KR100603778B1 - Apparatus manufacturing optical film and method thereof - Google Patents

Abstract

The present invention relates to an optical film manufacturing apparatus and a manufacturing method for minimizing the moiré phenomenon, the manufacturing apparatus is a film unwinding roll for supplying a film along a feed path, a coater for applying a resin composition on the optical film base material at a predetermined thickness, The pattern forming roller compresses the pattern with the resin layer while the direction of the pattern is inclined at an angle with respect to the rotational axis thereof to form a structured pattern surface which is oriented at a predetermined angle, and imparts tensile force to the optical film base material to be supplied. It comprises a tension roller, a UV light irradiator to harden the resin layer on which the structured surface is formed, and an optical film winding roll for winding the structured surface is formed and commercialized optical film, for the prism sheet Minimizing the consumption of the optical film has the effect of improving the productivity of the prism sheet.

 Prism sheet, moiré effect, optical film, pattern forming roller, tilting device

Description

Apparatus manufacturing optical film and method

1 is an exploded perspective view of a backlighting apparatus for illuminating an LCD panel.

2 is a pattern direction of the prism sheet and an electrode arrangement diagram of the liquid crystal panel to minimize the moiré effect.

3 is a detailed view of a cutting roller mounted on a conventional optical sheet cutting device.

Figure 4 is a schematic diagram of a pattern forming roller according to the present invention for producing an optical film for preventing the moiré effect.

Figure 5 is a schematic diagram showing a comparison between the pattern formed on the pattern forming roller and the pattern of the conventional pattern forming roller according to the present invention.

6 is a schematic view of an optical film manufacturing apparatus for a prism sheet according to the present invention.

7 is a schematic diagram of a pattern forming roller and a tilting apparatus employed in another optical film manufacturing apparatus according to the present invention.

8 is a schematic view showing an optical film base material being inclinedly supplied to a pattern forming roller in the optical film manufacturing method according to the present invention.

`` Explanation of symbols for main parts of drawings ''

2: cutting roller body 2a: rotation axis

3: thin sheet cutter 3a: shape cutting blade part

6: base film 8: optical film material

10 film unwinding roll 11 light source

12: reflection sheet 13: light guide plate

14: diffusion sheet 15, 16: prism sheet

17: protective sheet 18: display

20: optical film 30: support roll

40: coater 50: drying furnace

60, 65: tension roll 70: pattern forming roller

71 pattern 72 rotation axis

75: tilting device 80: UV light irradiator

90: film winding roll

The present invention relates to a manufacturing apparatus and a manufacturing method of an optical film used as a prism sheet used in the backlighting device for LCD, and more particularly, an optical interference shape generated between the pattern of the prism sheet or the pattern of the prism sheet and the liquid crystal panel. The present invention relates to an optical film production apparatus and a manufacturing method for minimizing the phosphorus moire phenomenon.

In general, a liquid crystal display (LCD) is a display device that enables a user to recognize the information processed by the information processing device by precisely controlling the light transmittance of the liquid crystal using the electro-optical characteristics of the liquid crystal.

The liquid crystal display device includes a liquid crystal display assembly for controlling a liquid crystal to implement a predetermined image and information, and a backlighting unit for supplying light to view an image, information, and the like implemented in the liquid crystal display assembly.

On the other hand, the performance of the image display means using the optical film is greatly affected by the performance of the backlight unit.

This is because a method of controlling the amount of light by reflecting or transmitting light through the optical film is the basis, and various optical films having excellent optical performance have been proposed to effectively apply the thin film optical film to the image display means.

1 shows a simple structure of a general LCD backlight unit.

In FIG. 1, a cold cathode ray tube lamp (CCFL), which is a type of LED or a discharge lamp, is used as the light source 11 for supplying light to the liquid crystal display.

The light guide plate 13 is used in the liquid crystal display device to make the linear light source or the point light source into a uniform surface light source.

The light guide plate 13 forms a uniform surface light source while guiding the light from one side or both sides, and the surface light source is evenly distributed to increase the uniformity of the light by the diffusion sheet 14 positioned on the light guide plate 13. The light emitted from the bottom surface of the light guide plate 13 is diffused by the reflective sheet 12 disposed below the light guide plate 12 to be incident again to the light guide plate 13.

In addition, the diffusion sheet 14 is disposed on the first and second prism sheets 15 and 16 and the second prism sheet 16 to concentrate the light passing through the diffusion sheet 14 to improve luminance. The protective sheet 17 is disposed to protect the thin film display 18, and the thin film display 18 is positioned at the top thereof.

The prism sheets 15 and 16 are thin film flexible optical films arranged at right angles to be used as a light collecting sheet, and are made of a transparent polymer material having a structured expression on one side and a smooth side opposite to the other. .

The structured surface of the optical film includes a linear array of small right angled isosceles prisms arranged side by side to form a plurality of peaks and grooves over the length of the optical film.

However, when the arrangement direction of the pattern formed on the prism sheet 16 and the arrangement direction of the pixel electrodes arranged in matrix form in the pixel electrode 18a formed on the liquid crystal display 18 coincide with each other, the two patterns This overlap causes optical problems, and a moire phenomenon, in which a streak is generated, causes a problem of use in which image characteristics realized on the screen are degraded.

As a method of minimizing the moiré phenomenon, there is an irregular method of using the periodicity of the prism sheet which is an optical film, and a method of stacking the multilayer optical film sheet.

According to the recently developed technology, it is known that the moiré phenomenon can be minimized by staggering the arrangement directions of the patterns of the prism sheets 15 and 16 as the most effective method for anomalous use of the periodicity of the prism sheet. .

FIG. 2 alternates the pattern formation direction by about 22.5 ° in the arrangement relationship between the pattern formation direction formed in the prism sheet 16 and the pixel electrodes arranged in a matrix form in the pixel electrode 18a formed in the liquid crystal display 18. The method of minimizing the moiré effect by avoiding the coincidence of the arrangement direction is shown.

At this time, the arrangement direction of the pattern formed on the optical film is formed to be inclined at a predetermined angle to manufacture a prism sheet. According to a conventional manufacturing method, a prism sheet material having a pattern normally formed at a predetermined desired angle at an arbitrary size. The prism sheet with which the pattern was formed inclined by cutting with the resin was produced.

Figure 3 shows a part of a cutting device for producing a prism sheet with a pattern inclined according to the conventional method.

The cutting roller installed in the optical film cutting device has a rotating shaft (2a) protruding in the center of both ends and the thin plate is installed to surround the outer periphery of the cylindrical body (2) and the body (2), the gear is installed on one side of the outer periphery. It consists of a cutter (3), in the center of the thin plate cutter (3) is a shape cutting blade portion (3a) for cutting the optical film material (8) protruding at a predetermined interval, and both sides of the shape cutting blade portion (3a) The room may be configured such that the hole-cutting blades are formed to protrude at regular intervals to penetrate the through holes for positioning for secondary processing on both sides of the base film 6 to which the optical film material 8 is attached to the upper surface. have.

The shape cutting blade portion 3a is formed by tilting a predetermined angle, so that the cutting process is performed at a predetermined angle with respect to the optical film material 8 having the pattern formed thereon, so that the pattern is inclined at a predetermined angle in the cut product. Will yield

However, in the production of the prism sheet by the cutting process as described above, the yield is significantly lower than that of the product in which the pattern is normally formed, and there is a lot of optical film material that is thrown away into the strip, and the waste of the raw material is severe.

In addition, in order to obtain a pattern formed at a desired angle, the shape cutting blade portion 3a of the cutting device has to be variously processed at any desired angle, but not only the machining is difficult but also the accuracy thereof is deteriorated.

The present invention has been made to solve the above problems, in order to minimize the moiré phenomenon to form a structured surface formed with a pattern inclined at a predetermined angle on the optical film in the manufacturing step of the optical film material forming a prism sheet In the optical film manufacturing apparatus for providing a pattern forming roller is a pattern processed at a predetermined angle.

It is also an object of the present invention to provide an optical film manufacturing apparatus and a manufacturing method for manufacturing a prism sheet having a structured surface in which the direction of the pattern is formed at a predetermined angle.

In addition, in order to improve the moire phenomenon in order to provide an optical film manufacturing apparatus capable of manufacturing an optical film by varying the angle of the pattern forming roller in the manufacture of the optical film formed by tilting the pattern at a predetermined angle.

The pattern forming roller of the optical film manufacturing apparatus according to the present invention for achieving the above object has a rotation axis in the center of both ends and the predetermined pattern protrudes at regular intervals on the outer periphery of the cylindrical body of the optical film manufacturing apparatus In the pattern forming roller is characterized in that the direction of the pattern formed on the roller is inclined at an angle to the rotation axis of the roller.

On the other hand, the optical film manufacturing apparatus according to the present invention is an optical film base material is wound and the film unwinding roll supplied along the feed path, a coater for applying a resin composition to be formed on the optical film base material with a predetermined thickness, the optical film base material A pattern forming roller which compresses the pattern with a resin layer so that the pattern is inclined at an angle to the rotation axis to form a structured pattern surface which is oriented at a predetermined angle, and an optical film base material conveyed and supplied onto the pattern forming roller. A tension roller to impart a tensile force to the resin layer of the optical film base material to form a structured surface, and a resin layer having the structured surface formed by irradiating ultraviolet rays to the optical film on which the structured surface is formed. UV light irradiator to cure this, and the structured surface is formed and commercialized optical peel The optical film includes a take-up roll to wind kept standing.

On the other hand, another optical film manufacturing apparatus according to the present invention is an optical film base material is wound and the film unwinding roll supplied along the feed path, the coater for applying a resin composition to be formed on the film base material with a predetermined thickness, the optical film base material A pattern forming roller for compressing the pattern on the resin layer to form a structured pattern surface, and applying a tensile force to the optical film base material transferred and supplied on the pattern forming roller so that the pattern is pressed against the optical film base material. Tensile roller to be formed, UV light irradiator to cure the resin composition on which the structured surface is formed by irradiating ultraviolet rays to the optical film on which the structured surface is formed, winding the productized optical film on which the structured surface is stored The pattern forming is connected to the optical film winding roll and the rotation axis of the pattern forming roller And a rotation axis tilting device of the pattern forming roller for tilting the pattern forming roller so that the pattern direction formed on the roller is inclined at an angle with respect to the horizontal direction of the film base material so that the structured surface formed by the pattern is formed on the film base material. do.

On the other hand, the optical film manufacturing method according to the present invention, the optical film base material supply step of continuously supplying the optical film base material, a resin coating step of applying a resin composition to be formed on one side of the supplied film, a predetermined pattern The formed pattern forming roller is pressed to form a structured surface having a pattern direction inclined at a predetermined angle in the resin layer applied on the optical film base material, and at the same time, the structured surface forming step of curing by irradiating UV light and the inclined pattern And a cutting step of cutting the optical film having a structured surface having a direction into a predetermined product size.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 4 is an embodiment of the pattern forming roller 70 according to the present invention in which the direction of the pattern 71 is formed at a predetermined angle on the optical film 20 for producing the prism sheets 15 and 16.

5 is a schematic view showing a conventional pattern forming roller 70 and a pattern 71 formed on the pattern forming roller 70 according to the present invention.

In FIG. 5, the pattern 71 formed on the pattern forming roller 70 represents a pitch continuously formed corresponding to peaks and grooves formed as a structured surface on the optical film 20, and the pattern formed on the roller 70. Groove (71) is formed continuously by the tip machining, the shape of which can be machined in various angles and shapes as well as the usual V-shape depending on the shape of the tip during tip processing.

Referring to the first picture of FIG. 5, a pattern 72 is formed on the conventional pattern forming roller 70 at a right angle with respect to the rotation axis x of the roller 70, but is seen in the second picture of FIG. 5. In the pattern forming roller according to the invention, the pattern 71 is inclined at a predetermined angle θ with respect to the rotation axis x of the roller in order to minimize the moiré effect.

4 and 5, the rotating shaft 72 is provided at the center of both ends, and a predetermined pattern 75 is formed at a predetermined interval on the outer periphery of the cylindrical body, and the pattern 72 is formed on the roller 70. The direction is formed to be inclined at an angle θ to the rotation axis x of the roller.

Here, the direction of the pattern 71 formed on the pattern forming roller 70 is inclined to the rotation axis of the pattern forming roller 70 to produce a structured surface formed on the prism sheet in order to minimize the optical interference due to the moiré effect. Preferably, the angle is larger than 0 ° and smaller than 45 °.

6 schematically shows an optical film manufacturing apparatus for a prism sheet according to the present invention.

In FIG. 6, the apparatus for manufacturing an optical film includes a film unwinding roll 10, on which a base material of the optical film 20 is wound and supplied along a conveying path, and a resin composition on which a pattern is to be formed on the base material of the optical film 20. The pattern is squeezed to the resin layer in a state in which the direction of the pattern is inclined at an angle with respect to the axis of rotation to the coater 40 to be applied and the base film of the optical film 20 to form a structured pattern surface oriented at a predetermined angle. The pattern forming roller 70 and the pattern forming roller 70 impart a tensile force to the optical film 20 base material transferred to the pattern forming roller 70 so that the pattern is pressed onto the resin layer of the optical film 20 base material and the structured surface is Tensile rollers 60 and 65 to be formed, UV light irradiator 80 to irradiate the optical film 20, the structured surface is formed to cure the resin layer on which the structured surface is formed, and the sphere It comprises an optical film winding roll 90 is formed to the surface is formed and wound to produce a commercialized optical film 20.

In addition, a drying furnace 50 for drying the resin layer of the base film formed by applying the resin composition may be further disposed according to the composition of the resin.

Here, reference numeral 30 is a support roll 30 that can adjust the amount of resin applied to the coater, it is possible to adjust the thickness of the coating by adjusting the distance between the support roll 30 and the coater, the film feed rate The coating thickness of the resin composition can also be adjusted.

In addition, reference numeral 25 denotes a vibration suppression apparatus for removing fine dust in the coating chamber, reference numerals 66 and 67 denote guide rolls for guiding the optical film to the pattern forming roller 70, and reference numeral 68 denotes the optical It shows a tension sensor 68 that senses the tensile force of the film.

In the optical film manufacturing apparatus shown in FIG. 6, the direction of the pattern formed on the pattern forming roller 70 is inclined with respect to the axis of rotation of the pattern forming roller 70 as shown in FIG. 4. Greater than 0 ° and set to 45 ° or less.

Further, in the optical film manufacturing apparatus, the pattern formed on the pattern forming roller 70 is a groove formed by the tip processing (groove) is formed continuously.

7 shows a pattern forming roller 70 employed in another optical film manufacturing apparatus according to the present invention.

Another optical film manufacturing apparatus according to the present invention comprises a pattern forming roller 70 shown in FIG. 7 in the apparatus shown in FIG.

That is, the optical film manufacturing apparatus of the other embodiment forms a structured surface by pressing the pattern on the resin layer of the film unwinding roll 10, the coater 40, the optical film 20 base material constituted in a conventional manufacturing apparatus In addition to the pattern forming roller 70, the tension roller (60, 65), UV light irradiation 80, the optical film winding roll 90 is connected to the rotation axis 72 of the pattern forming roller 70 The pattern forming roller is formed so that the pattern formed on the pattern forming roller 70 is inclined at an angle with respect to the horizontal direction of the optical film 20 base material so that the structured surface formed by the pattern is formed on the optical film 20 base material. It is configured to include a rotation axis tilting device 75 of the pattern forming roller 70 for tilting (70).

In addition, the rotating shaft tilting device 75 may be implemented by various mechanisms.

Here, the rotating shaft tilting device 75 is installed on any part of the rotating shaft 72 of the pattern forming roller 70 or both ends of the rotating shaft 72 of the pattern forming roller 70 according to the mechanism applied. Can be installed on

In addition, since the direction of the pattern is greater than 0 ° and less than 45 ° in the prism sheet optical film 20 formed to minimize the moiré effect, the rotation axis of the pattern forming roller 70 is rotatable in the angle range. The tilting device 75 is movable.

In addition, in the optical film manufacturing apparatus, the pattern forming roller 70 and the tilting device 75 shown in FIG. 4 may be configured together, and at this time, the rotation angle of the rotating shaft by the tilting device 75 may be adjusted. The range of the pattern 71 formed on the pattern forming roller 70 is limited by a predetermined angle (θ) inclined by the rotation axis x of the roller, and the forming direction of the structured pattern formed on the optical film as a whole is horizontal. Can be adjusted to greater than 0 ° and up to 45 ° relative to.

Now, a method of manufacturing an optical film for a prism sheet using the optical film manufacturing apparatus according to the present invention will be described.

Referring to Figure 6, the optical film manufacturing method for a prism sheet according to the present invention is as follows.

The first step is an optical film base material supplying step of continuously supplying the optical film 20 base material in the film unwinding roll 10. The optical film fabric for manufacturing a prism sheet is supplied to a device.

The second step is a resin coating step of applying the resin composition to the optical pattern to be formed on one side of the film to be supplied in the coater 40.

In order to form the pattern of the prism sheet, the applied resin composition may be an organic composition such as an oligomer, and a process of flattening the coating thickness may be performed.

The third step is a resin layer drying step of drying the resin layer applied on the optical film 20 to harden in a semi-solidified state.

However, the step is a process step that can be omitted depending on the composition of the resin, the volatile solvent is added to the resin composition to be applied is carried out by infrared irradiation in the drying furnace 50 to remove it and the resin layer by the drying step It is hardened to the sol-gel state and is in a state suitable for pattern formation for the structured surface.

In the fourth step, the pattern forming roller 70 having a predetermined pattern is squeezed to form a structured surface having a pattern inclined at a predetermined angle on the resin layer applied on the optical film 20 base material. Irradiating ultraviolet rays with a UV light irradiator 80 to the formed resin layer is a step of curing.

At this stage, the tilt in the pattern direction occurs at a predetermined angle designed to minimize the moiré effect.

Here, a process of pre-processing the pattern forming roller 70 by varying the predetermined pattern formed on the pattern forming roller 70 at a predetermined angle is required.

In addition, the rotation axis of the pattern forming roller 70 including a process of driving the tilting device 75 connected to the rotation axis 72 of the pattern forming roller 70 in which the predetermined pattern is formed in place of the processing process ( 72), the direction of the pattern can be tilted.

Furthermore, as shown in FIG. 8, when the optical film 20 base material is supplied to the pattern forming roller 70 in the optical film 20 base material supply step of continuously supplying the optical film 20 base material. Forming the pattern by varying the advancing angle of the base material of the optical film 20 so that the horizontal direction of the base material of the optical film 20 is a predetermined angle with respect to the rotation axis 72 of the pattern forming roller 70 The direction may be tilted, and in this case, a mechanism or a driving device may be additionally provided to control the advancing direction of the base film 20.

The fifth step is a cutting step of cutting the optical film having a structured surface having the inclined pattern with a conventional cutting device as a predetermined product size.

In the cutting step, as shown in FIG. 3, the prism sheet is produced by cutting the shape of the cutting edge portion 3a in the form of a conventional cutting edge without tilting, thus greatly improving productivity and discarding the substrate of the optical film 20. The scab is greatly reduced.

According to the present invention, there is an advantage that it is easier and simpler in constructing a structured surface on which a pattern inclined at a predetermined angle is formed on a prism sheet to minimize the moiré phenomenon.

In addition, according to the present invention, by providing an optical film manufacturing apparatus and a manufacturing method for manufacturing a prism sheet having a structured surface, the direction of the pattern is formed at a predetermined angle to minimize the portion of the optical film for prism sheet is discarded Reducing the consumption has the effect of improving the productivity of the prism sheet.

Although the present invention has been described in detail only with respect to the specific embodiments described, it will be apparent to those skilled in the art that various modifications and variations are possible within the technical scope of the present invention, and such modifications and modifications belong to the appended claims. .

Claims (13)

In the pattern forming roller of the optical film manufacturing apparatus having a rotation axis in the center of both ends and the predetermined pattern protrudes at regular intervals on the outer periphery of the cylindrical body, The pattern forming roller of the optical film manufacturing apparatus, characterized in that the direction of the pattern formed on the roller is formed at an angle with respect to the rotation axis of the roller. The method of claim 1, The pattern forming roller of the optical film manufacturing apparatus, characterized in that the inclination of the pattern formed on the pattern forming roller with respect to the rotation axis of the pattern forming roller is greater than 0 ° and less than 45 °. A film unwinding roll on which an optical film base material is wound and which supplies an optical film along a conveying path; A coater for coating the resin composition to be formed on the optical film base material at a predetermined thickness; A pattern forming roller which forms a structured pattern surface oriented at a predetermined angle by pressing the pattern with the resin layer while the direction of the pattern is inclined at a predetermined angle to the rotation axis of the optical film base material; A tension roller to impart a tensile force to the optical film base material transferred and supplied on the pattern forming roller so that the pattern is compressed to the resin layer of the optical film base material to form a structured surface; UV light irradiator to irradiate the optical film on which the structured surface is formed to cure the resin layer on which the structured surface is formed; And Optical film manufacturing apparatus comprising an optical film winding roll for winding the structured surface is formed and productized optical film wound. The method of claim 3, wherein Optical film manufacturing apparatus, characterized in that the inclination of the pattern formed on the pattern forming roller with respect to the rotation axis of the pattern forming roller is greater than 0 ° and less than 45 °. The method according to claim 3 or 4, The optical film manufacturing apparatus further comprises a drying furnace for drying the resin layer of the optical film base material formed by applying the resin composition. A film unwinding roll on which an optical film base material is wound and supplied along a conveying path; A coater for applying the resin composition to be formed with a pattern on the film base material at a predetermined thickness; A pattern forming roller for pressing the pattern onto the resin layer of the optical film base material to form a structured surface; A tension roller to impart a tensile force to the optical film base material transferred and supplied on the pattern forming roller to form a structured surface by pressing the pattern onto the optical film base material; UV light irradiator to irradiate the optical film on which the structured surface is formed to cure the resin composition on which the structured surface is formed; An optical film winding roll for winding and storing a productized optical film having the structured surface formed thereon; And The pattern forming roller is connected to the rotation axis of the pattern forming roller so that the pattern direction formed on the pattern forming roller is inclined at an angle with respect to the horizontal direction of the film base material so that the structured surface formed by the pattern is formed on the film base material. Optical film manufacturing apparatus comprising a tilting device for rotating shaft of the pattern forming roller for tilting. The method of claim 6, The tilting device is an optical film manufacturing apparatus, characterized in that installed on at least one end of the rotation axis of the pattern forming roller. The method according to claim 6 or 7, Optical film manufacturing apparatus, characterized in that the variable range of the angle at which the pattern forming roller is rotated by the tilting device is greater than 0 ° and less than 45 °. The method according to claim 6 or 7, The optical film manufacturing apparatus further comprises a drying furnace for drying the resin layer of the optical film base material formed by applying the resin composition. An optical film base material supplying step of continuously supplying the optical film base material; Resin coating step of applying a resin composition to form a pattern on one side of the film to be supplied; A structured surface forming step of pressing a pattern forming roller on which a predetermined pattern is formed to form a structured surface having a pattern direction inclined at a predetermined angle on a resin layer applied on the optical film base material, and simultaneously irradiating and curing UV light; And And a cutting step of cutting the optical film having a structured surface having the inclined pattern direction to a predetermined product size. The method of claim 10, And varying the predetermined pattern formed on the pattern forming roller at a predetermined angle in the structured surface forming step to process the pattern forming roller. The method of claim 10, And varying the rotation axis of the pattern forming roller by driving a tilting device connected to the rotation axis of the pattern forming roller on which the predetermined pattern is formed in the structured surface forming step. The method of claim 10, When the optical film base material is supplied to the pattern forming roller in the optical film base material supplying step of continuously supplying the optical film base material, the horizontal direction of the optical film base material is formed at a predetermined angle with respect to the rotation axis of the pattern forming roller. Optical film manufacturing method comprising the step of varying the progress angle of the optical film base material.

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