JP6986274B2 - 光学シートモジュールの製造方法および製造装置 - Google Patents
光学シートモジュールの製造方法および製造装置 Download PDFInfo
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Description
200 第2ベースフィルム
Claims (13)
- 第1ベースフィルムの上面に液体状態の原料を塗布して、第1構造化パターンを形成する第1パターン成形段階と、
前記第1構造化パターンを、形状を維持したまま、半硬化させるパターン仮硬化段階と、
第2ベースフィルムの一面に接着層を塗布する接着層塗布段階と、
前記第2ベースフィルムに塗布された前記接着層を半硬化させる接着層仮硬化段階と、
前記第1ベースフィルムの第1構造化パターンの少なくとも一部と前記第2ベースフィルムの下面を接着させる接着段階と、
前記第1ベースフィルムと前記第2ベースフィルムが接着された状態で前記第1構造化パターンを硬化させる本硬化段階と、
前記本硬化段階を経た前記第2ベースフィルムの上面に液体状態の原料を塗布して、第2構造化パターンを形成する第2パターン成形段階と、
を含み、
前記第1ベースフィルム及び前記第2ベースフィルムは、前記第1ベースフィルム及び前記第2ベースフィルムの上下に設けられた接合ローラーを通過しながら接合され、
前記第2パターン成形段階は、パターンベルトと前記第2ベースフィルムに塗布された前記原料とを接触させて前記第2構造化パターンを形成し、
前記パターンベルトは、循環するベルト形態で形成され、その表面に前記第2構造化パターンの前記原料と接触する既定のパターンを有し、モールドとして形成され、その表面がラバーで形成され、前記第2構造化パターンの前記原料と接する光学シートモジュールの製造方法。 - 前記第2構造化パターンを硬化させるパターン硬化段階をさらに含むことを特徴とする請求項1に記載の光学シートモジュールの製造方法。
- 前記接着層は、
既定のパターンをもって形成されることを特徴とする請求項2に記載の光学シートモジュールの製造方法。 - 前記第1パターン成形段階は、
前記第1ベースフィルムの上面に液体状態である前記第1構造化パターンの原料を塗布する第1過程と、
前記第1ベースフィルムに塗布された前記原料に既定のパターンが形成された第1パターン成形部を加圧して、前記第1構造化パターンを形成する第2過程と、を含むことを特徴とする請求項1に記載の光学シートモジュールの製造方法。 - 前記第1パターン成形部は、
前記第1構造化パターンの原料と接触する面に既定のパターンが形成されたパターンローラーまたは循環するパターンベルトのうちいずれか一つで形成されることを特徴とする請求項4に記載の光学シートモジュールの製造方法。 - 前記第1構造化パターンは、前記第2構造化パターンと異なるピッチまたは上下方向の高さを有することを特徴とする請求項1に記載の光学シートモジュールの製造方法。
- 前記第1構造化パターンと、前記第2構造化パターンおよび前記接着層は、
紫外線(UV)硬化性材料であることを特徴とする請求項1に記載の光学シートモジュールの製造方法。 - 前記第1構造化パターンおよび前記第2構造化パターンは、
アクリレートモノマー(Acrylated monomer)、ジアクリレートモノマー(Diacrylated monomer)、ウレタンアクリレートオリゴマー(Urethane acrylate oligomer)、ポリエステルアクリレートオリゴマー(Polyester Acrylate oligomer)、およびエポキシアクリレートオリゴマー(Epoxy acrylated oligomer)のうち少なくともいずれか一つを含むことを特徴とする請求項7に記載の光学シートモジュールの製造方法。 - 前記接着層は、
アクリレートモノマー(Acrylated monomer)、ジアクリレートモノマー(Diacrylated monomer)、ウレタンアクリレートオリゴマー(Urethane acrylate oligomer)、ポリエステルアクリレートオリゴマー(Polyester Acrylate oligomer)、エポキシアクリレートオリゴマー(Epoxy acrylated oligomer)のうち少なくとも一つを含むことを特徴とする請求項7に記載の光学シートモジュールの製造方法。 - シート形状の第1ベースフィルムが移送される第1移送経路と、前記第1移送経路上で前記第1ベースフィルムの上面に第1構造化パターンを形成する第1パターン成形部と、前記第1パターン成形部により形成された前記第1構造化パターンを形状が維持されるように半硬化させるパターン仮硬化部と、前記第1移送経路と別に設けられ、シート形状の第2ベースフィルムが移送される第2移送経路と、前記第2移送経路上に設けられ、移送される前記第2ベースフィルムの一面に接着層を形成する接着層塗布部と、前記第2移送経路上に設けられ、塗布された前記接着層を半硬化させる接着層仮硬化部と、前記第1移送経路および前記第2移送経路上の下流上にそれぞれ連結されて相互合わさるように構成され、前記第1ベースフィルムと前記第2ベースフィルムを移送させる統合移送経路と、前記統合移送経路上に設けられ、前記第1ベースフィルムの上部に前記第2ベースフィルムを積層させ、上下部で加圧して前記第1構造化パターンと前記接着層を接着させる接合ローラーと、前記統合移送経路上で接合された前記第1構造化パターンと前記接着層を硬化させる本硬化部とを含む第1工程ユニットと、
前記統合移送経路と別に設けられ、接合された前記第1ベースフィルムと前記第2ベースフィルムを移送させる第3移送経路と、前記第3移送経路上で前記第2ベースフィルムの上面に原料を塗布し、第2構造化パターンを形成する第2パターン成形部と、前記第2ベースフィルムの上面に形成された前記第2構造化パターンを硬化させるパターン硬化部とを含む第2工程ユニットと、を含み、
前記第2パターン成形部は、少なくとも前記第3移送経路上の領域に循環するベルト形態で形成され、その表面に前記第2構造化パターンの前記原料と接触する既定のパターンを有し、モールドとして形成され、その表面がラバーで形成され、前記第2構造化パターンの前記原料と接するパターンベルトを含む光学シートモジュールの製造装置。 - 前記第1パターン成形部は、
前記第1構造化パターンの原料と接触する面に既定のパターンが形成されたパターンローラーを含むことを特徴とする請求項10に記載の光学シートモジュールの製造装置。 - 前記第2パターン成形部は、
少なくとも一部が前記第2構造化パターンの原料と接触した状態で前記パターン硬化部を経由することを特徴とする請求項10に記載の光学シートモジュールの製造装置。 - 前記第1工程ユニットと前記第2工程ユニットが連続して連結され、連続工程が可能となるように構成されることを特徴とする請求項10に記載の光学シートモジュールの製造装置。
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