form an antireflection layer.

  The antireflection layer 57 may be a single layer or a multilayer composed of two layers, three layers, four layers, or more layers. The thickness of the antireflection layer 57 and the thickness of each layer when it is a multilayer are appropriately selected depending on the number of layers, the refractive index of the substance used for each layer, and the like. The antireflection layer 57 is formed by a method of applying a solution containing the above material onto the retardation layer 56 or a method of bonding a film having a layer formed from the above material onto the retardation layer 56. Can do. As a method for forming the antireflection layer 57, for example, Japanese Patent Application Laid-Open No. 2003-114302, Japanese Patent Application Laid-Open No. 7-56002, Japanese Patent No. 4190337, Japanese Patent No. 4259957, Japanese Patent No. 4032771, Japanese Patent Application Laid-Open No. 2010-122599. Examples include the method described in the publication. Since the display device member 51B has the antireflection layer 57, generation of reflected light derived from external light can be reduced, and the original display output light and reflected light from the display device member 51B can be reduced. Interference can also be suppressed. As a result, display characteristics can be improved. Further, the retardation layer 56 can be protected by the antireflection layer 57.

  Furthermore, a known antifouling layer, antistatic layer, and hard coat layer may be formed on the light emitting side of the antireflection layer 57 as necessary.

  FIG. 6 shows a schematic cross-sectional configuration of a liquid crystal display device (generally indicated by reference numeral 40) as an example of a display device configured using the liquid crystal display member 51A of FIG.

  The liquid crystal display device 40 is configured by arranging an array substrate 91, a liquid crystal layer LC, and a liquid crystal display device member 51A as a color filter substrate in order from the backlight 90 side (also referred to as a back surface).

  The backlight 90 is a surface light source that emits natural light, and includes a well-known white LED (light emitting diode) and a light scattering plate (not shown) in this example. Instead of the white LED, a cold cathode ray tube may be used.

  The array substrate 91 is of a known type and includes a transparent glass substrate 93. A polarizing plate 92 is bonded to the main surface (back surface) of the substrate 93 on the backlight 90 side. The polarizing plate 92 has a transmission axis (not shown) in a specific direction along the plate surface. The polarizing plate 92 selectively transmits linearly polarized light along the transmission axis of the natural light generated by the backlight 90 to the substrate 93 side. In this example, the transmission axis of the polarizing plate 92 is set in a direction orthogonal to the transmission axis 70a of the polarizing layer 54 of the liquid crystal display member 51A.

  On the other hand, the main surface of the substrate 93 on the light emission side F is provided with liquid crystal drive electrodes (not shown) having a matrix pattern for defining pixels, wiring patterns, thin film transistors, etc. An alignment film 99 that determines the alignment direction of the liquid crystal molecules is disposed in contact with the layer LC.

  The above-described color filter layer 52 is disposed on the back side of the substrate 53 constituting the liquid crystal display member 51A, and further, on the back side, an alignment film that determines the alignment direction of the liquid crystal molecules in contact with the liquid crystal layer LC. 49 is arranged. Further, on the back side of the liquid crystal display member 51A, a photo spacer (not shown) is provided for determining the thickness of the liquid crystal layer LC between the array substrate 91 and the liquid crystal display member 51A.

  On the light emission side F of the substrate 53 constituting the liquid crystal display member 51A, the above-described polarizing layer 54, alignment film 55 and retardation layer 56 are arranged in order (in FIG. 6, for simplicity, The polarizing layer 54 and the alignment film 55 are not shown.)

  In this liquid crystal display device 40, the matrix pattern of the liquid crystal drive electrodes of the array substrate 91 corresponds to the color filters A1, A2,...; B1, B2,. As described above, the array substrate 91 and the liquid crystal display member 51A are aligned. As a result, pixels are formed between the liquid crystal drive electrodes of the array substrate 91 and the color filters of the liquid crystal display member 51A via the liquid crystal layer LC.

  The liquid crystal display device 40 operates as follows.

  In the liquid crystal display device 40, the backlight 90 generates natural light. The polarizing plate 92 selectively transmits linearly polarized light in one direction out of the natural light generated by the backlight 90 to the substrate 93 side. The linearly polarized light transmitted through the polarizing plate 92 and incident on the substrate 93 is transmitted or blocked to the light emitting side F of the substrate 53 for each pixel through the liquid crystal layer LC. As already described with reference to FIG. 5, the polarizing layer 54 transmits the light transmitted through the substrate 53 along the direction of the transmission axis 70 a to the light emitting side F. Here, when viewed from the light emitting side F, the slow axis 71a of the phase difference region 71A intersects at 45 degrees with respect to the direction of the transmission axis 70a of the polarizing layer 54 (this is assumed to be 0 degrees). The slow axis 71b of the phase difference region 71B intersects at 135 degrees. With such an arrangement, the phase difference regions 71A and 71B convert the linearly polarized light from the polarizing layer 54 into circularly polarized light rotating in the opposite directions, and respectively output to the light emitting side F. In this example, the light that has passed through the polarizing layer 54 and then passed through the retardation region 71A is emitted as left circularly polarized light, while the light that has passed through the polarizing layer 54 and then passed through the retardation region 71B. Is emitted as right circularly polarized light.

  More specifically, the light that has passed through the color filter (for example, A1, A2,...) For displaying the image for the left eye, the retardation layer 71A of the polarizing layer 54 and the retardation layer 56 in this order becomes left circularly polarized light. . On the other hand, light that has passed through the color filter (for example, B1, B2,...) For displaying the right-eye image, the retardation layer 71B of the polarizing layer 54 and the retardation layer 56 in this order becomes right circularly polarized light.

  By using glasses (not shown) in which each observer has a circularly polarizing plate that converts right circularly polarized light into linearly polarized light and a circularly polarizing plate that converts left circularly polarized light into linearly polarized light, An image emitted from the display device can be observed as a stereoscopic image.

  Thus, according to the liquid crystal display device 40, a display device capable of displaying a stereoscopic image can be provided.

In this example, the shape and size of the phase difference regions 71A, 71B of the phase difference layer 56 in the direction along the main surfaces 53a, 53b are respectively the plurality of color filters A1, A2,. , B2,... Are formed in a stripe shape in accordance with the shape and size of the array. Thereby, the display apparatus which can display a stereo image can be comprised preferably.

  In addition, when a liquid crystal display device is configured using, for example, the liquid crystal display device member 51B of FIG. 4 as a color filter substrate instead of the liquid crystal display device member 51A of FIG. 3, a stereoscopic image can be displayed similarly. A display device can be provided.

  Examples of the liquid crystal display device include a transmissive type, a reflective type, and a transflective type. The operation mode of the liquid crystal cell is not particularly limited, and may be any of twisted nematic, vertical alignment, OCB (Optically Compensated), IPS (In-Plane Switching), and the like.

  As a display device manufactured by the manufacturing method of the present invention, in addition to the liquid crystal display device described above, an organic electroluminescence (EL) display device, a plasma display, a field emission display device (field emission display), a surface conduction electron A display device (SED) having an emission element, electronic paper, and the like can be given. When the manufacturing method of the present invention is applied to these other display devices, the substrate used in the step (1) is formed with a color filter constituting these other display devices (a plurality of pixels are arranged) Thing).

  For example, when using a substrate on which an organic EL display element is formed as the substrate, first, an organic film such as an anode and a light emitting layer and a cathode are laminated on a glass substrate provided with a transparent electrode, and an arrangement of a plurality of color filters. An organic EL element and a wiring pattern corresponding to the above are formed. Next, for example, a metal cap (protection plate) formed of SUS, Al, or the like is placed on each organic EL element laminated on the transparent electrode glass, and adhered to the transparent electrode glass with an adhesive. Finally, the transparent electrode glass is divided for each organic EL element. As a method for producing a substrate on which an organic EL display element is formed, for example, a method described in Japanese Patent No. 3626728 may be mentioned. The polarizing layer 54, the alignment film 55, and the retardation layer 56 are formed on the light emitting side of the substrate on which the organic EL display element is formed by the above steps (1) to (4). Since the polarizing layer (polarizing plate) 54 formed in the step (1) on the substrate on which the organic EL display element is formed can suppress external light reflection, it may be a circularly polarizing plate.

  Hereinafter, the present invention will be described in more detail with reference to examples. Unless otherwise specified, “%” and “parts” in the examples are% by mass and parts by mass.

Example 1
[Production of photo-alignment polymer]
A photo-alignable polymer represented by the formula (A) was produced by the method described in Macromol. Chem. Phys. 197, 1919-1935 (1996) to obtain a polymer having a number average molecular weight of 23,000.

重合性液晶化合物：ＬＣ２４２（ＢＡＳＦ社製、下記式で表される化合物）

重合性開始剤：イルガキュア３６９（ＢＡＳＦジャパン社製）
レベリング剤：ＢＹＫ３６１Ｎ（ビックケミージャパン製）
溶剤：ＰＧＭＥＡ（プロピレングリコール１−モノメチルエーテル２−アセタート、東京化成工業（株）製） [Adjustment of liquid crystal composition]
The components described in Table 1 were mixed to prepare a liquid crystal composition (represented by symbol E).

Polymerizable liquid crystal compound: LC242 (made by BASF, a compound represented by the following formula)

Polymerizable initiator: Irgacure 369 (manufactured by BASF Japan)
Leveling agent: BYK361N (manufactured by Big Chemie Japan)
Solvent: PGMEA (propylene glycol 1-monomethyl ether 2-acetate, manufactured by Tokyo Chemical Industry Co., Ltd.)

(Production of retardation layer)
A mask 1 shown in FIG. 1 in which a 280 μm line width pattern made of SUS is engraved is placed on a glass substrate, ink is applied by spraying and dried, and a patterned glass substrate to which the pattern of mask 1 is transferred is obtained. Produced. A polarizing plate 54 is formed by sticking a polarizing plate (iodine polarizing plate; TRW842AP7; manufactured by Sumitomo Chemical Co., Ltd.) to the surface opposite to the surface on which the ink of the obtained patterned substrate is coated with an adhesive. did. A 1% by mass cyclopentanone solution of the photoalignable polymer represented by the formula (A) was applied on the polarizing layer 54 and dried to form a film having a thickness of 200 nm. Next, the mask 1 shown in FIG. 1 is placed on the obtained film, and 20 mW using a spot cure (SP-7, manufactured by Ushio Electric Co., Ltd.) with a polarized UV irradiation jig from the direction perpendicular to the glass substrate surface. Linearly polarized light in a direction of 45 degrees with respect to the transmission axis 70a of the polarizing layer 54 was irradiated at an intensity of / cm ² for 5 minutes. Next, the mask 1 shown in FIG. 1 is shifted in the width direction by the line width, placed so that the first polarized UV unirradiated portion and the gap 2 of the mask 1 overlap, and irradiated with the second polarized UV. . The second polarized UV was irradiated with linearly polarized light in a direction of 135 degrees with respect to the transmission axis 70a of the polarizing layer 54 at an intensity of 20 mW / cm ² for 5 minutes to form the patterned alignment film 55. After removing the mask 1, the liquid crystal composition E was applied onto the patterned alignment film 55 using a bar coater and heated to 100 ° C. to obtain a film aligned in the liquid crystal phase. Thereafter, the retardation layer 56 is irradiated with ultraviolet rays at a wavelength of 365 nm at an intensity of 40 mW / cm ² for 1 minute using UniCure (VB-15201BY-A, manufactured by Ushio Electric Co., Ltd.) while being cooled to room temperature. Produced. Next, an antireflection film (manufactured by Dai Nippon Printing Co., Ltd.) is bonded onto the retardation layer 56, whereby a glass substrate with a pattern, a polarizing layer 54, a patterned alignment film 55, a retardation layer 56, and an antireflection coating. A laminate in which the layer 57 was laminated was obtained.

(Example 2)
(Production of retardation layer)
In the same manner as in Example 1, a patterned glass substrate was obtained, and a polarizing layer 54 was formed thereon. A 2% by weight aqueous solution of polyvinyl alcohol (polyvinyl alcohol 1000 completely saponified type, manufactured by Wako Pure Chemical Industries, Ltd.) was applied on the polarizing layer 54 and dried to form a film having a thickness of 89 nm. Subsequently, a first rubbing treatment was performed on the surface of the obtained film. The first rubbing treatment is performed by using a semi-automatic rubbing apparatus (trade name: LQ-008 type, manufactured by Joyo Engineering Co., Ltd.) with a cloth (trade name: YA-20-RW, manufactured by Yoshikawa Chemical Co., Ltd.). The measurement was performed in the direction of 45 degrees with respect to the transmission axis 70a of the polarizing layer 54 without using a mask under the conditions of an amount of 0.15 mm, a rotation speed of 500 rpm, and 16.7 mm / s. The mask 1 shown in FIG. 1 having a pattern with a line width of 280 μm made of SUS is placed on the surface subjected to the first rubbing treatment, and the second direction is 135 degrees with respect to the direction of the transmission axis 70 a of the polarizing layer 54. The patterned alignment film 55 was formed by performing the rubbing process. The second rubbing treatment is performed by using a semi-automatic rubbing apparatus (trade name: LQ-008, manufactured by Joyo Engineering Co., Ltd.), using a cloth (trade name: YA-20-RW, manufactured by Yoshikawa Chemical Co., Ltd.) This was performed under the conditions of an indentation amount of 0.10 mm, a rotation speed of 500 rpm, and 16.7 mm / s. After removing the mask 1, the liquid crystal composition E was applied onto the patterned alignment film 55 using a bar coater and heated to 100 ° C. to obtain a film aligned in the liquid crystal phase. Then, ultraviolet rays were irradiated for 1 minute at an intensity of 40 mW / cm ^{2 at} a wavelength of 365 nm using Unicure (VB-15201BY-A, manufactured by USHIO INC.) In a state cooled to room temperature. Thereby, the retardation layer 56 was produced. Next, an antireflection film (manufactured by Dai Nippon Printing Co., Ltd.) is bonded onto the retardation layer 56, whereby a glass substrate with a pattern, a polarizing layer 54, a patterned alignment film 55, a retardation layer 56, and an antireflection coating. A laminate in which the layer 57 was laminated was obtained.

(Example 3)
The glass substrate with a pattern, the polarizing layer 54, and the patterning were performed in the same manner as in Example 1 except that the conditions of the second rubbing treatment were changed to an indentation amount of 0.10 mm, a rotation speed of 500 rpm, and 8.35 mm / s. A laminated body in which the alignment film 55, the retardation layer 56, and the antireflection layer 57 were laminated was obtained.

<Measurement of optical properties>
About the laminated body obtained above, the retardation value (nm) and the orientation angle of the retardation layer 56 were measured with a measuring instrument (KOBRA-WPR, manufactured by Oji Scientific Instruments). Table 2 shows the measurement results of the orientation angle of the liquid crystalline component in the retardation layer 56 and the retardation value (retardation value) Re (nm) at a wavelength of 549 nm. For example, when the orientation angle is different between the retardation region 71A and the retardation region 71B of the retardation layer 56 shown in FIG. 5, it means that the regions have different slow axis directions. In Table 2, the orientation angle is about 45 degrees or about 135 degrees because the direction of the transmission axis 70a of the polarizing layer 54 is 0 degrees. The closer the retardation value Re is to λ / 4 (that is, 135 nm), the more natural light that passes through the polarizing layer 54 and the retardation layer 56 is converted to light that is closer to circularly polarized light. When the orientation angle is 45 degrees, circularly polarized light (left circularly polarized light) rotating leftward when viewed from the phase difference layer 56 from the emission side is shown, and when 135 degrees, circularly polarized light (right circularly polarized light) rotating rightward is shown. .

<Measurement of misalignment>
The deviation between the pattern of the formed retardation layer 56 and the pattern formed of ink on the glass substrate was measured using a polarizing microscope (BX51, manufactured by Olympus Corporation). Table 3 shows the result of measuring the positional deviation between the boundary line of the pattern region in a state where the mask 1 is placed on the substrate and the boundary line where the orientation angle of the liquid crystal compound changes.

Example 4
[Production of display device members]
A polarizing layer 54 is formed by bonding a polarizing plate to the main surface 53a of the glass substrate 53 on which the color filter, the black matrix, and the ITO film are formed on the opposite side of the color filter using an adhesive. A 1 wt% cyclopentanone solution of the photoalignable polymer represented by the formula (A) is applied on the polarizing plate and dried to form a 200 nm thick photoalignable polymer film. Subsequently, the mask 1 shown in FIG. 1 in which a stripe pattern is formed in accordance with the pixel width of the color filter is placed on the obtained film, and the UV irradiation apparatus with a polarized UV irradiation jig is viewed from the direction perpendicular to the substrate surface. (SP-7, manufactured by USHIO INC.) Is used to irradiate linearly polarized light in a direction of 45 degrees with respect to the transmission axis 70a of the polarizing layer 54. Next, the mask 1 shown in FIG. 1 is shifted in the width direction by the line width, placed so that the first polarized UV non-irradiated portion and the gap portion of the mask 1 overlap, and irradiated with the second polarized UV. The second polarized UV is irradiated with linearly polarized light in the direction of 135 degrees with respect to the transmission axis 70 a of the polarizing layer 54, thereby forming the patterned alignment film 55. After removing the mask 1, the liquid crystal composition 1 is applied onto the patterned alignment film 55 in a film thickness such that the retardation value is 135 nm using a bar coater and heated to 100 ° C. A phase oriented film is obtained. After that, the retardation layer 56 is formed by irradiating with ultraviolet rays at a wavelength of 365 nm with an intensity of 40 mW / cm ² for 1 minute using UniCure (VB-15201BY-A, manufactured by USHIO INC.) While being cooled to room temperature. To do. Next, an antireflection film (manufactured by Dai Nippon Printing Co., Ltd.) is bonded onto the retardation layer 56. As a result, a laminated body in which the glass substrate 53 on which the color filter 52 is formed, the polarizing layer 54, the patterned alignment film 55, the retardation layer 56, and the antireflection layer 57 are laminated as shown in FIG.

  In a liquid crystal display device manufactured using this laminate (which constitutes a display device member 51B described later), in the retardation layer 56 having two retardation regions 71A and 71B having different slow axis directions, It can be confirmed that the light emitted from the phase difference regions 71A and 71B is left circularly polarized light and right circularly polarized light, respectively. Further, the positional deviation between the phase difference regions 71A, 71B and the color filters A1, A2,..., B1, B2,.

(Example 5)
[Production of display device members]
A polarizing layer 54 is formed by bonding a polarizing plate to the main surface 53a of the glass substrate 53 on which the color filter, the black matrix, and the ITO film are formed on the opposite side of the color filter using an adhesive. An aqueous solution of polyvinyl alcohol is applied onto the polarizing plate and dried to form an oriented polymer film having a thickness of 89 nm. Subsequently, a first rubbing process is performed on the surface of the obtained film. The first rubbing process is performed in the direction of 45 degrees with respect to the transmission axis 70a of the polarizing layer 54 under the conditions of an indentation amount of 0.15 mm, a rotation speed of 500 rpm, and 16.7 mm / s. The mask 1 shown in FIG. 1 in which a pattern is engraved in accordance with the SUS color filter pixel width is placed on the surface subjected to the first rubbing treatment, and the direction is 135 degrees with respect to the direction of the transmission axis 70a of the polarizing layer 54. Then, a patterned alignment film 55 is formed by performing a second rubbing process. The second rubbing process is performed under the conditions of an indentation amount of 0.10 mm, a rotation speed of 500 rpm, and 16.7 mm / s. After removing the mask 1, the liquid crystal composition 1 is applied on the patterned alignment film 55 to a film thickness such that the retardation value becomes 135 nm using a bar coater, and heated at 100 ° C. A phase oriented film is obtained. After that, the retardation layer 56 is formed by irradiating with ultraviolet rays at a wavelength of 365 nm with an intensity of 40 mW / cm ² for 1 minute using UniCure (VB-15201BY-A, manufactured by USHIO INC.) While being cooled to room temperature. To do. Next, an antireflection film (manufactured by Dai Nippon Printing Co., Ltd.) is bonded onto the retardation layer 56. As a result, a laminated body in which the glass substrate 53 on which the color filter 52 is formed, the polarizing layer 54, the patterned alignment film 55, the retardation layer 56, and the antireflection layer 57 are laminated as shown in FIG.

  In a liquid crystal display device manufactured using this laminate (which constitutes a display device member 51B described later), in the retardation layer 56 having two retardation regions 71A and 71B having different slow axis directions, It can be confirmed that the light emitted from the phase difference regions 71A and 71B is left circularly polarized light and right circularly polarized light, respectively. Further, the positional deviation between the phase difference regions 71A, 71B and the color filters A1, A2,..., B1, B2,.

(Example 6)
[Production of liquid crystal display device]
An alignment film 49 is formed on the color filter 52 side (back side) of the laminate obtained in Example 4, and a display device member 51B as a color filter substrate is formed as shown in FIG. obtain. Also, a known type of array substrate 91 is prepared. The array substrate 91 is provided with a liquid crystal driving electrode (not shown) having a matrix pattern for defining pixels, a wiring pattern, a thin film transistor, and the like on the main surface of the light emission side F of the glass substrate 93, and further on the light emission side. In F, an alignment film 99 is disposed. A polarizing plate 92 is bonded to the main surface (back surface) of the glass substrate 93 on the backlight 90 side.

  Next, in a direction in which the alignment film 99 of the array substrate 91 and the alignment film 49 of the liquid crystal display member 51A face each other, the matrix pattern of the liquid crystal drive electrodes of the array substrate 91 and the liquid crystal display device member 51A have a matrix shape. The array substrate 91 and the liquid crystal display member 51A are aligned so that the color filters A1, A2,...; B1, B2,. A liquid crystal panel is obtained by injecting and sealing a liquid crystal layer LC into a cell between the array substrate 91 and the liquid crystal display member 51A. Thus, pixels are configured via the liquid crystal layer LC between the respective liquid crystal drive electrodes of the array substrate 91 and the respective color filters of the liquid crystal display device member 51A, and the liquid crystal panel includes a plurality of liquid crystal panels arranged in a matrix. It has a pixel. The liquid crystal display device 40 is obtained by assembling the liquid crystal panel, a liquid crystal driving IC (integrated circuit) (not shown) and the backlight 90.

  In the liquid crystal display device 40, in the phase difference layer 56 having two phase difference regions 71A and 71B having different slow axis directions, light emitted from the phase difference regions 71A and 71B is left circularly polarized light and right circularly polarized light, respectively. It can be confirmed that Further, the positional deviation between the phase difference regions 71A, 71B and the color filters A1, A2,..., B1, B2,.

  The manufacturing method of the display device of the present invention can be applied to manufacturing various types of display devices, in particular, display devices capable of displaying images stereoscopically.

  In addition, the display device of the present invention can be applied to various types of display devices, particularly display devices capable of displaying images three-dimensionally.

DESCRIPTION OF SYMBOLS 1 Mask 2 Cavity part 3 Real part 40 Liquid crystal display device 51A, 51B Member for liquid crystal display device 52 Color filter 53 Glass substrate 54 Polarizing layer 55 Alignment film 56 Phase difference layer 57 Antireflection layer 70a Transmission axis 71A, 71B Phase difference region 71a , 71b Slow axis 90 Back light 91 Array substrate 92 Polarizing plate 93 Glass substrate LC Liquid crystal layer

Claims (6)

A substrate having a plurality of color filters arranged along the main surface on the back side of the two main surfaces, and a transmission axis in a specific direction along the main surface, arranged on the light emitting side of the substrate And a retardation layer disposed on the light exit side of the polarizing layer and having a plurality of retardation regions having slow axes that intersect the transmission axis at different angles along the principal surface. A display device member manufacturing method for manufacturing a display device member comprising a layer,
The manufacturing method of the member for display apparatuses characterized by including the following process (1) thru | or (4).
(1) A step of forming the polarizing layer along the main surface on the light emitting side of the substrate on which the color filter is formed (2) On the polarizing layer formed in the step (1), A function of arranging liquid crystal components of a liquid crystal composition, which is a material of the retardation layer, in positions corresponding to the arrangement of the plurality of color filters on the substrate in different alignment directions according to the direction of the slow axis; A step (3) of forming an alignment film having a plurality of pattern regions, and applying a liquid crystal composition containing a polymerizable liquid crystal compound on the alignment film formed in the step (2) to form a coating film; The coating film is held at a temperature at which the liquid crystal component of the liquid crystal composition exhibits a liquid crystal phase, and the liquid crystal component is aligned in different alignment directions for each region corresponding to the plurality of pattern regions of the alignment film. Step (4) The above step (3) In the polymerizable liquid crystal compound forming the formed liquid crystal component, by polymerizing while maintaining the oriented direction, the step of forming the retardation layer having the plurality of retardation region In the manufacturing method of the member for display devices according to claim 1,
With respect to the direction along the main surface, the shape and size of the plurality of retardation regions of the retardation layer respectively match the shape and size of the array of the plurality of color filters on the substrate. A method for manufacturing a member for a display device. In the manufacturing method of the member for display devices according to claim 1 or 2,
The method (2) includes the following steps (2a) to (2c): A method for manufacturing a member for a display device.
(2a) A step of applying a solution containing a photoalignable polymer on the polarizing layer to form a photoalignable polymer film (2b) The plurality of the photoalignable polymer films formed in the step (2a) Of the first pattern region by irradiating the first polarized light having the first polarization direction through a first mask having a gap corresponding to the first pattern region of the first pattern region. Step (2c) of causing the direction of regulation force to correspond to the first polarization direction In a second pattern region different from the first pattern region of the photo-alignment polymer film irradiated with the first polarization The second polarized light having a second polarization direction different from the first polarization direction is irradiated through the second mask having a gap corresponding to the second pattern region, and the second The direction of the orientation regulating force in the pattern area of Step to correspond to the second polarization direction In the manufacturing method of the member for display devices according to claim 1 or 2,
The method (2) includes the following steps (2f) to (2h): A method for manufacturing a member for a display device.
(2f) A step of applying a solution containing an orientation polymer on the polarizing layer to form an orientation polymer film (2g) The orientation polymer film formed in the step (2f) on the light emitting side Performing a first rubbing process on the surface along the first rubbing process direction so that the direction of the orientation regulating force of the surface on the light emitting side corresponds to the first rubbing process direction (2h) The first rubbing treatment is performed on the oriented polymer film that has been subjected to the first rubbing treatment according to (2g) through a mask having a void corresponding to the second pattern region other than the first pattern region. Performing a second rubbing process along a second rubbing process direction different from the direction, and changing a direction of the orientation regulating force of the second pattern region to correspond to the second rubbing process direction. In the manufacturing method of the member for display devices according to any one of claims 1 to 4,
The manufacturing method of the member for display apparatuses characterized by including the process of forming the reflection preventing layer which prevents reflection of external light in the said light-projection side of the said phase difference layer.   A display device comprising a display device member manufactured by the method for manufacturing a display device member according to claim 1.

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