KR101173839B1 - Apparatus and method for manufacturing an optical sheet - Google Patents

Abstract

An apparatus for manufacturing an optical sheet according to an embodiment of the present invention includes a first roll to which the base film is wound; A second roll to which the base film coated with the coating liquid is wound; Two or more guide rolls provided between the first roll and the second roll to convey the base film; Coating liquid injection means for injecting a coating liquid into the base film; And a pattern molding part disposed to be engaged with any one of the guide rolls, and allowing the coating liquid injected from the coating liquid injection means to be applied onto the base film in a predetermined pattern shape. The pattern molding part includes a predetermined pattern shape. The molded mold, a master roll for compressing the injected coating liquid to the molding mold, a plurality of pattern guide rolls for transferring the molding mold, and a pre-coating device for filling the coating liquid into a pattern of the molding mold. It is characterized by.

Optical sheet, pre-coating unit

Description

Apparatus and method for manufacturing an optical sheet

The present invention relates to an apparatus for manufacturing an optical sheet and a method of manufacturing the same, and more particularly, to be used in a display or an optical element, and to continuously mass-produce an optical sheet having a pattern of micro or nano scale, The manufacturing apparatus of the optical sheet which can improve a production yield, and its manufacturing method are related.

Recently, the use of liquid crystal displays (LCDs) among flat panel displays is increasing, and the liquid crystal displays display information by using the electrical / optical properties of liquid crystals injected into the liquid crystal display panels, and lamps A non-light emitting display device that displays an image by using a light source such as a light source.

That is, the liquid crystal display panel, unlike the cathode ray, is a liquid crystal material injected between the TFT substrate and the color filter substrate because it is not a light emitting material that emits light, but a light receiving material that controls the amount of light from the outside and displays it on the screen. A separate device, i.e., a backlight assembly, for irradiating the light is necessarily required.

The backlight assembly includes a mold frame in which a storage space is formed, a reflective sheet disposed on a base surface of the storage space to reflect light toward the liquid crystal display panel, a light guide plate installed on the upper side of the reflective sheet, and guiding light, and sidewalls of the light guide plate and the storage space. A lamp unit disposed between and emitting light, optical sheets stacked on an upper surface of the LGP and diffusing and condensing light, and installed on an upper part of the mold frame to reach a side of the mold frame at a predetermined position of the edge of the LCD panel. It consists of a top chassis covering the area.

Here, the optical sheets include a diffusion sheet for diffusing light, a prism sheet for condensing the light diffused and stacked on an upper surface of the diffusion sheet, and transferring the light to a liquid crystal display panel, and a protective sheet for protecting the diffusion sheet and the prism sheet. It is composed.

1 and 2 are a cross-sectional view and a perspective view of a general prism sheet.

1 and 2, the conventional prism sheet 10 includes a body portion 11 into which light diffused by a light guide plate and a diffusion sheet is first introduced, and an isosceles triangular column to allow the diffused light to be uniformly progressed. It is composed of a protrusion 12 of the shape, the protrusion 12 is linearly arranged in a stripe shape on the body portion (11).

The isosceles triangular pillar-shaped protrusion 12 has a pitch of several tens of micrometers to several hundreds of micrometers, and the vertex angle α of the triangular prism is in the range of 60 to 130 degrees. In addition, as the angle of the vertex angle α is an acute angle, the luminance is increased, but the viewing angle is narrowed.

Therefore, the conventional prism sheet has a problem that it is difficult to expect both to have improved luminance characteristics and a wide viewing angle.

In order to solve this problem, the applicant of the present invention has proposed an optical sheet in which a microlens pattern is formed through an application number 10-2005-33262 KR (published number: 10-2006-011090A), which is illustrated in FIG. have.

3 is a perspective view of an optical sheet on which a micro lens pattern is formed.

3 shows an optical sheet 20 capable of simultaneously improving the characteristics of the luminance and the viewing angle, and the optical sheet 20 includes a body 21 and a convex portion 22 or a micro lens pattern.

The convex portions 22 formed on the optical sheet 20 can more efficiently collect and diffuse light.

On the other hand, with respect to an apparatus for manufacturing an optical sheet having the shapes as described above and a method for manufacturing the same, the applicant of the present application No. KR 10-605386 (name of the invention: a manufacturing apparatus and manufacturing method of an optical member having a fine shape and Molding mold for this), and to overcome the phenomenon that can occur mainly in the case of manufacturing an optical sheet having a shape as shown in Figure 3 using the invention described in KR 10-605386 The proposed embodiment will be described in detail by dividing the terms.

This invention discloses the manufacturing apparatus of the optical sheet which can improve the production yield in manufacturing the optical sheet which has a predetermined pattern, and its manufacturing method.

An apparatus for manufacturing an optical sheet according to an embodiment of the present invention includes a first roll to which the base film is wound; A second roll to which the base film coated with the coating liquid is wound; Two or more guide rolls provided between the first roll and the second roll to convey the base film; Coating liquid injection means for injecting a coating liquid into the base film; And a pattern molding part disposed to be engaged with any one of the guide rolls, and allowing the coating liquid injected from the coating liquid injection means to be applied onto the base film in a predetermined pattern shape. The pattern molding part includes a predetermined pattern shape. The molded mold, a master roll for compressing the injected coating liquid to the molding mold, a plurality of pattern guide rolls for transferring the molding mold, and a pre-coating device for filling the coating liquid into a pattern of the molding mold. It is characterized by.

Moreover, the manufacturing apparatus of the optical sheet which concerns on this invention is a manufacturing apparatus which manufactures the optical sheet which has a 1st pattern, Comprising: The 1st roll by which a base film is wound; A second roll to which the optical sheet is wound; Two or more guide rolls disposed between the first roll and the second roll to convey the base film or the optical sheet; A pattern molding part including a master roll disposed to be in engagement with any one of the guide rolls, and a plurality of pattern guide rolls for transferring a molding mold in which a second pattern which is reversed from the first pattern is formed; A pre-coating device formed between the pattern guide rolls and filling the coating liquid in the pattern of the molding mold; And coating liquid injection means for further filling the coating liquid into the pattern of the molding mold in which the coating liquid is filled by the pre-coating device.

According to another aspect, a method of manufacturing an optical sheet of the present invention includes a method for manufacturing an optical sheet having a first pattern, the method comprising: transferring a base film serving as a material of the optical sheet; Firstly filling a coating liquid into a molding mold in which a second pattern that is reversed from the first pattern is molded; Filling the coating mold with the coating liquid by injecting the coating liquid into a region where the base film and the molding mold are engaged; By curing the coating solution, the coating solution is applied onto a base film; And separating the molding mold and the base film to which the coating liquid is applied.

By the manufacturing apparatus and manufacturing method of the optical sheet as proposed, it is possible not only to reduce the manufacturing cost by improving the handling and yield in production of the optical sheet having a fine pattern, but also to easily mold various and enlarged patterns. There is an advantage.

In addition, there is an advantage that the processing cost of the master pattern is reduced by the film-shaped molding mold for pattern molding.

First, with regard to the technical features of the present invention, it is necessary to refer to the matter disclosed in the Republic of Korea Registration No. 10-605386 (hereinafter referred to as 'related invention').

In addition, below, the problems that may occur in manufacturing the optical sheet having the shape shown in FIG. 3 will be described again, and the embodiments proposed in order to solve them will be described in detail. However, the embodiment of the present invention can be applied not only to the optical sheet having a micro lens pattern as shown in FIG. 3 but also to the optical sheet for diffusing or condensing light.

According to the above related invention, in the case of manufacturing an optical sheet having a shape as shown in FIG. 3, a molding mold as shown in FIG. 4 is required.

DETAILED DESCRIPTION Specific embodiments of the present invention will be described in detail with reference to the accompanying drawings, and it is to be considered that some of the elements are enlarged for the purpose of more clearly disclosed.

4 is a cross-sectional view of a molding mold according to an embodiment of the present invention.

Referring to FIG. 4, the molding mold 40 includes a pattern layer 42 having a phase opposite to that of a pattern of an optical sheet to be manufactured and a base layer 41 forming a body.

According to the related invention, by injecting a coating liquid into the pattern layer 42, and then hardened and removed, an optical sheet having a pattern that is inverse to the pattern constituting the pattern layer 42 can be manufactured. have.

The manufacturing method of the molding mold 40 is described below.

First, a master having a metal or thin film form is fixed, and a polymer resin for a mold is coated on the master. Then, after applying the molding film base film 41 on the master coated with the polymer resin, by moving the cylindrical roller thereon, a predetermined pressure is evenly applied.

At this time, the applied polymer resin is pushed and filled between the patterns of the master, and uniformly distributed to a predetermined thickness by the pressure of the roller. Thereafter, according to the properties of the resin, the base film is separated from the master after curing by irradiating heat or UV in the contact state filled with the resin between the master and the base film.

Here, as the base film, a surface-treated one may be used to have a polymer resin for adhesion or adhesion, if necessary.

On the other hand, in order to improve the production yield of the optical sheet, when the moving speed of the molding mold 40 is faster, as shown in Figure 5, the coating liquid 50 is a pattern layer of the molding mold 40 The phenomenon that 42 cannot be completely filled may occur.

That is, when the intaglio patterns constituting the pattern layer 42 of the molding mold 40 are formed in units of several micrometers, the air layer 51 may be formed in the intaglio patterns of the pattern layer 42. In this case, the coating liquid 50 injected toward the molding mold 40 may not be completely injected into the intaglio pattern.

In such a case, the optical sheet of the anode pattern to be produced will not be distorted in the shape of the convex portions or become the shape which was to be manufactured.

Embodiments of the present invention can prevent this phenomenon to increase the production yield of the optical sheet.

6 is a configuration diagram illustrating an apparatus for manufacturing an optical sheet according to an embodiment of the present invention.

Referring to FIG. 6, in the apparatus for manufacturing an optical sheet according to an embodiment of the present invention, the first roll 120 on which the base film 110 is wound and the second roll on which the patterned optical sheet 112 is wound 150 and guide rolls 130a to 130e for transferring the base film 110 and the patterned optical sheet 112 are included.

In addition, the guide rolls 130a to 130e may have a first guide roll 130a, a second guide roll 130b, a third guide roll 130c, a fourth guide roll 130d, and a fifth according to the formed position. The guide rolls 130e may be divided, and the number and position of the guide rolls 130a to 130e may be changed in various ways according to the embodiments of the present invention.

In addition, the optical sheet manufacturing apparatus according to the embodiment of the present invention is provided between the third guide roll 130c and the fourth guide roll 130d to apply the patterned coating liquid to the base film 110. The pattern molding part 140 is further provided, and the pattern molding part 140 serves as a pattern roll. This is also a matter disclosed in the related invention.

However, the pattern molding part 140 has a main coating area and a pre-coating area, and in particular, the pattern molding part 140 is injected by dividing the coating solution at least twice into the pattern layer of the molding mold. . This technical configuration will be described in more detail with reference to the drawings.

The pattern molding part 140 is formed by pattern molding the coating liquid according to the pattern provided in the molding mold 142 by forming a molding mold 142 having a pattern shape and the coating liquid injected into close contact with the molding mold 142. A master roll 144 for applying to the base film 110 and pattern guide rolls 146a and 146b for transferring the molding mold 142 are included.

In addition, the molding mold 142 is a pattern layer formed with a pattern formed on the film-shaped base layer, is formed in a belt type, and serves to pattern the coating liquid, as described above the pattern roll.

For reference, only a part of the pattern implemented in the pattern layer of the molding mold 142 illustrated in FIG. 6 is illustrated. In some embodiments, the pattern may be implemented in the entire molding mold.

In addition, the installation of the molding mold 142 wraps an extension line connecting the master roll 144 and the pattern guide rolls 146a and 146b with the molding mold 142 and then ends both ends of the molding mold 142. Can be done by connecting.

In particular, when the molding mold 142 moves in the direction of the arrow shown in the pattern molding part 140, the mold for injecting a coating liquid into the pattern layer of the intaglio pattern of the molding mold 142 partially. Coating areas 200, 201, 202 are formed.

That is, the pre-coated regions 200, 201, and 202 are first filled (or 'coated') with a coating liquid in the molding mold 142 in the pattern molding part 140, and the first molding in the pre-coating region. Is transferred to the master roll 144. Then, the transferred molding mold 142 is secondaryly filled by the coating liquid coming out of the coating liquid injection means 160 provided on one side of the master roll 144.

Therefore, the composition for injecting the coating liquid into the molding mold 142 may be composed of the primary filling in the pre-coating region and the secondary filling in the vicinity of the master roll 144.

However, the pre-coated regions 200, 201, and 202 are illustrated as three regions, but may be more than this, or only a single pre-coated region may be set. For reference, the pre-coating region illustrated in FIG. 7 will be described using the pre-coating region 200 formed between the first pattern guide roll 146a and the second pattern guide roll 146b as an example.

In addition, the apparatus for manufacturing an optical sheet according to an embodiment of the present invention, the coating liquid injection means 160 for injecting the coating liquid into the area where the base film 110 is introduced into the pattern molding portion 140, and heat or UV ( UltraViolet) includes a curing means 170 for curing the coating solution.

On the other hand, the operation of the optical sheet manufacturing apparatus according to the embodiment of the present invention will be described below.

First, the base film 110 wound on the first roll 120 is transferred by the guide rolls 130a to 130e. In this case, the molding mold 142 provided in the pattern molding part 140 is also transported / rotated while the master roll 144 and the pattern guide rolls 146a and 146b are wound.

In addition, since the master roll 144 is engaged with the third guide roll 130c and the fourth guide roll 130d, the base film 110 is formed by the third guide roll 130c by the forming mold ( 142).

In particular, the third guide roll 130c serves as a gap control for controlling the thickness of the pattern layer of the finished optical sheet 112 by adjusting the thickness of the coating liquid applied to the base film 110.

In detail, as the third guide roll 130c is attached to the master roll 144, the thickness of the pattern layer of the optical sheet is thinner, and conversely, the third guide roll 130c is spaced apart from the master roll 144. The thickness of the pattern layer of an optical sheet is formed thick. The thickness of the pattern layer of the optical sheet may be adjusted by the viscosity of the coating liquid, the patterning speed, and the tension of the base film in addition to the gap between the third guide roll 130c and the master roll 144.

On the other hand, the coating liquid is injected by the coating liquid injection means 160 in the predetermined region where the base film 110 is engaged with the third guide roll 130c and the master roll 144, the molding mold 142 The filling is pushed through the pattern of. Here, before the coating liquid is filled between the patterns of the molding mold by the coating liquid injection means 160, the coating liquid stored in the coating liquid container (described later) in the pre-coating regions 200, 201 and 202 is first filled in the pattern of the molding mold. do.

The coating liquid supplied from the coating liquid injection means 160 is uniformly distributed on the base film 110 by the pressure between the third guide roll 130c and the master roll 144 to form a pattern. In addition, the coating liquid distributed between the patterns is cured by heat or UV emitted from the curing means 170.

The base film 110 to which the patterned coating solution is cured and applied is drawn out by the fourth guide roll 130d, separated from the molding mold 142, and the finished optical sheet 112 is separated from the fifth guide. It is conveyed by the roll 130e and wound on the second roll 150.

Here, the fourth guide roll 130d serves to separate the optical sheet 112 coated with the coating liquid from the molding mold 142. In other words, the fourth guide roll 130d separates the optical sheet 112 on which the pattern layer is formed from the molding mold 142.

In the above-described embodiment of the present invention, the base film 110 and the finished optical sheet 112 are classified according to whether the coating solution is applied according to the embodiment of the present invention in a state connected to each other.

That is, the base film 110 refers to a state before the pattern is formed, and the optical sheet 112 refers to a state in which the coating liquid, which is pattern-formed while passing through the pattern molding part 140, is applied to the base film and completed. do. In FIG. 6, only a part of the pattern layer formed on the optical sheet 112 is illustrated. In fact, the optical sheet wound on the second roll 150 also has a pattern layer formed thereon.

Hereinafter, the precoat apparatus and the precoat method of the manufacturing apparatus of the optical sheet which concerns on the Example of this invention are demonstrated in detail.

7 is an enlarged view of a part of an apparatus for manufacturing an optical sheet according to an embodiment of the present invention, and FIG. 8 is an enlarged view of a part of an apparatus for manufacturing an optical sheet according to another embodiment of the present invention. 9 is a view showing a configuration of a pre-coating roll according to an embodiment of the present invention, Figure 10 is a view showing a state in which a coating liquid is first coated on a molding mold according to an embodiment of the present invention, Figure 11 is a view of the present invention According to the embodiment is a view showing a state in which the coating liquid is secondary coating on the molding mold.

First, in FIG. 7, the structure of a precoat area | region is enlarged in the manufacturing apparatus of an optical sheet. Next, an embodiment in the case where a pre-coating region is provided between the first pattern guide roll 146a and the second pattern guide roll 146b in FIG. 6 will be described.

Referring to FIG. 7, the molding mold inverted to the pattern shape of the optical sheet to be manufactured is moved along the first pattern guide roll 146a and then first coated in the pre-coating region 200 and then the second mold. It is conveyed along the pattern guide roll 146b.

Here, the molding mold is made of a base layer and a pattern layer, as described above, and the pattern layer is formed with an intaglio pattern which is a reverse phase of the micro lens pattern.

In addition, the pre-coating region 200 is provided with a first pre-coating roll 201 and a second pre-coating roll 202 for transferring the molding mold. In addition, a portion of the second pre-coating roll 202 is contained in the coating liquid container 210 so that the coating liquid may be injected into the molding mold by the second pre-coating roll 202.

Accordingly, as the second pre-coating roll 202 is rotated, the coating liquid stored in the coating liquid container 210 is transferred between the first pre-coating roll 201 and the second pre-coating roll 202. Is injected into the pattern layer.

That is, since the coating liquid (the raw material of the optical sheet) for filling the intaglio pattern formed in the molding mold is a material having a predetermined viscosity, the coating liquid stored in the coating liquid container 210 is formed on the surface of the second pre-coating roll 202. As a result, the mold may be touched.

If the first pre-coating roll 201 and the second pre-coating roll 202 are shown in front in FIG. 7, a side view of the first pre-coating roll 201 and the second pre-coating roll 202 is shown. 9 is shown.

Meanwhile, as shown in FIG. 8, the coating liquid container 210 may be manufactured to have a size that can accommodate the second pre-coating roll 202 and other pre-coating rolls located at one side thereof.

Referring to FIG. 9, bearings 201a and 202a are installed at the sides of the pre-coating rolls 201 and 202 so that they can be rotated with a small force. The second pre-coating roll 202 is an intaglio pattern of a molding mold. The coating liquid may be filled in the first precoating roll 201, and the first precoating roll 201 may be properly maintained at a distance from the second precoating roll 202 so that the molding mold may be conveyed tautly.

On the other hand, after injecting the coating liquid into the intaglio pattern of the molding mold, in order to prevent the coating liquid from remaining on the surface of the second pre-coating roll 202, the surface of the second pre-coating roll 202 The cleaning means 220 is further formed to remove the remaining coating liquid due to the friction.

Here, the first pre-coating roll 201, the second pre-coating roll 202 and the coating liquid container 210 may be referred to as a pre-coating device, which is shown in the pre-coating region 200 As described above, a plurality may be formed. As the plurality of pre-coating devices are formed, bubbles can be more effectively prevented from being generated in the intaglio pattern of the molding mold, and even when the optical sheet is manufactured at high speed, the production yield does not decrease.

In addition, the pre-coating device may also be installed in various positions in the pattern molding unit 140 shown in FIG.

The shape of the molding mold coated by the pre-coating device is shown in FIG. 10. The pattern layer 142b having the intaglio pattern of the molding mold 142 is coated with the coating liquid contained in the coating liquid container 210. It is.

Here, the coating of the pattern layer 142b by the pre-coating device is performed on the intaglio pattern predetermined portion of the pattern layer 142b.

On the other hand, in the above-described pre-coating region, the first molding mold is transferred to the master roll 144 in Figure 6, the coating liquid injected from the coating liquid injection means 160 is secondly coated.

11 illustrates a state in which the coating liquid 161 is filled in the intaglio pattern of the molding mold by the coating liquid 161 supplied from the coating liquid injection means 160.

Then, the molding mold secondary coated by the master roll 144 of FIG. 6 is applied to the base film 110, thereby manufacturing an optical sheet having a micro lens pattern as shown in FIG.

1 and a cross-sectional view of a general prism sheet.

2 is a perspective view of a general prism sheet.

3 is a perspective view of an optical sheet on which a micro lens pattern is formed.

4 is a cross-sectional view of a molding mold according to an embodiment of the present invention.

5 is a view for explaining the appearance that the coating liquid is insufficiently filled in the pattern layer of the molding mold.

6 is a configuration diagram for explaining an optical sheet manufacturing apparatus according to an embodiment of the present invention.

7 is an enlarged view of a part of a configuration of an apparatus for manufacturing an optical sheet according to an embodiment of the present invention.

8 is an enlarged view of a part of a configuration of an apparatus for manufacturing an optical sheet according to another embodiment of the present invention.

9 is a view showing the configuration of a pre-coated roll according to an embodiment of the present invention.

10 is a view showing a state in which a coating liquid is first coated on a molding mold according to an embodiment of the present invention.

11 is a view showing a state in which the coating liquid is a secondary coating on the molding mold according to an embodiment of the present invention.

Claims (12)

A first roll to which the base film is wound; A second roll to which the base film coated with the coating liquid is wound; Two or more guide rolls provided between the first roll and the second roll to convey the base film; Coating liquid injection means for injecting the coating liquid transferred to the base film; And And a pattern molding part disposed to be engaged with any one of the guide rolls, such that the coating liquid injected from the coating liquid injection means is transferred to the base film in a predetermined pattern shape. The pattern molding part may include a molding mold in which a predetermined pattern shape is implemented; A pre-coating device for primary filling the coating liquid in the pattern of the molding mold, and a master roll for pressing the molding mold, the secondary coating material being filled with the coating liquid by means of the coating liquid injection means, after the primary filling of the coating liquid with the base film; Includes; a plurality of pattern guide roll for transferring the molding mold, And the molding mold is positioned on an extension line of the master roll and the pattern guide roll. delete The method of claim 1, The pre-coating apparatus is a plurality of optical sheet manufacturing apparatus characterized in that provided in the pattern molding portion. The method of claim 1, The pre-coating device is composed of a first pre-coating roll, a second pre-coating roll and the coating liquid container, The molding mold is transferred by rotation of the first pre-coating roll and the second pre-coating roll, The coating liquid stored in the coating liquid container by the rotation of the second pre-coating roll is filled in the pattern of the molding mold along the surface of the pre-coating roll. delete The method of claim 1, Apparatus for producing an optical sheet, characterized in that the thickness of the coating liquid applied on the base film is changed as the interval between the guide roll and the master roll engaging the master roll is changed. As a manufacturing apparatus which manufactures the optical sheet which has a 1st pattern, A first roll to which the base film is wound; A second roll to which the optical sheet is wound; Two or more guide rolls disposed between the first roll and the second roll to convey the base film or the optical sheet; A pattern molding part including a master roll disposed to be engaged with any one of the guide rolls, and a plurality of pattern guide rolls configured to transfer a molding mold in which a second pattern that is reversed from the first pattern is formed; A pre-coating device formed between the pattern guide rolls and primarily filling the coating liquid in the pattern of the molding mold; And And coating liquid injecting means for additionally filling the coating liquid into a pattern of the molding mold in which the coating liquid is filled by the pre-coating device in a predetermined region where the guide roll and the master roll are engaged. The method of claim 7, wherein The pre-coating apparatus includes a first and second pre-coating rolls for transferring the molding mold, and a coating liquid container in which the coating liquid is stored. The method of claim 8, A part of said 2nd precoat roll is contained in the coating liquid of the said coating liquid container, The manufacturing apparatus of the optical sheet characterized by the above-mentioned. In the method for manufacturing the optical sheet on which the first pattern is formed, Transferring a base film serving as a material of the optical sheet; A part of the pre-coating roll is deposited in the coating liquid container in which the coating liquid is stored, and the second coating of the molding mold is formed by forming a second pattern in which the coating liquid stored in the coating liquid container is reversed from the first pattern by rotating the pre-coating roll. First filling the coating liquid in the pattern; Filling the coating mold with the coating liquid by injecting the coating liquid into a region where the base film and the molding mold are engaged; By curing the coating solution, the coating solution is applied onto a base film; And And separating the molding mold and the base film to which the coating liquid is applied. delete 11. The method of claim 10, The filling of the coating mold into the molding mold in the second step may include coating the liquid supplied from the coating liquid injecting means provided in a region where the base film and the molding mold are in engagement with each other in the second pattern of the molding mold. Manufacturing method.

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