KR101906253B1 - Reflective polizer dispered polymer and Manufacturing method thereof - Google Patents

Abstract

Since the method of the present invention comprises preparing a plurality of sea-island composite streams having different average optical thicknesses by using a plurality of sea-island extrusion dies and joining them in a molten state, a separate adhesive layer and / or a protective layer (PBL) . This makes it possible to remarkably reduce the manufacturing cost and to maximize optical properties at a limited thickness.
In addition, the reflection type polarizer manufactured through the manufacturing method of the present invention has a very small number of birefringent polymers in comparison with the conventional birefringent polymer-containing reflection type polarizer, It is possible not only to achieve extremely excellent optical properties but also to reflect all the S waves in the visible light wavelength region since a plurality of groups having different average optical thicknesses are formed.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a reflective polarizer having a polymer dispersed therein,

The present invention relates to a reflective polarizer in which a polymer is dispersed and a method for producing the same, and more particularly, to a reflective polarizer in which a polymer is remarkably improved in brightness compared to a conventional dispersed type polarizing polarizer and a method for producing the same.

Flat panel display technology is mainly composed of liquid crystal display (LCD), projection display, and plasma display (PDP), which have already secured a market in the TV field. In addition, field emission display (FED) and electroluminescence display (ELD) And it is expected to occupy the field according to each characteristic. Liquid crystal displays are currently being used in a wide range of applications such as notebook computers, personal computer monitors, liquid crystal TVs, automobiles, and aircrafts, accounting for 80% of the flat panel market, and booming demand for LCDs worldwide.

Conventional liquid crystal displays place a liquid crystal and an electrode matrix between a pair of light absorbing optical films. In liquid crystal displays, the liquid crystal portion has an optical state that changes accordingly by moving the liquid crystal portion by an electric field generated by applying a voltage to the two electrodes. This process displays an image by using a polarized light in a specific direction as a 'pixel' containing information. For this reason, liquid crystal displays include a front optical film and a rear optical film that induce polarization.

  The optical film used in such a liquid crystal display does not necessarily have a high utilization efficiency of light emitted from the backlight. This is because 50% or more of the light emitted from the backlight is absorbed by the back side optical film (absorption type polarizing film). Therefore, in order to improve the utilization efficiency of the backlight in the liquid crystal display, a reflection type polarizer is provided between the optical cavity and the liquid crystal assembly.

  1 is a view showing the optical principle of a conventional reflective polarizer. Specifically, the P polarized light from the optical cavity toward the liquid crystal assembly is transmitted through the reflective polarizer to the liquid crystal assembly. The S polarized light is reflected from the reflective polarizer into the optical cavity, Direction is reflected in a randomized state and is then transmitted to the reflective polarizer so that the S polarized light is converted into P polarized light that can pass through the polarizer of the liquid crystal assembly and is transmitted to the liquid crystal assembly after passing through the reflective polarizer.

The selective reflection of the S polarized light and the transmission of the P polarized light with respect to the incident light of the reflective polarizer are performed in such a manner that the refractive index of each optical layer in the state of alternately stacking the flat optical layer having the anisotropic refractive index and the flat optical layer having the isotropic refractive index The optical thickness of each of the optical layers in accordance with the difference and the elongation process of the laminated optical layer, and the change of the refractive index of the optical layer.

  That is, the light incident on the reflective polarizer repeats the reflection of the S polarized light and the transmission of the P polarized light while passing through each optical layer, and finally, only the P polarized light of the incident polarized light is transmitted to the liquid crystal assembly. On the other hand, as described above, the reflected S polarized light is reflected in the polarization state of the diffused reflection plane of the optical cavity in a randomized state and then transmitted to the reflective polarizer. As a result, it is possible to reduce the waste of power with loss of light generated from the light source.

 However, such a conventional reflective polarizer has a structure in which an isotropic optical layer and an anisotropic optical layer having different refractive indexes are alternately stacked and subjected to an elongation treatment, whereby the optical thickness and refractive index of each optical layer, which can be optimized for selective reflection and transmission of incident polarized light, The manufacturing process of the reflection type polarizer is complicated. In particular, since each optical layer of the reflective polarizer has a flat plate structure, the P polarized light and the S polarized light must be separated in accordance with a wide incident angle range of incident polarized light, so that the number of layers of the optical layer is excessively increased and the production cost exponentially There was an increasing problem. Further, there is a problem that optical performance is deteriorated due to optical loss due to the structure in which the number of layers of the optical layer is excessively formed.

2 is a cross-sectional view of a conventional multilayer reflective polarizer (DBEF). Specifically, in the multilayer reflective polarizer, the skin layers 9 and 10 are formed on both sides of the core layer 8. The core layer 8 is divided into four groups (1, 2, 3, 4), in which each of the isotropic layers and the anisotropic layers are alternately stacked to form approximately 200 layers. Separate adhesive layers 5, 6, and 7 are formed between the four groups 1, 2, 3, and 4 forming the core layer 8. In addition, since each group has a very thin thickness of about 200 layers, these groups often contain a protective layer (PBL) since individual groups can be damaged if they are individually pneumatically shipped. In this case, there is a problem that the thickness of the core layer becomes thick and the manufacturing cost rises. In addition, since the reflective polarizer included in the display panel is limited in the thickness of the core layer for slimming, if the adhesive layer is formed on the core layer and / or the skin layer, the core layer is reduced by the thickness thereof, There was no problem. Further, since the inside of the core layer and the core layer and the skin layer are bonded by the adhesive layer, there is a problem that when the external force is applied, the elapse of time elapses, or the storage place is poor, delamination occurs. In addition, not only the defect rate is excessively increased in the process of adhering the adhesive layer, but also the destructive interference to the light source occurs due to the formation of the adhesive layer.

Skin layers 9 and 10 are formed on both sides of the core layer 8 and separate adhesive layers 11 and 12 are formed between the core layer 8 and the skin layers 9 and 10 for bonding them. do. When the conventional skin layer of polycarbonate and PEN-coPEN are integrated with the alternately laminated core layer by co-extrusion, peeling may occur due to the compatibility member and the crystallization degree is about 15% There is a high risk of occurrence of birefringence. Accordingly, in order to apply the polycarbonate sheet of the non-smelting process, an adhesive layer has to be formed. As a result, the yield decreases due to external foreign matters and process defects due to the addition of the adhesive layer process. Generally, in producing a polycarbonate-free sheet of the skin layer, birefringence occurs due to uneven shear pressure due to the winding process, It is necessary to control the molecular structure of the polymer and speed control of the extrusion line in order to compensate for the deterioration of productivity.

The method of producing the conventional multilayer reflective polarizer described above will be briefly described. After four co-extruded groups having different average optical thicknesses forming the core layer are separately co-extruded, the four co-extruded four groups are stretched, And then the four layers are adhered with an adhesive to form a core layer. This is because the peeling phenomenon occurs when the core layer is stretched after bonding the adhesive. Thereafter, the skin layers are bonded to both sides of the core layer. As a result, in order to construct a multi-layer structure, a two-layer structure is folded to form a four-layer structure, and a group (209-layer) is formed through a process of forming a multi-layer structure in a continuous folding manner. It was difficult to form a group in the multilayer in the process. As a result, four groups having different average optical thicknesses have to be separately co-extruded and bonded.

Since the above-described process is intermittently performed, a remarkable increase in the manufacturing cost has been brought about. As a result, the cost of all the optical films included in the backlight unit is the most expensive. As a result, there has been a serious problem that liquid crystal displays other than the reflective polarizer are frequently released even when the decrease in luminance is reduced in terms of cost reduction.

Thus, there has been proposed a reflective polarizer in which a birefringent polymer stretched in the longitudinal direction is arranged in a substrate, not a multilayer reflective polarizer, and a polymer capable of achieving the function of the reflective polarizer is dispersed. 3 is a perspective view of a reflective polarizer 20 including a rod-shaped polymer, in which birefringent polymers 22 stretched in the longitudinal direction are arranged in one direction inside the base material 21. Fig. The birefringent interface between the base material 21 and the birefringent polymer 22 causes a light modulation effect to perform the function of the reflection type polarizer. However, as compared with the above-mentioned alternately stacked reflective polarizer, it is difficult to reflect light in the entire wavelength range of visible light, resulting in a problem that the light modulation efficiency is too low. Accordingly, in order to have a transmittance and a reflectance similar to those of the alternately stacked reflective polarizer, an excessively large number of birefringent polymers 22 must be disposed inside the substrate. Specifically, in order to have optical properties similar to those of the above-described laminate-type reflective polarizer in the substrate 21 having a width of 1580 mm and a height (thickness) of 400 μm or less when a horizontal 32-inch display panel is manufactured on the basis of the vertical cross section of the reflective polarizer, At least 100% of circular or elliptical birefringent polymer 22 having a cross-sectional diameter in the longitudinal direction of 0.1 to 0.3 탆 must be contained. In this case, not only the production cost is excessively increased but also the facilities are excessively complicated, There is a problem that it is difficult to produce the facility itself and thus it is difficult to commercialize it. Further, since it is difficult to make various optical thicknesses of the birefringent polymer 22 contained in the sheet, it is difficult to reflect light in the entire visible light region, and there is a problem that the physical properties are reduced.

In order to overcome this problem, a technical idea including a birefringent sea chart was proposed in the substrate. FIG. 4 is a cross-sectional view of a birefringent chart paper included in the inside of the base material. The birefringent chart paper can generate a light modulation effect at the light modulation interface of the internal part and the dissolution part, The optical properties can be achieved without arranging chart marks. However, since the fiber is a birefringent graphite sheet, compatibility with a base material such as a polymer, ease of handling, and adhesiveness have been encountered. Furthermore, the light-scattering is induced by the circular shape, and the reflection polarizing efficiency against the light wavelength in the visible light region is lowered. As a result, the polarizing characteristic is lowered compared with the existing product and the luminance improvement is limited. In addition, As the area is subdivided, due to the occurrence of pores, light leakage, that is, light loss phenomenon, has been caused. In addition, due to the structure of the fabric in the form of a structure, there is a problem that limitations are imposed on improvement of reflection and polarization characteristics due to limitations of the layer structure.

In addition, when the surface of the reflective polarizer is directly angled to improve the luminance, there is a risk of damaging the reflective polarizer, and the pattern shape is difficult to be precisely cut, resulting in a problem that the luminance increasing effect is lower than expected.

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and a first object of the present invention is to provide a dispersion type polarizing element capable of remarkably improving the optical properties of the conventional dispersion type polarizing polarizer, And a method for producing the same.

A second object of the present invention is to provide a method of manufacturing a semiconductor device, which can be manufactured by integrally forming an adhesive layer between respective groups in a core layer, and a polymer pattern capable of minimizing diffuse reflection and significantly improving brightness, And to provide a dispersed reflective polarizer and a manufacturing method thereof.

In order to solve the first problem, a method of manufacturing a reflective polarizer in which a polymer is dispersed according to the present invention comprises: preparing a reflective polarizer in which a polymer including a core layer in which a plurality of first components are dispersed is dispersed, (1) supplying a first component and a second component to the extruding portions, respectively; (2) Two or more sea-island complex streams in which a plurality of first components are dispersed in the second component are formed, and in order to reflect the transverse waves of a desired wavelength (S waves) The method comprising the steps of: injecting the first component and the second component transferred from the first component into a plurality of seaweed extrusion ports to form two or more sea-island composite streams having different first optical components of the first components; (3) combining the two or more sea-island complex streams together to form a core layer; (4) inducing spreading in the flow control so that the first component inside the core layer forms a plate-like shape; (5) stretching the core layer; And (6) forming a structured surface layer on at least one side of the drawn core layer.

According to a preferred embodiment of the present invention, the first component is selected from the group consisting of polyethylene naphthalate (PEN), copolyethylene naphthalate (co-PEN), polyethylene terephthalate (PET), polycarbonate (PC) (PS), heat resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene ), Polyurethane (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile blend (SAN), ethylene vinyl acetate (EVA), polyamide (PA), polyacetal Phenol, epoxy (EP), urea (UF), melamine (MF), unsaturated polyester (UP), silicone (SI) and cycloolefin polymers.

According to another preferred embodiment of the present invention, the second component is selected from the group consisting of polyethylene naphthalate (PEN), copolyethylene naphthalate (co-PEN), polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate (PS), heat resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile (SAN), ethylene vinyl acetate (EVA), polyamide (PA) (EP), urea (UF), melamine (MF), unsaturated polyesters (UP), silicon (SI) and cyclic olefin polymers may be used alone or in combination. More preferably, co- .

According to another preferred embodiment of the present invention, the step (2) may form three or more sea-view complex streams.

According to another preferred embodiment of the present invention, the step (2) may form four or more sea-type complex streams.

According to another preferred embodiment of the present invention, the plurality of extrusion ports can be integrated.

According to another preferred embodiment of the present invention, the first component transferred in the extruding portion between the step (1) and the step (2) includes a plurality of components having a different discharge amount in order to have different average optical thicknesses Shaped pushing-out mouth through the first pushing means, respectively.

According to another preferred embodiment of the present invention, the second component transferred from the extruding unit between the steps (1) and (2) is discharged through the second pressurizing unit into the different seawater extrusion orifices, respectively .

According to another preferred embodiment of the present invention, the second component transferred in the extrusion between the step (1) and step (2) comprises a plurality of particles having different discharge amounts in order to have different average optical thicknesses And can be discharged through the second pressurizing means into different seawater extrusion orifices respectively.

According to another preferred embodiment of the present invention, in order to produce a sea-island composite flow, the plurality of seawater extrusion orifices may have different diameters and shapes Sectional area, and the like.

According to another preferred embodiment of the present invention, the plurality of sea-island type extrusion / taking-out ports are formed by arranging a layer of a component supply path on a delivery distribution plate on which a first component is fed and distributed, The number may be different.

According to another preferred embodiment of the present invention, the plurality of sea-island extrusion ports may have a number of layers of 25 or more holes of each of the seawater extrusion orifices.

According to another preferred embodiment of the present invention, the plurality of graphite-type extrusion / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching /

According to another preferred embodiment of the present invention, the plurality of sea-island extrusion / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching / detaching /

According to another preferred embodiment of the present invention, the aspect ratio of the plate-like shape, which is the ratio of the minor axis length to the major axis length, is 1/200 or less, 1/300 or less, 1/500 or less, 1/1000 or less, 1/2000 or less, 1/5000 or less or 1/10000 or less.

 According to another preferred embodiment of the present invention, the flow control unit may be a T-die or a coat-hanger die.

According to another preferred embodiment of the present invention, after step (6), the aspect ratio of the plate-like shape may be 1/1000 or less, 1/3000 or less, 1/5000 or less, 1/10000 or less or 1/30000 or less.

According to another preferred embodiment of the present invention, the average optical thicknesses among the first components forming the different sea-island complex streams may be different from each other.

According to another preferred embodiment of the present invention, the optical thicknesses of the first components forming the same sea-island complex stream may have a deviation of within 20% and within 15% of the average optical thickness.

According to another preferred embodiment of the present invention, the plurality of sea-island composite streams may have an average optical thickness different by 5% or more.

According to another preferred embodiment of the present invention, the plate-like shape of the step (4) may have an aspect ratio of 1/200 or less, which is the ratio of the shortening length to the long-axis length with respect to the vertical section.

According to another preferred embodiment of the present invention, after the step (5), the aspect ratio of the plate-like shape may be 1/1000 or less.

According to another preferred embodiment of the present invention, the optical thicknesses of the first components forming the same sea-island complex stream may have a deviation within 20% of the average optical thickness.

According to another preferred embodiment of the present invention, the method may further comprise forming a primer layer on at least one side of the core layer between the step (5) and the step (6).

According to another preferred embodiment of the present invention, the structured surface layer may be a fine patterned layer, and more preferably, the fine pattern is formed of a material selected from the group consisting of prism, lenticular, microlens, triangular pyramid and pyramid pattern It can be more than one.

According to another preferred embodiment of the present invention, the step (6) may be carried out through a pattern-forming mold film.

According to another preferred embodiment of the present invention, the step (6) comprises the steps of: a) transferring the core layer; b) transferring the mold film for pattern formation formed on one surface of the reversed phase pattern of the structured surface layer; c) bringing the one side of the core layer and the one side of the pattern-forming mold film into contact with each other; d) injecting a fluid material into a region where the core layer and the mold film for pattern formation are in close contact with each other to fill the spaces between the patterns; e) applying the material to the core layer by curing the material filled between the patterns; And f) separating the mold film for pattern formation from the core layer coated with the material, wherein steps a) and b) may be performed in any order.

According to another preferred embodiment of the present invention, between step d) and step e), a step of evenly filling the material between the patterns by applying pressure to the core layer and the mold film in close contact .

According to another preferred embodiment of the present invention, the step e) may include irradiating heat or UV to the material filled between the patterns.

According to another preferred embodiment of the present invention, the step (6) comprises the steps of: i) closely contacting and transferring the core layer to a master roll formed on one surface of the reversed phase pattern of the structured surface layer, Applying a molten polymer resin to the core layer surface; And ii) UV-curing the polymer resin by irradiating UV or heat while the polymer resin is press-formed on the pattern surface of the master roll, and separating the polymer resin.

According to another preferred embodiment of the present invention, the polymer resin may be secondarily cured by irradiating UV or heat again after the step ii).

According to another preferred embodiment of the present invention, there is provided a polarizing plate comprising a plurality of plate-shaped polymers dispersed in a substrate to transmit externally irradiated first polarized light and reflect second polarized light, Wherein the substrate is elongated in at least one axial direction and the plurality of plate-shaped polymers each form a group for reflecting a transverse wave (S wave) of a desired wavelength, Wherein a plurality of groups are formed, the average optical thicknesses of the inter-group plate-like polymers are different, and the aspect ratio of the minor axis to the major axis length is less than 1/1000 on the basis of the vertical cross section of the plate- And a structured surface layer formed on at least one side of the core layer.

According to another preferred embodiment of the present invention, a primer layer for enhancing adhesion between the core layer and the structured surface layer may be further included.

According to another preferred embodiment of the present invention, the structured surface layer may be a fine patterned layer, and more preferably, the fine pattern is formed of a material selected from the group consisting of prism, lenticular, microlens, triangular pyramid and pyramid pattern It can be more than one.

According to another preferred embodiment of the present invention, the prism pattern may have a height of 10 to 50 μm and a pitch of 20 to 100 μm.

According to another preferred embodiment of the present invention, the microlens pattern may have a height of 10 to 50 탆 and a lens diameter of 20 to 100 탆.

According to another preferred embodiment of the present invention, the lenticular pattern may have a height of 10 to 50 탆 and a lens diameter of 20 to 100 탆.

Hereinafter, terms used in this specification will be briefly described.

'Polymer has birefringence' means that when light is irradiated to fibers of different refractive index along the direction, the light incident on the polymer is refracted into two light beams with different directions.

'Isotropic' means that the refractive index is constant regardless of direction when light passes through the object.

'Anisotropy' means that the optical properties of an object are different according to the direction of light, and anisotropic objects have birefringence and correspond to isotropy.

'Light modulation' means that the irradiated light reflects, refracts, scatters, changes the intensity of the light, the period of the wave or the nature of the light.

The 'aspect ratio' means the ratio of the shortening length to the longest length based on the vertical section in the longitudinal direction of the elongated body.

Since the method of the present invention comprises preparing a plurality of sea-island composite streams having different average optical thicknesses by using a plurality of sea-island extrusion dies and joining them in a molten state, a separate adhesive layer and / or a protective layer (PBL) . This makes it possible to remarkably reduce the manufacturing cost and to maximize optical properties at a limited thickness.

In addition, the reflection type polarizer manufactured through the manufacturing method of the present invention has a very small number of birefringent polymers in comparison with the conventional birefringent polymer-containing reflection type polarizer, It is possible not only to achieve extremely excellent optical properties but also to reflect all the S waves in the visible light wavelength region since a plurality of groups having different average optical thicknesses are formed.

Furthermore, the risk of damage to the reflective polarizer can be minimized compared with the case of forming a fine pattern with a conventional direct angle, and the pattern shape can be precisely tilted to prevent irregular reflection and to maximize the luminance increase effect.

1 is a schematic view for explaining the principle of a conventional reflective polarizer.
2 is a cross-sectional view of a currently used multi-layer reflective polarizer (DBEF).
3 is a perspective view of a reflection type polarizer including a bar-shaped polymer.
4 is a cross-sectional view showing a path of light incident on a birefringent chart used for a reflection type polarizer.
Figs. 5 and 6 are perspective views showing the coupling structure of the claw distribution plates of the sea-island type extrusion cage which can be used in the present invention.
7 is a cross-sectional view of a claw distribution plate according to another preferred embodiment of the present invention.
FIG. 8 and FIG. 9 are cross-sectional views illustrating an arrangement of a supply line of a detachable distribution plate according to a preferred embodiment of the present invention.
Figs. 10 and 11 are perspective views showing a coupling structure of a cowling distribution plate of a sea-island type extrusion cortex usable in the present invention. Fig.
FIG. 12 is a view showing a plurality of chart type extrusion / taking-out apparatuses according to a preferred embodiment of the present invention.
FIG. 13 is a schematic view including first pressing means for forming two sea-view type mixed flows according to a preferred embodiment of the present invention.
FIG. 14 is a schematic view including two second pressing means for forming two sea-island type mixed flows according to a preferred embodiment of the present invention.
Fig. 15 is a schematic view including one second pressing means for forming two sea-view composite flows according to a preferred embodiment of the present invention; Fig.
Fig. 16 is a schematic view showing a joint part of a sea-island type combined flow according to a preferred embodiment of the present invention.
Figure 17 is a cross-sectional view of a coat-hanger die in accordance with a preferred embodiment of the present invention, and Figure 18 is a side view.
FIG. 19 is a schematic view of a process of forming a fine pattern according to a preferred embodiment of the present invention, and FIG. 20 is a cross-sectional view showing the detailed structure of the forming unit of FIG.
21 is a schematic view of a process of forming a fine pattern according to a preferred embodiment of the present invention.
22 is a schematic view of a process of forming a fine pattern according to a preferred embodiment of the present invention.

23 is a sectional view of a reflective polarizer according to another embodiment of the present invention.
24 and 25 are cross-sectional views of a reflective polarizer according to another preferred embodiment of the present invention.
FIG. 26 is a perspective view of a reflective polarizer having a lenticular pattern regularly formed according to a preferred embodiment of the present invention, and FIG. 27 is a perspective view of a reflective polarizer having an irregular lenticular pattern.
FIG. 28 is a perspective view of a reflective polarizer in which microlenses are regularly formed according to a preferred embodiment of the present invention, and FIG. 29 is a perspective view of a reflective polarizer in which microlenses are irregularly formed.
FIG. 30 is a perspective view of a reflective polarizer in which a prism pattern is regularly formed according to a preferred embodiment of the present invention, and FIG. 31 is a perspective view of a reflective polarizer in which a prism pattern is irregularly formed.
32 is a cross-sectional view of a sheet-like polymer according to a preferred embodiment of the present invention.
33 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to a preferred embodiment of the present invention.
34 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to another preferred embodiment of the present invention.
35 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to another preferred embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in more detail with reference to the accompanying drawings.

According to a preferred embodiment of the present invention, there is provided a method of manufacturing a reflective polarizer in which a polymer is dispersed, the core polarizer including a core layer having a plurality of first components dispersed therein, the method comprising the steps of: (1) Supplying the two components to the extruding portions, respectively; (2) Two or more sea-island complex streams in which a plurality of first components are dispersed in the second component are formed, and in order to reflect the transverse waves of a desired wavelength (S waves) The method comprising the steps of: injecting the first component and the second component transferred from the first component into a plurality of seaweed extrusion ports to form two or more sea-island composite streams having different first optical components of the first components; (3) combining the two or more sea-island complex streams together to form a core layer; (4) inducing spreading in the flow control so that the first component inside the core layer forms a plate-like shape; (5) stretching the core layer; And (6) forming a structured surface layer on at least one side of the stretched core layer.

First, as step (1), the first component and the second component are supplied to the extruding portions, respectively. The first component is a polymer dispersed in the second component forming the base material, and may be used without limitation as long as it is used in a reflective polarizer in which a conventional polymer is dispersed. Preferably, the first component is polyethylene naphthalate (PEN), copolyethylene Polymers such as phthalates (co-PEN), polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate (PC) alloys, polystyrene (PS), heat resistant polystyrene (PS), polymethylmethacrylate (PB), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane (PU), polyimide (PI), polyvinyl chloride (SAN), ethylene vinyl acetate (EVA), polyamide (PA), polyacetal (POM), phenol, epoxy (EP), urea (UF), melanin (MF), unsaturated polyesters (SI) and cycloolefin polymers Number and may be more preferably PEN.

The second component forms a substrate and can be used without limitation as long as it is used as a material of a substrate in a reflective polarizer in which a polymer is dispersed. Preferably, the second component is selected from the group consisting of polyethylene naphthalate (PEN), co-polyethylene naphthalate ), Polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate (PC) alloy, polystyrene (PS), heat resistant polystyrene (PS), polymethylmethacrylate (PMMA), polybutylene terephthalate ), Polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile (EVA), polyamide (PA), polyacetal (POM), phenol, epoxy (EP), urea (UF), melanin (MF), unsaturated polyester (UP) The olefin polymer may be used singly or in combination Can be used and may be more preferably, dimethyl 2,6-naphthalenedicarboxylate, dimethyl terephthalate and ethylene glycol, Im chroman-hexane dimethanol (CHDM), such as the monomers are suitably polymerized co-PEN.

Meanwhile, the first component and the second component may be separately supplied to independent extruders, and in this case, the extruder may be composed of two or more. It is also included in the present invention to feed one extruded portion including a separate supply path and a distribution port so that the polymers do not mix. The extruder may be an extruder, which may further include a heating means or the like to convert the supplied polymers in the solid phase into a liquid phase.

Next, (2) two or more sea-island complex streams in which a plurality of first components are dispersed in the second component are formed, and in order to reflect a transverse wave (S wave) of a desired wavelength, The first component and the second component transferred from the extrusion portion are introduced into a plurality of seawater extrusion orifices to form two or more sea-island composite streams having different first optical components of the first components. 5 and 6 are perspective views illustrating the coupling structure of the cage dividing plates of the sea type extrusion orifice which can be used in the present invention. The first pickling distribution plate S1 located at the upper end of the sea-island extrusion port can be constituted by the first component supply path 50 and the second component supply path 51 therein. So that the first component transferred through the extrusion portion can be supplied to the first component supply path 50 and the second component can be supplied to the second supply path 51. A plurality of such supply paths may be formed as the case may be. Polymers that have passed through the first receiving distribution plate S1 are transported to the second receiving distribution plate S2 located below. The first component injected through the first component supply path 50 is branched and transferred to the plurality of first component supply paths 52 and 53 along the flow path. In addition, the second component injected through the second component supply path (51) is branched and transferred to the plurality of second component supply paths (54, 55, 56) along the flow path. The polymers passing through the second separating distribution plate S2 are transported to the third separating distribution plate S3 located below. The first components injected through the first component supply paths 52 and 53 are branched along the flow path to the first component supply paths 59, 60, 63 and 64 formed in the third pickling distribution plate S3 Lt; / RTI > Likewise, the second components injected through the second component supply paths 54, 55 and 56 are respectively supplied to the second component supply paths 57, 58, 61, 62, 65, 66 ) Along the flow path. The polymers that have passed through the third separation distribution plate S3 are transferred to the fourth separation distribution plate S4 located below. The first components injected through the first component supply paths 59, 60, 63 and 64 are respectively spread over the first component supply paths 69 formed in the fourth separate distribution plate S4, The second component introduced through the component supply paths 57, 58, 61, 62, 65 and 66 is connected to the second component supply passages 67 and 68 formed at the upper and lower ends of the first component supply passages 69 along the flow path. ). At this time, the number of layers of the first component included in the sea-island complex flow is determined by the number of vertical layers (n) of the first component supply paths 69. For example, when the number of longitudinal direction layers is 50, the number of layers of the first component included in the first isolar compound current is 50. [ The number of component layers in the fourth corrugated distribution plate S4 may be at least 25, more preferably at least 50, more preferably at least 100, and most preferably at least 150. Thereafter, in the fifth separating plate S5, the first component seeps between the dispersed first components to form a sea-island complex stream in which the first component is dispersed in the second component, and then the sea- And discharged through the discharge port 70 of the sixth housing distribution plate S6. Meanwhile, FIGS. 5 and 6 are illustrations of sea-island brassiere distribution boards that can be used according to the present invention. In order to manufacture a sea-island complex type in which a first component is dispersed in a second component, It is self-evident that a person skilled in the art appropriately designs and uses the size and shape of the hole. Preferably, the diameter of the through-hole of the isometric-supply path may be 0.17 to 5 mm, but is not limited thereto.

On the other hand, as the number of layers of the component supply channels in the fourth bundling distribution plate increases, bonding phenomena may occur between the components (first components). In order to prevent this, it is possible to divide the island-shaped water supply passage as shown in FIG. 7 and to form the sea component supply passages 71 and 72 on the partition, so that the sea component can permeate more smoothly between the island components. Accordingly, even if the number of layers of the supply channel is increased, bonding between the components (first components) included in the final substrate can be minimized. On the other hand, it is also possible that each of the divided component supply channels forms separate sea-island complex streams, which is interpreted as a plurality of integrated sea-island extrusion ports. As a result, in the present invention, not only a plurality of sea-island extrusion ports are formed, but also all of those capable of forming a plurality of sea-island composite streams integrally formed.

In FIG. 5, the arrangement of the supply conduits of the fourth housing distribution plate may be arranged in a straight line as shown in FIG. 8, but preferably in order to minimize the joining and to distribute the component more inside the substrate, Likewise, it is possible to arrange the feed channel in a zigzag manner.

 Specifically, Figures 10 and 11 are views of the detachment of a sea water extrusion orifice according to one preferred embodiment of the present invention. Specifically, there are 6 custody distribution plates (T1 to T6) of the sea type reflection custody, and the custody distribution plates of FIG. 5 are different in the fourth custody distribution plate (T4) and the fifth custody distribution plate (T5). 5, the fourth holding distribution plate T4 of FIG. 10 includes the second component supply path between the first component supply path assembly parts 100, 101 and 102 as in the case of FIG. It is divided into the euro. Thereby allowing the second component to evenly penetrate between the first components.

On the other hand, it is also possible to form a plurality of sea-island composite streams through the fourth pick-and-wire distribution plate T4 and the fifth pick-and-place distribution plate T5 of FIG. In other words, a separate sea-island complex flow is formed through the partitioned distribution ducts 100, 101, 102 of the fourth separation distribution plate T4 and three sea-like complex flows are formed in the interior After that, you can join together again. For this purpose, the design and modification of a separate distribution plate is obvious to a person skilled in the art, and is included in a plurality of integrated seawater extrusion apparatuses.

In the present invention, a plurality of sea-island complex streams including the first component dispersed in the second component are formed, and preferably the number of the sea-island complex streams is two or more, more preferably three or more , More preferably four or more. For this purpose, as shown in FIG. 12, a plurality of sea-island extrusion orifices capable of forming respective sea-island complex streams may be provided, or a plurality of sea-island extrusion orifices may be integrally formed. In this case, it is also possible to form the sea water supply path in a redundant manner, preferably between adjacent pushing-out ports.

It is also obvious to those skilled in the art that the sea-island extrusion orifices are individually or integrally arranged to form a plurality of sea-island complex streams, and that the number and structure of the appropriately distributed distribution plates are appropriately designed and arranged. For example, when four sea-island extrusion ports are integrally formed to form four sea-island complex streams, the first detachable distribution plate may be manufactured as four as the number of the fourth detachable distribution plates, And it is also possible to supply them in a branched manner to the four interrupted distribution distribution boards.

On the other hand, in order to cover different wavelength ranges of the light, the plurality of sea-island complex streams have optical thicknesses of the first component, the optical thickness of the second component, the number of layers of the first component, Can be different. For this purpose, the diameter, cross-sectional area, shape, and / or number of layers of the isotonic powder feed path and / or the seawater feed path formed in the respective seawater extrusion orifices may be different. This is because a plurality of groups are formed in the reflection type polarizer manufactured through the spreading and stretching process, and the plurality of groups have different average optical thicknesses. For this purpose, considering the spreading degree of the first components, The diameters of the above-described supply paths can be determined.

More specifically, the optical thickness means n (refractive index) x d (physical thickness). Therefore, if two sea-island complex streams are formed, the optical thickness is proportional to the physical thickness (d) if the first component in the sea-island complex stream is the same. Therefore, it is possible to derive the difference in optical thickness between the sea-island complex streams by varying the average value of the physical thickness (d) of the first component and / or the second component included in each sea-island complex stream. On the other hand, in order to cover the entire visible light region, the average optical thickness of the sea-island complex currents should be determined so as to correspond to various light wavelengths. For example, in order to set the average optical thickness of the first component of the sea-island complex type so as to correspond to 450 nm, 550 nm, and 650 nm of the wavelength range of each light, May be different by at least 5% or more, and more preferably by 10% or more. This allows reflection of the S wave in the entire visible region.

 In addition, the diameter, cross-sectional area, shape, and the like of the island component supply path and / or the sea component supply path may be the same or different in a sea-island extrusion port forming a single sea-type complex flow. Furthermore, the optical thicknesses of the first components forming the same sea-island complex stream may have a deviation of preferably within 20%, more preferably within 15% of the average optical thickness. For example, if the average optical thickness of the first components of the first sea current type complex stream is 100 nm, then the first components forming the same first sea current type complex stream have an optical thickness variation within about 20% . On the other hand, the wavelength of light and the optical thickness are defined by the following relational expression (1).

[Relation 1]

λ = 4nd

Where? Is the wavelength of light (nm), n is the refractive index, d is the physical thickness (nm)

Therefore, when the optical thickness (nd) deviates, it is possible to cover not only the wavelength of the target light but also the wavelength range of the light including the target, thereby greatly improving uniform optical properties. The deviation of the optical thickness described above can be achieved by imparting a deviation to the diameter, the cross-sectional area, and the like of the isometric feed path from one seawater extrusion or, if the feed path has the same diameter, the natural fine pressure distribution And the difference between them can be achieved naturally.

According to another preferred embodiment of the present invention, the first component transferred in the extruding part between steps (1) and (2) includes a plurality of particles having different discharge amounts in order to have different average optical thicknesses And then discharged through the first pressurizing means into different seawater extrusion orifices respectively. Specifically, FIG. 13 is a schematic view including first pressing means for forming two sea-view type composite streams, in which a first component transferred from an extruding portion (not shown) passes through the plurality of first pressing means 130 and 131, And is separately supplied to each of the sea-island extrusion ports 132, 133 in each of the first pressurizing means 130, 131. At this time, the first pressurizing means 130 and 131 have discharge amounts different from each other, and through which the respective seawater extrusion / take-out ports 132 and 133 have the same specifications (when the shape diameters of the ingredient supply paths etc. are the same) May have different average optical thicknesses of the first component of the first sea-island-type complex stream and the second sea-island complex stream formed through the first sea-view complex stream. When the first pressurizing means 130, 131 have different discharge amounts, the area of the first composite flow and the first component formed in the second composite flow through the seawater extrusion orifices 132, 133 communicated therewith An area difference occurs due to a different discharge amount, resulting in a difference in optical thickness between the composite streams.

To this end, the discharge amount of the first pressurizing means 130 and 131 may be preferably 1 to 100 kg / hr, but is not limited thereto.

On the other hand, one first pressurizing means feeds the first component to the two seawater-shaped push-out mouths, and two sea-island-type composite streams formed by the two sea-island push- It is also possible that one group is formed. In this case, the final reflection type polarizer may be formed of four groups through four first component pressing means and eight chart type extrusion / detaching mechanisms. It is also possible that one of the first pressing means transports the first component to three or more sea-island extrusion orifices.

According to another preferred embodiment of the present invention, the second component transferred in the extrusion between the step (1) and step (2) comprises a plurality of particles having different discharge amounts in order to have different average optical thicknesses And can be discharged through the second pressurizing means into different seawater extrusion orifices respectively. Specifically, Fig. 14 is a schematic diagram including two second pressing means for forming two sea-view type composite flows, in which a second component transferred from an extrusion portion (not shown) passes through the plurality of second pressing means 140, 141 and fed separately to each of the seawater extrusion seats 142, 143 at the respective second pressurizing means 140, At this time, the second pressurizing means 140 and 141 have different discharge amounts, and through which the respective seawater extrusion orifices 142 and 143 have the same specifications (when the shape diameters of the ingredient supply paths etc. are the same) The average optical thickness or the thickness of the base material (core layer) of the second component of the first sea-island type complex stream and the second sea-view complex stream formed through the first sea-island complex stream may differ. For this, the discharge amount of the second pressurizing means 140 and 141 may be preferably 1 to 100 kg / hr, but is not limited thereto.

On the other hand, one second pressurizing means feeds the second component to the two seawater-shaped push-out mouths, and two sea-island composite streams formed by the two sea-island push-out seams are joined together to form a single sea- It is also possible that one group is formed. In this case, the final reflection type polarizer may be formed of four groups through four second component pressing means and eight chart type extrusion / detaching mechanisms. It is also possible that one second pressing means transports the second component to three or more sea-island extrusion orifices.

According to another preferred embodiment of the present invention, between the steps (1) and (2), the second component transferred from the extruding unit is discharged through the second pressurizing unit into the different seawater extrusion orifices . Fig. 15 is a schematic view including one second pressing means for forming two sea-view type composite streams, in which a second component transferred from an extrusion portion (not shown) is supplied to the second pressing means 150, Shaped extrusion seats 151 and 152 through the plurality of seaweed extrusion seats 151 and 152, respectively. The average optical thickness of the second component of the first sea-island type complex stream and the second sea-type complex stream formed through the first sea-view complex stream and the thickness of the base material (core layer) may be the same. In this case, It is possible to arrange them in a plurality so that the average optical thicknesses of the first components included in the respective sea-island complex streams are different from each other.

In the next step (3), the two or more sea-island complex streams are combined to form a core layer. Specifically, FIG. 16 is a schematic view showing a joint portion of a sea-view complex type, and a plurality of sea-island composite streams 161, 162, 163, and 164 manufactured through respective sea-island extrusion / ). On the other hand, the lapping step may be performed in a separate place, or in the case of using an integral type seaweed extrusion apparatus, it may be joined together through a separate collecting / distributing distribution plate. In addition, when the number of sea-island complex streams is large, it is also possible to perform a multi-stage sea-island structure in which some sea-island complex streams are first lapped and lapped again to facilitate linting.

Meanwhile, a separate preliminary spreading step may be further performed between the steps (2) and (3) or between the steps (3) and (4) to facilitate the spreading of the first component .

Next, in step (4), the first component of the core layer induces a spread in the flow control section to form a plate-like shape. Specifically, Fig. 17 is a cross-sectional view of a coat-hanger die, which is a kind of preferred flow control portion applicable to the present invention, and Fig. 18 is a side view. Accordingly, the degree of spreading of the core layer can be appropriately adjusted so that the vertical cross section of the first component in the longitudinal direction can be adjusted to have a plate-like shape. In Fig. 17, since the core layer transferred through the flow path spreads widely from side to side in the coat-hanger die, the first component contained therein also spreads to the left and right. Also, as shown in the side view of FIG. 18, the coat hanger die is widely spread to the left and right but has a structure of shrinking up and down, so that the skin layer purges in the horizontal direction of the laminated core layer and shrinks in the thickness direction. This is based on Pascal's principle, in which the fluid in the enclosure is guided to spread widely in the width direction by the principle that the pressure is transmitted to the fine portion by a certain pressure. Therefore, the outlet size is wider in the width direction than the die inlet size, and the thickness is reduced. This requires the use of the Pascal principle in which the molten liquid material can flow and shape controlled by pressure in a closed system, preferably a polymer flow rate and viscosity induction such that a flow of laminar flow of less than 2,500 Reynolds numbers is preferred. When the flow of the turbulent flow is 2,500 or more, the induction of the plate-like type becomes uneven, and there is a possibility that the optical characteristic is varied. The left and right die width of the outlet of the coat-hanger die may be between 800 and 2,500 mm and the fluid flow of the polymer is required to regulate the pressure so that the Reynolds number does not exceed 2,500. The reason is that the polymer flow becomes turbulent and the arrangement of the cores may be disturbed. Also, the internal temperature may be 265 to 310 ° C. On the other hand, the degree of spreading may be influenced by the compatibility of the first component and the second component, and in order to have excellent spreadability, PEN as the first component and CO-PEN as the second component may be used. Further, the degree of spreading can be controlled by appropriately polymerizing monomers constituting CO-PEN, for example, dimethyl-2,6-naphthalene dicarboxylate, dimethyl terephthalate, ethylene glycol and cyclohexane dimethanol (CHDM) have. The flow control part may be a T-die or a manifold type Coat-hanger die so that the first component can form a plate-like shape. However, the present invention is not limited to this, and it is possible to induce the spreading of the core layer to induce the first component into a plate- Anything that can be used can be used without limitation.

On the other hand, the plate-like shape has an aspect ratio of 1/200 or less, 1/300 or less, or 1/500 or less, which is the ratio of the minor axis length to the major axis length, 1/1000 or less, 1/2000 or less, 1/5000 or less, 1/10000 or less, or 1/20000 or less. If the aspect ratio is more than 1/200, it is difficult to achieve the desired optical properties even if the aspect ratio is reduced through the elongation of the polarizer thereafter. In particular, when the aspect ratio of the first component is adjusted by controlling the aspect ratio of the final first component through induction of spreading with an aspect ratio exceeding 1/200 and then by a high draw ratio of 6 times or more, the area of the first component is smaller than the area of the second component, Due to the light leakage phenomenon, there is a problem of deterioration of optical characteristics.

As a result, the smaller the ratio of the minor axis length to the major axis length is, the more desirable the desired optical properties can be attained even if a smaller number of the plate-like polymer is contained in the substrate.

The manufacturing method of the present invention is characterized in that a plurality of sea-island composite streams having different average optical thicknesses of the first component are produced by using a plurality of sea-island extrusion orifices and joined together in a molten state, so that a separate adhesive layer and / . Thus, the manufacturing cost can be remarkably reduced. In addition, the reflection type polarizer manufactured through the manufacturing method of the present invention has a very small number of birefringent polymers in comparison with the conventional birefringent polymer-containing reflection type polarizer, It is possible not only to achieve extremely excellent optical properties but also to reflect all the S waves in the visible light wavelength region since a plurality of groups having different average optical thicknesses are formed.

According to a preferred embodiment of the present invention, after step (4), the reflective polarizer is stretched as step (5).

First, after the step (4), the polarizer transferred from the flow control unit can be cooled and smoothed, which can be cooled and solidified by using a conventional reflective polarizer, and then smoothed through a casting roll process or the like.

Thereafter, a step of stretching the polarizer through the smoothing step may be performed. The stretching may be effected through a conventional process of stretching the reflective polarizer, thereby causing a refractive index difference between the first component and the second component to cause a light modulation phenomenon at the interface, and the spreading induced first component The aspect ratio is further reduced through stretching. Therefore, in order to adjust the optical thickness by deriving the desired aspect ratio of the plate-like first component in the final reflective polarizer, the optical thickness can be appropriately set in consideration of the diameter of the island component supply path, the spreading inducing condition, will be. For this purpose, the uniaxial stretching or biaxial stretching can be preferably performed in the stretching step, and more preferably uniaxial stretching can be performed. In the case of uniaxial stretching, stretching may be performed in the longitudinal direction of the first component. The stretching ratio may be 3 to 12 times. On the other hand, a method of changing an isotropic material to birefringent is commonly known. For example, when stretching under appropriate temperature conditions, polymer molecules may be oriented so that the material becomes birefringent.

Next, the reflective polarizer can be manufactured through a step of heat-setting the stretched polarizer. The thermal fixation may be heat-set through a conventional method, preferably at 180 to 200 ° C for 0.1 to 3 minutes through an IR heater. Meanwhile, in the present invention, when the aimed average optical thickness and the aspect ratio are determined in the present invention, the standard of the isometric extrusion nozzle, the discharge amount of the pressurizing means, the specification of the flow control portion, A polarizer can be manufactured.

Next, a structured surface layer is formed on at least one surface of the reflective polarizer (core layer) manufactured as the step (6). At this time, a primer layer may be further formed on at least one surface of the core layer to facilitate the formation of the structured surface layer. This makes it possible to improve the adhesion, appearance and electrophotographic characteristics of the structured surface layer. Examples of the material include, but are not limited to, acrylic, ester, and urethane. The primer layer can be formed thinner than the other layers, and the thickness of the primer layer can be adjusted to improve the light transmittance and reduce the reflectance.

The thickness of such a primer layer may be from 5 nm to 300 nm. If the thickness of the primer layer is less than 5 nm, the adhesion between the core layer and the structured surface layer may be insufficient. If the thickness of the primer layer exceeds 300 nm, unevenness or molecular aggregation may occur during primer treatment.

Meanwhile, the reflective polarizer of the present invention can form a structured surface layer on at least one surface to maximize the light collecting effect and prevent irregular reflection on the surface, thereby remarkably improving the brightness.

The structured surface layer that can be applied in the present invention is a structure capable of improving the light collecting effect, and may be a fine pattern layer. The fine patterns that can be applied in this case may be any one or more selected from the group consisting of prisms, lenticular, microlenses, triangular pyramid, and pyramid patterns, and each of them may be formed by forming a pattern alone or in combination. Also, even when a pattern is formed alone, the pattern may be constant, or the height, the pitch, and the like may be differently arranged.

The material of the structured surface layer is preferably a polymer resin including a thermosetting or photocurable acrylic resin or the like. For example, the prism pattern can be an unsaturated fatty acid ester, an aromatic vinyl compound, an unsaturated fatty acid and a derivative thereof, or a vinyl cyanide compound such as methacryl nitrile. Specific examples thereof include uretanic acrylate, methacrylic acryl Late resin and the like can be used. The structured surface layer can also be made of a material having a higher refractive index than the reflective polarizer.

On the other hand, the fine pattern layer can be produced through a mold film for pattern formation. As the material of the mold film for pattern formation, a film having transparency, flexibility, predetermined tensile strength and durability can be used, and it is preferable to use a PET film.

In this case, according to a preferred embodiment of the present invention, the step (6) includes the steps of: i) closely contacting and transferring the core layer to a master roll formed on one side of a pattern that is a reverse phase of the structured surface layer, Applying a molten polymer resin to the core layer surface; And ii) UV-curing the polymer resin by irradiating UV or heat while the polymer resin is press-formed on the pattern surface of the master roll, and separating the polymer resin.

According to another preferred embodiment of the present invention, the polymer resin may be secondarily cured by irradiating UV or heat again after the step ii).

19 is a schematic view showing a process of forming a fine pattern according to a preferred embodiment of the present invention, and FIG. 20 is a sectional view showing a detailed structure of the forming unit of FIG. In FIG. 19, the reflective polarizer 770 is unwound from the star trolley 755, passes through the guide roll 754, and passes through the infrared lamp 751. In this process, the reflection type polarizer 770 is surface-modified by the infrared rays of the infrared lamp, and the adhesion with the pattern formation layer 771 is improved. The reflective polarizer 770 leaving the star trolley 755 enters the master roll 705 via the pattern guide roll 764 so that the patterned surface of the master roll 705 from the injection unit 742, (771) material, a pattern layer polymer is applied and merged with the base layer (770). In this process, the resin is a resin melted at room temperature and can be primary-cured due to the primary UV light emitted from the primary UV curing unit 752 provided under the master roll 705. In this case, the temperature around the curing unit 752 is 20 to 30 ° C, the temperature of the heat generated when the resin is cured is 40 to 80 ° C, and the glass transition temperature (Tg:

A temperature that indicates a change in properties such as soft rubber before undergoing a complete phase change from solid to liquid). In the glass transition state, the pattern forming layer 771, which completely copies the pattern shape of the master roll surface, passes through the pattern guide rolls 764 again, and a pattern in which the reflection type polarizing element 770 and the pattern forming layer 771 are combined is formed Shaped by the reflection type polarizer 772, passed through the guide roll 754, and wound on the finish roll 756.

As shown in FIG. 20, the cross section of the reflection type polarizer 772 formed with the turn produced by irradiating UV twice is a surface contrary to the cross section of the master roll 705. For example, If it is an engraved surface, the reflective polarizer 772 with the turn formed becomes the embossed surface of the emboss.

In this case, according to a preferred embodiment of the present invention, the step (6) includes the steps of: a) transferring the core layer; b) transferring the mold film for pattern formation formed on one surface of the reversed phase pattern of the structured surface layer; c) bringing the one side of the core layer and the one side of the pattern-forming mold film into contact with each other; d) injecting a fluid material into a region where the core layer and the mold film for pattern formation are in close contact with each other to fill the spaces between the patterns; e) applying the material to the core layer by curing the material filled between the patterns; And f) separating the mold film for pattern formation from the core layer coated with the material, wherein steps a) and b) may be performed in any order.

Preferably, between step d) and step e), a pressure is applied to the adhered core layer and the mold film to fill the material evenly between the patterns.

Advantageously, the step e) may comprise irradiating the material filled between the patterns with heat or UV.

21 is a schematic view of a process of forming a fine pattern according to another preferred embodiment of the present invention. First, the reflective polarizer 810 wound on the first roll 820 is conveyed by guide rollers 830a through 830c. At this time, the shaping mold 842 of the pattern molding unit 840 is also conveyed / rotated while being wound around the master roll 844 and the pattern guide rolls 846a and 846b. At this time, since the master roll 844 is engaged with the guide rolls 830c and 830d, the reflective polarizer 810 is attracted to the guide roll 830c and engaged with the molding die 842. [ Here, the guide roll 830c performs a gap adjusting function to adjust the thickness of the pattern layer of the coating liquid applied to the reflective polarizer 810, that is, the angled reflective polarizer 812 in which the pattern layer is made of resin. More specifically, when the guide roll 830c is brought into close contact with the master roll 844, the pattern layer of the reflective polarizer can be made thinner. On the contrary, when the guide roll 830c is further separated from the master roll, The pattern layer can be formed thicker. The thickness of the reflective polarizer pattern layer can be controlled by the viscosity of the coating liquid, the patterning speed, and the tension of the reflective polarizer in addition to the interval between the guide roll 830c and the master roll 844.

The coating liquid is injected by the coating liquid injecting means 860 at the point where the guide roll 830c and the master roll 844 are engaged with each other by the reflective polarizer 810 and is pushed into the patterns of the molding die 842, Is uniformly distributed and pattern-formed by the pressure between the guide roll 830c and the master roll 844. [ The coating liquid distributed between the patterns is cured by heat or UV emitted from the curing means 870. The reflection type polarizing element having the patterned coating liquid cured and applied is separated from the molding die 842 while being guided by the guide roll 830d and the reflective polarizing element 812 having the pattern is conveyed by the guide roll 830e, 2 roll 850. As shown in Fig. Here, the guide roll 830d performs a peeling function for separating the reflective polarizer 812 having the coating liquid applied thereto, that is, the pattern layer formed thereon, from the molding die 842.

In the above description, the reflective polarizer 810 and the reflective polarizer 812 having the pattern layer are connected to each other and are classified for ease of explanation. That is, the reflective polarizer 810 refers to a state before a pattern is formed, and the reflective polarizer 812 having the pattern layer formed thereon is coated with the coating liquid, which is patterned while passing through the pattern molding portion 840, And the state is completed. In Fig. 21, only a part of the pattern layer formed on the reflective polarizer 812 on which the pattern layer is formed is shown. In reality, the reflective polarizer wound on the second roll 850 also has a pattern layer formed thereon.

22 is a schematic view of a process of forming a fine pattern according to another preferred embodiment of the present invention. Specifically, the forming mold 942 is formed into a roll type with a length corresponding to the length of the reflective polarizer 910, so that the reflective polarizer 912 on which the pattern layer is formed has no seams.

The second embodiment of the optical member manufacturing apparatus according to the present invention also includes a first roll 920 on which a reflective polarizer 910 is wound and a second roll 950 on which a reflective polarizer 912 with a pattern layer is wound Guide rolls 930a to 930f are provided between the first roll 920 and the second roll 950 for transferring the reflective polarizer having the reflective polarizer and the pattern layer formed on both sides thereof. Between the guide roll 930c and the guide roll 930d, a master roll 946 of the pattern molding portion 940 is closely attached to apply the coating liquid to the reflective polarizer 910. It goes without saying that the number and position of the guide rollers 930a to 930f may be changed according to the operation state. The pattern molding unit 940 includes a film forming mold 942 in which a pattern shape is implemented, a third roll 944 on which a forming mold is wound, a pressing roll 944 for pressing the coating liquid onto the forming mold, A master roll 946 for shaping and applying this to the reflection type polarizer 910, pattern guide rolls 947a to 947d for conveying the forming mold, and a fourth roll 948 for conveying the formed molding mold. It goes without saying that the number and position of the pattern guide rolls 947a to 947d can be changed according to the operation state.

The shaping mold 942 is conveyed by the master roll 946 and the guide rolls 947a to 947d while being wound on the third roll 944 unlike the embodiment of Figure 21 and is fed to the reflective polarizer 910 After the pattern of the coating liquid is formed, it is wound on the fourth roll 948. At this time, it is preferable that the forming mold 942 is formed to have the same length as that of the reflection type polarizer 910, and the reflection type polarizer 912 having the pattern layer formed thereon can be provided with the entire area So that the pattern is uniformly formed. Although only a part of the pattern embodied in the pattern layer of the forming mold is shown in Fig. 22, in actual practice, the pattern is implemented throughout the forming mold.

A coating liquid injecting unit 960 for injecting a coating liquid is provided at a point where the reflective polarizer 910 is drawn into the pattern molding unit 940, that is, at a point where the guide roll 930c and the master roll 946 are in close contact with each other A curing unit 970 for curing the coating liquid by irradiating heat or UV is provided at a point where the reflection type polarizer and the forming mold 942 are in close contact with each other.

The reflection type polarizer in which the polymer produced through the above-described method is dispersed includes a plurality of plate-like polymers dispersed in the substrate so as to transmit the first polarized light radiated from the outside and reflect the second polarized light, The polymer is different in refractive index in at least one axial direction from the substrate, and the substrate is elongated in at least one axial direction, and the plurality of plate-shaped polymers each form a group to reflect a transverse wave of a desired wavelength (S wave) Wherein the plurality of groups are formed, the average optical thicknesses of the inter-group plate-shaped polymers differ, and the aspect ratio of the minor axis length to the major axis length based on the longitudinal cross-section of the platy polymer comprises not more than 1/1000 A core layer and a structured surface layer formed on at least one side of the core layer.

According to another embodiment of the present invention, the average optical thicknesses of the inter-group polymers are different, and the maximum value of the interval between adjacent polymers forming the same group may be smaller than the maximum value of the interval between adjacent polymers between neighboring groups . And no inter-group adhesive layer in the core layer is formed.

23 is a cross-sectional view of a reflective polarizer according to a preferred embodiment of the present invention. Specifically, the core layer 180 is divided into two groups (A, B). In the drawing, a dotted line dividing groups A and B means a virtual line. The average optical thicknesses of the first components contained in the group A are different from the average optical thicknesses of the first and second polymer components 181 and 182 and the first component included in the group B, This makes it possible to reflect different wavelengths of light. Further, the optical thicknesses of the first components contained in the group A, that is, the plate-like polymers 181 and 182 are preferably within 20%, more preferably within 15%, based on the average optical thickness of the group A Lt; / RTI > Therefore, if the average optical thickness of the group A is 100 nm, it is possible to reflect a transverse wave (S wave) of a wavelength of 400 nm by the above-mentioned relational expression (1). In this case, if the thickness deviation is 20%, the wavelength band of about 320 to 480 nm can be covered. If the average optical thickness of the group B plate-like polymers 233 and 234 is 130 nm, the transverse wave (S wave) of 520 nm wavelength can be reflected by Relation 1, and if the thickness deviation is 20% It is possible to cover the wavelength band and partially overlap the wavelength band of the group A, thereby maximizing the light modulation effect. In the case where the polymer as the first component has optical birefringence, since the P wave is transmitted and the S wave is reflected, the refractive index (n) is set on the basis of the thickness direction (the z axis refractive index) through which light passes and the average optical thickness is calculated .

On the other hand, the maximum value of the inter-polymer distance within the group A and the group B is smaller than the maximum value of the inter-polymer distance between the group A and the group B. Specifically, the maximum value d ₁ of the inter-polymer distance of the group A and the maximum value d ₂ of the inter-polymer distance of the group B are smaller than the maximum value d ₃ of the inter-polymer distance between the groups A and B. In other words, the spacing of the polymers in the same group is less than the distance between the adjacent groups of polymers.

Further, the plate-like polymers dispersed in the core layer form a plurality of layers with a space between them. In this case, the number of layers formed by the sheet-like polymers in one group may be 25 or more, preferably 50 or more, more preferably 100 or more, and most preferably 150 or more.

On the other hand, they are integrally formed without an adhesive layer between the group and the group. As a result, deterioration of optical properties due to the adhesive layer can be prevented, and more layers can be added to a limited thickness, so that optical properties can be remarkably improved.

24 is a cross-sectional view of a reflective polarizer according to another embodiment of the present invention. 19, three groups (A, B, C) having different average optical thicknesses are formed in the core layer, and the maximum value of the distance between the plate-shaped polymers in the groups A, B, Is smaller than the maximum value of the interplanar polymer distance between the groups A, B and C.

25 is a cross-sectional view of a reflective polarizer according to another embodiment of the present invention. Specifically, the core layer is formed of four groups, and each of the groups can be adjusted in the average optical thickness to cover the light wavelength band of 350 nm, 450 nm, 550 nm and 650 nm, respectively. In this case, the outer layer of the core layer is formed with groups having a large average optical thickness, and groups having a small average optical thickness in the inner layer can be formed. On the other hand, in order to cover the entire visible light region, the average optical thickness of the plate-like polymers should be determined so as to correspond to various light wavelengths. To set the average optical thickness of the first component per group within the core layer to correspond to the optical wavelength band of 350 nm, 450 nm, 550 nm and 650 nm, the average optical thickness of the first component between the groups is at least 5% , And more preferably by at least 10%. This allows reflection of the S wave in the entire visible region.

On the other hand, the area of the plate-like polymers within a certain area within the same group may be larger than the area of the plate-like polymers within a certain area between the groups. Specifically, the density of the polymers in a certain area S ₁ inside the group A and the certain area S ₂ inside the group B is larger than a certain area S ₃ between the group A and the group B. In other words, the area occupied by the (쨉 m ² ) plate-shaped polymer within the same group is larger than the area occupied by the plate-shaped polymer per unit area (쨉 m ² ) between the group and the group.

26 is a perspective view of a reflective polarizer in which a structured surface layer is formed according to a preferred embodiment of the present invention. In the second polymer 210, a plurality of plate-shaped polymers 211 are elongated in the longitudinal direction, They form a core layer. In this case, each of the plate-like polymers 211 can be elongated in various directions, but it is preferable to elongate them in parallel in any one direction, more preferably, in a direction perpendicular to the light irradiated from the external light source, Is effective in maximizing the light modulation effect. A primer layer 212 may be selectively formed on one surface of the core layer. This makes it possible to improve the adhesion, appearance and electrophotographic characteristics of the structured surface layer. Examples of the material include, but are not limited to, acrylic, ester, and urethane. The primer layer can be formed thinner than the other layers, and the thickness of the primer layer can be adjusted to improve the light transmittance and reduce the reflectance.

The thickness of the primer layer 212 may be 5 nm to 300 nm. If the thickness of the primer layer is less than 5 nm, the adhesion between the core layer and the structured surface layer may be insufficient. If the thickness of the primer layer exceeds 300 nm, unevenness or molecular aggregation may occur during primer treatment.

Meanwhile, the reflective polarizer of the present invention can maximize the light condensing effect by preventing the diffuse reflection on the surface by forming the structured surface layer 213 on at least one surface, and thus the brightness can be remarkably improved.

The structured surface layer 213 that can be applied in the present invention is a structure capable of improving the light collecting effect, and may be a fine pattern layer. The fine patterns that can be applied in this case may be any one or more selected from the group consisting of prisms, lenticular, microlenses, triangular pyramid, and pyramid patterns, and each of them may be formed by forming a pattern alone or in combination.

26, the lenticular pattern layer 213 is formed on one surface of the reflection type polarizer, and the height (a) of the lenticular may be 10 to 50 mu m. If the height of the lenticular pattern is less than 10 mu m, it may be difficult to realize the pattern layer. If the height of the lenticular pattern is more than 50 mu m, the brightness may decrease due to an increase in the total reflection amount of light.

The pitch (b) of the lenticular may be 20 to 100 mu m. If the pitch of the lenticular pattern is less than 20 占 퐉, the convergence effect of the lens shape is somewhat deteriorated due to an increase in the valley portion of the film per unit area, and the limitation of the accuracy of shape processing and the pattern shape are too narrow, If the thickness exceeds 100 탆, the possibility of occurrence of moire between the pattern structure and the panel becomes very large.

On the other hand, when the short axis radius of the elliptical cross section is a and the long axis radius is b, the ratio of the major axis / minor axis (b / a) is 1.0 to 3.0 per lenticular lens. If the ratio of the major axis / minor axis (b / a) is out of the above-mentioned range, there may arise a problem that the luminance line concealing efficiency for the light passing through the birefringent polarizing layer is inferior.

Further, in defining the height h of the lenticular lens, the tangent angle alpha at both end points of the lower end of the lens must be between 30 and 80 degrees. At this time, if? Is less than 30 degrees, the luminance line concealment efficiency is lowered, and if it is larger than 80 degrees, there is a problem that lens pattern production becomes difficult. When the cross-sectional shape of the lenticular lens is triangular, it is preferable that the vertex angle &thetas; satisfies 90 to 120 degrees for the hue line concealment effect.

On the other hand, the lenticular shape may be formed as a pattern having the same height and pitch as shown in Fig. 26, or lenticular patterns having different heights and pitch as shown in Fig. 27 may be mixed.

28 shows a microlens pattern layer formed on one surface of the reflective polarizer, and the height of the microlens may be 10 to 50 mu m. If the height of the microlens pattern is less than 10 mu m, the light collecting effect is somewhat deteriorated, and the pattern implementation may be difficult. When the height exceeds 50 mu m, the moiré phenomenon tends to occur and the pattern may appear in the image.

Further, the diameter of the microlenses may be 20 to 100 mu m. Preferably 30 to 60 mu m. The light-converging function and the light-diffusing property of the microlens can be excellent while the appearance characteristic is good in the above-mentioned range, and the microlens can be actually manufactured easily. If the diameter of the microlens pattern is less than 20 mu m, there is a problem of low condensing efficiency with respect to the incident light incident at an angle that is not effective. If the diameter exceeds 100 mu m, the condensing efficiency with respect to the vertical light is reduced. May occur.

On the other hand, the microlens pattern layer may be formed in a pattern having the same height and diameter as shown in FIG. 28, or microlens patterns having different heights and diameters as shown in FIG. 29 may be mixed. It is ideal that the microlens pattern increases the density to a maximum and has a degree of impregnation of 1/2 because the optical characteristics vary greatly depending on the density and the aspect ratio of the lens.

In FIG. 30, a prism pattern layer 213 is formed on one surface of the reflective polarizer, and the height (a) of the prism may be 10 to 50 μm. If the height of the prism pattern is less than 10 mu m, the base film may be damaged by pressure when manufacturing the shape of the prism pattern portion. If the height exceeds 50 mu m, the light transmittance of the light incident on the light source may be reduced.

Also, the pitch b of the prism may be 20 to 100 mu m. If the pitch of the prism pattern is less than 20 탆, the embossing is difficult and the complication of the pattern layer implementation and manufacturing process may occur. If the pitch exceeds 100 탆, the moire phenomenon tends to occur, .

On the other hand, the prism shape may be formed in a pattern having the same height and pitch as shown in FIG. 30, or prism patterns having different heights and pitch as shown in FIG. 31 may be mixed. Such a prism pattern may be made of a material having a refractive index higher than that of the base film. If the refractive index of the base film is higher, a part of the light incident on the back surface of the base film may not be incident on the prism structure Because. Preferably, the prism shape is preferably a linear prism shape, the vertical section is triangular, and the triangle has an angle of 60 to 110 degrees with respect to a vertex opposed to the lower surface.

The material of the structured surface layer is preferably a polymer resin including a thermosetting or photocurable acrylic resin or the like. For example, the prism pattern can be an unsaturated fatty acid ester, an aromatic vinyl compound, an unsaturated fatty acid and a derivative thereof, or a vinyl cyanide compound such as methacryl nitrile. Specific examples thereof include uretanic acrylate, methacrylic acrylate Resin or the like can be used. The structured surface layer can also be made of a material having a higher refractive index than the reflective polarizer.

According to a preferred embodiment of the present invention, the shape of the vertical cross section in the longitudinal direction of the plate-like polymer may be 1/1000 or less, which is the short axis length to the long axis length. 32 is a vertical section in the longitudinal direction of the plate-like polymer that can be used in the present invention. The ratio of the relative lengths of the major axis length (a) and the minor axis length (b), when the major axis length is a and the minor axis length is b, ) Must be less than 1/1000. In other words, when the major axis length (a) is 1000, the minor axis length (b) should be less than or equal to 1, which is 1/1000. If the ratio of the minor axis length to the major axis length is larger than 1/1000, it is difficult to achieve the desired optical properties. The aspect ratio can be appropriately adjusted through spreading induction and stretching of the first component during the above-described manufacturing steps.

More specifically, in the case of a display having a size of 1580 mm and a height of 400 μm based on a vertical section of the reflective polarizer based on a 32-inch standard display, a conventional reflective polarizer should contain more than 100 million birefringent polymers to achieve desired optical properties. In contrast, the reflective polarizer of the present invention can achieve an optical property that the transmittance of the reflective polarizer in the transmission axis direction is 90% or more and the transmittance in the reflective axis direction is 30% or less even when the number of the plate- More preferably, the optical transmittance in the transmission axis direction is not less than 87% and the transmittance in the reflection axis direction is not more than 10%, and most preferably, the transmittance transmittance is not less than 85% The transmittance may be 7% or less. In this case, preferably, the reflection type polarizer of the present invention may contain not more than 500,000 of the above-mentioned plate-like polymer, and most preferably not more than 300,000 of the above-mentioned plate-like polymer. For this purpose, according to a preferred embodiment of the present invention, the ratio of the short axis length to the long axis length of the polymer is preferably 1/1000 or less, more preferably 1/1500 or less, more preferably 1/2000 or less Preferably 1/3000 or less, more preferably 1/5000 or less, still more preferably 1/10000 or less, still more preferably 1/30000, still more preferably 1/50000 or less, and most preferably 1/70000 ~ 1/170000. On the other hand, although the cross section of the polymer is shown as the ratio of the minor axis length to the major axis length of the present invention is larger than 1/1000, this is only a problem of the method expressed in the drawings for the sake of understanding, The long axis direction is longer and the shorter axis direction is shorter than that of the polymer.

As a result, the smaller the ratio of the minor axis length to the major axis length is, the more desirable the desired optical properties can be attained even if a smaller number of the plate-like polymer is contained in the substrate.

However, when the aspect ratio of the plate-like polymer becomes very small, the spacing space between the plate-like plane forming polymers forming the same layer can be extremely small. However, in the reflection type polarizer of the present invention, at least one spacing space necessarily exists between the plate-like polymers forming the same layer.

According to a preferred embodiment of the present invention, the reflective polarizer comprises a plurality of plate-shaped polymers satisfying the above-mentioned aspect ratio condition among all the plate-like polymers contained in the substrate, , Preferably not less than 60%, more preferably not less than 70%, more preferably not less than 80%, and most preferably not less than 90%.

According to a preferred embodiment of the present invention, a birefringent interface may be formed between the substrate (second component) and the plate-like polymer forming the core layer (first component). Specifically, in a reflection type polarizing element including a polymer in a substrate, the magnitude of the substantial agreement or inconsistency of the refractive index along the X, Y, and Z axes in space between the substrate and the plate-like polymer depends on the scattering degree of the polarized light ray along the axis . Generally, the scattering ability changes in proportion to the square of the refractive index mismatch. Thus, the greater the degree of discrepancy in refractive index along a particular axis, the more scattered light rays are polarized along that axis. Conversely, when the inconsistency along a particular axis is small, the polarized light rays along the axis are scattered to a lesser degree. If the refractive index of the substrate along an axis is substantially coincident with the refractive index of the sheet-like polymer, the incident light polarized with an electric field parallel to this axis will pass through the polymer without scattering, regardless of the size, shape and density of the portion of the polymer . Also, when the refractive index along the axis is substantially coincident, the light rays pass through the object without being substantially scattered. More specifically, the first polarized light (P wave) is transmitted without being influenced by the birefringent interface formed at the interface between the base and the polymer, while the second polarized light (S wave) is transmitted through the birefringent interface Modulation of light is affected by this effect. As a result, the P wave is transmitted and the S wave is modulated by light such as scattering and reflection of light, resulting in separation of polarized light.

Therefore, when the substrate is optically isotropic, the plate-like polymer may have birefringence, and conversely, when the substrate is optically birefringent, the plate-like polymer may have birefringence The polymer may have optical isotropy. Specifically, when the refractive index of the polymer in the x-axis direction is nX1, the refractive index in the y-axis direction is nY1, the refractive index in the z-axis direction is nZ1, and the refractive index of the base is nX2, nY2 and nZ2, Can occur. More preferably, at least one of the X, Y, and Z axis refractive indexes of the substrate and the polymer may be different, and more preferably, when the elongation axis is the X axis, the difference in refractive index between the Y axis and the Z axis direction is 0.05 or less , And the difference in refractive index with respect to the X-axis direction may be 0.1 or more. On the other hand, when the difference in the refractive index is 0.05 or less, it is interpreted as matching.

According to a preferred embodiment of the present invention, the total number of layers of the plate-like polymer may be 50 to 3000, the number of the plate-like polymers forming one layer is 30 to 1,000, Lt; / RTI > And the separation distance between adjacent plate-like polymers forming one layer may be at most 0.01 to 1.0 mu m. In addition, the short axis length of the vertical cross section of the plate-like polymer in the longitudinal direction may be 0.01 to 1.0 탆, and the long axis length of the vertical cross section of the elongate in the length direction may be 100 to 17,000 탆. Meanwhile, the layer spacing, the number of layers, the spacing distance, the short axis length, etc. of the present invention can be appropriately adjusted according to the aspect ratio and the desired wavelength of light of the present invention.

In the present invention, the thickness of the core layer may be 20 to 180 mu m.

According to a preferred embodiment of the present invention, there is provided an apparatus for producing a reflective polarizer in which a polymer is dispersed, the first and second components including a core layer having a plurality of first components dispersed therein, Two or more extruded portions individually inserted; A plurality of sea-island composite streams in which a first component is dispersed in the second component are formed, and in order to reflect a transverse wave (S wave) of a desired wavelength, And a plurality of seawater extrusion orifices for injecting the first component and the second component transferred from the extruding unit into which the second component is introduced to form two or more sea-island composite streams having different average optical thicknesses of the first components A block portion; A collection block unit that forms a core layer by combining two or more sea-island complex streams transferred from the spin block unit; And a flow control part for leading the spreading of the first component of the core layer transferred in the collection block part to form a plate-like shape.

33 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to a preferred embodiment of the present invention. And includes a first extrusion portion 220 into which the first component is injected, and a second extrusion portion 221 into which the second component is injected. The first extruding portion 220 is connected to the spin block portion C including four chart type extrusion orifices 223, 224, 225, and 226. At this time, the first extruding unit 220 supplies the first component in the molten state to the four sea-island extrusion orifices 223, 224, 225, and 226. The second extruding portion 221 is also connected to the spin block portion C and supplies the second component to the four marginal type extrusion orifices 223, 224, 225, and 226 contained therein in a molten state. The first component is dispersed inside the second component through the four isometric extrusion ports 223, 224, 225, and 226 to produce four sea-island composite streams having different average optical thicknesses. The four sea-island extrusion ports 223, 224, 225, and 226 may be the sea-island extrusion port shown in FIG. 5 or FIG. In addition, although four seawall-shaped extrusion seams are taken as an example, it is also within the scope of the present invention that an integrated seawater extrusion seam can be used. The four sea-island composite flows produced through the four sea-island extrusion ports 223, 224, 225 and 226 are joined together in the collection block portion 227 to form one core layer. In this case, the collection block unit 227 may be formed separately, or in the case of using a single integrated seawater extrusion orifice, the sea-like composite streams may be joined together in the form of a cantilever in the seawater extrusion orifice. The core layer laminated in the collection block section 227 is transferred to the flow control section 229, and the spread of the first component in the second component is induced to form a plate-like shape. Preferably, the flow control may be a T-die or a coat-hanger die.

34 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to another preferred embodiment of the present invention. 33, the first extruding unit 220 feeds the first component to the four first pressing units 233, 234, 235, and 236. The first pressurizing means 233, 234, 235, and 236 have different discharge amounts and discharge the first component to the plurality of the sea-island push-out ports 241, 242, 243, and 244. The second extruding portion 221 feeds the second component to the four second pressing means 237, 238, 239, 240. The second pressurizing means 237, 238, 239 and 240 have discharge amounts different from each other and discharge the second component to the plurality of the sea-island extrusion orifices 241, 242, 243 and 244. On the other hand, there is only one second pressurizing means, and it is also possible to discharge it by a plurality of sea-island extrusion orifices 241, 242, 243, 244. The first component is dispersed within the second component through the four isometric extrusion ports 241, 242, 243 and 244 to produce four sea-island complex streams having different average optical thicknesses. The first pressing means, the second pressing means, and the plurality of seawater extrusion orifices form a spin block portion (C).

On the other hand, regarding the specific constitution and effect of the method and apparatus for producing a reflective polarizer in which a polymer is dispersed, the contents of Korean Patent Application No. 2011-0145131 are incorporated by reference.

35 is a schematic view of an apparatus for producing a reflective polarizer in which a polymer is dispersed according to another preferred embodiment of the present invention. 25, the present invention is characterized in that, in order to manufacture a reflective polarizer having four groups, eight sea-island extrusion nozzles are used instead of four sea-island extrusion nozzles, and multi-stage laminating is performed. Specifically, the first pressing means 233 discharges the first component to the two seawater-shaped pushing-out portions 250, 251. The second pressurizing means 234 also discharges the first component to the two chart type extrusion orifices 250, 251. Since the first component and the second component are transferred through the same first pressurizing means and the second pressurizing means, the two isometric extrusion ports 250 and 251 have the same average optical thickness between the sea-island composite streams. In this way, eight sea-island complex streams are formed and the average optical thicknesses of the two sea-island complex streams are equal to each other. The two chart-type mixed streams having the same average optical thickness are laminated in the first leg portions 258, 259, 260, and 261 to form four sea-view composite streams, and the four sea- And a single core layer is formed by joining together in the branch portion 262. [

On the other hand, in FIG. 35, it has been described that one first pressing means feeds the first component to two seawater extrusion orifices. However, it is possible to convey the first component to two or more sea- And this can be equally applied to the second pressing means.

Hereinafter, the present invention will be described in detail with reference to Examples and Experimental Examples. The following Examples and Experimental Examples are merely illustrative of the present invention, and the scope of the present invention is not limited to the following Examples and Experimental Examples.

≪ Example 1 >

The process was performed as shown in FIG. Specifically, a mixture of PEN having a refractive index of 1.65 as a first component and dimethyl terephthalate and dimethyl-2,6-naphthalene dicarboxylate as a second component in a molar ratio of 6: 4 was mixed with ethylene glycol (EG) and 1 : 2 molar ratio of co-PEN having a refractive index of 1.64 were charged into the first extruder and the second extruder, respectively. The extrusion temperature of the first component and the second component was 295 ° C and the polymer flow was calibrated through IV adjustment by Cap. The first component was transferred to four first pressing means (Kawasaki gear pump) and the second component was also transferred to four second pressing means (Kawasaki gear pump). The discharge amounts of the first and second pressurizing means are 10.5 kg / h, 5.3 kg / h, 6.9 kg / h and 8.9 kg / , 6.9 kg / h, and 8.9 kg / h. Four composite seawater having different average optical thicknesses were manufactured using four seawater extrusion ports as shown in Fig. Specifically, the first component transferred from the first pressurizing means and the first component transferred from the second pressing means were introduced into the first isostatic pressing apparatus to produce the first composite flow. The fourth composite stream was prepared in this order. The number of layers of the fourth component distribution plate (T4) in the first to fourth isosceles extrusion ports is 96, the diameter of the hole of the component supply channel is 0.17 mm, and the number of the four component supply channels is Respectively. The diameter of the discharge port of the sixth prismatic distribution plate was 15 mm x 15 mm. The seabed extrusion detention uses the same detention. Four composite streams discharged through the four seawater-shaped push-pull cores were transported through separate channels and then lapped in a collection block to form one core layer polymer. The aspect ratio of the first composite stream was 1/13500, 2 aspect ratio of the composite stream is 1/25000 The core layer polymer in which the skin layer is formed such that the aspect ratio of the third composite stream is 1/19500 and the aspect ratio of the fourth composite stream is 1/15900 is shown in FIG. , And 18 coats hanger dies. Specifically, the width of the die inlet is 200 mm, the thickness is 10 mm, the width of the die outlet is 960 mm, the thickness is 0.78 mm, The flow rate is 1 m / min. Then, a smoothing process was performed on the cooling and casting rolls and stretched 6 times in the MD direction. As a result, the major axis length of the first component was not changed but the minor axis length was decreased. Thereafter, thermal fixation was performed through an IR heater at 180 ° C for 2 minutes to prepare a reflective polarizer in which the polymer was dispersed as shown in Fig. The refractive index (nx: 1.88, ny: 1.64, nz: 1.64) of the first component of the produced reflective polarizer was 1.64 and the refractive index of the second component was 1.64. The aspect ratio of the A layer was 1/101000, the number of layers was 96, the minor axis length (thickness direction) was 100 nm, the major axis length was 10.1 mm, the average optical thickness was 164 nm, and the optical thickness variation was about 20%. The B layer had an aspect ratio of 1/184000 and a layer number of 96 layers. The minor axis length (thickness direction) was 54.9 nm, the major axis length was 10.1 mm, the average optical thickness was 90 nm, and the optical thickness variation was about 20%. C layer had an aspect ratio of 1/148000 and a number of layers of 96 layers. The minor axis length (thickness direction) was 68.3 nm, the major axis length was 10.1 mm, the average optical thickness was 112 nm, and the optical thickness variation was about 20%. The aspect ratio of the plate of the D layer was 1/120000 and the number of layers was 96 layers. The minor axis length (thickness direction) was 84 nm, the major axis length was 10.1 mm, the average optical thickness was 138 nm, and the optical thickness variation was about 20%. The core layer thickness is 59 탆.

Thereafter, the produced reflective polarizer was subjected to the same process as shown in FIG. 21 to prepare a reflective polarizer having a urethane acrylic lenticular pattern layer having a refractive index of 1.59. The height in the lenticular pattern was 25 mu m and the pitch was 50 mu m.

≪ Example 2 >

A reflective polarizer was produced in the same manner as in Example 1, except that a reflective polarizer having a microlens pattern layer having a height of 30 탆 and a diameter of 60 탆 was formed instead of a lenticular pattern layer.

≪ Example 3 >

A reflective polarizer was produced in the same manner as in Example 1, except that a reflective polarizer having a prism pattern layer having a height of 12 탆 and a pitch of 24 탆 was formed instead of the microlens pattern layer.

≪ Comparative Example 1 &

A reflective polarizer was produced in the same manner as in Example 1, except that a lenticular pattern layer (having the same height and pitch) was formed in a straight-line pattern in the drawing step.

≪ Comparative Example 2 &

A reflective polarizer was produced in the same manner as in Example 1 except that the height of the lenticular pattern was 55 mu m and the pitch was 110 mu m.

≪ Comparative Example 3 &

A reflective polarizer was produced in the same manner as in Example 1 except that the microlens had a height of 55 탆 and a diameter of 110 탆.

≪ Comparative Example 4 &

A reflective polarizer was produced in the same manner as in Example 1 except that the height of the prism was 55 μm and the pitch was 110 μm.

<Experimental Example>

The following properties of the reflective polarizer prepared in Examples 1 to 3 and Comparative Examples 1 to 4 were evaluated, and the results are shown in Table 1.

1. Relative luminance

In order to measure the brightness of the produced reflective polarizer, the following procedure was performed. The panel was assembled on a 32 "direct-type backlight unit equipped with a diffuser plate and a reflective polarizer, and the brightness was measured at nine points using a BM-7 meter of Topcon Co. The average value was shown.

The relative luminance is a relative value of the luminance of the other Embodiment 2, Embodiment 3 and Comparative Examples 1 to 4 when the luminance of the reflection type polarizer of Embodiment 1 is taken as 100 (reference).

2. Moire

The moire phenomenon of the produced reflective polarizer was laminated on a prism sheet of a backlight unit in which a light source, a diffuser plate and a prism sheet were laminated in order, and then the degree of occurrence of a moire phenomenon caused by the prism sheet was visually judged Respectively.

Relative luminance (%) Moire Example 1 100 none Example 2 96.1 none Example 3 104.2 none Comparative Example 1 70.2 none Comparative Example 2 98.6 Occur Comparative Example 3 95.1 Occur Comparative Example 4 103.9 Occur

As can be seen from Table 1, the reflection type polarizers of Examples 1 to 3 of the present invention have improved optical properties due to an increase in the amount of vertical output light and an efficiency of light collection compared with the reflection type polarizers of Comparative Examples 1 to 4 , It can be confirmed that excellent image quality can be realized due to excellent moiré prevention effect.

Since the reflective polarizer of the present invention has excellent light modulation performance, it can be widely used in fields where optical modulation is required. Specifically, it can be widely used in flat panel display technologies such as a liquid crystal display device, a projection display, a plasma display, a field emission display, and an electroluminescence display which require high brightness such as a mobile display, an LCD and an LED.

Claims (20)

1. A method for producing a reflective polarizer in which a polymer is dispersed, the core polarizer comprising a core layer in which a plurality of first components are dispersed in a second component,
(1) supplying a first component and a second component to the extruding portions, respectively;
(2) Two or more sea-island complex streams in which a plurality of first components are dispersed in the second component are formed, and in order to reflect the transverse waves of a desired wavelength (S waves) The method comprising the steps of: injecting the first component and the second component transferred from the first component into a plurality of seaweed extrusion ports to form two or more sea-island composite streams having different first optical components of the first components;
(3) combining the two or more sea-island complex streams together to form a core layer;
(4) inducing spreading in the flow control so that the first component inside the core layer forms a plate-like shape;
(5) stretching the core layer; And
(6) forming a structured surface layer on at least one side of the stretched core layer. The method according to claim 1,
Wherein the plate-like shape of step (4) has an aspect ratio of 1/200 or less, which is a ratio of a short axis length to a long axis length with respect to a vertical cross section. The method according to claim 1,
A method for producing a reflective polarizer in which a polymer is dispersed in the step (5), wherein the aspect ratio of the plate-like shape is 1/1000 or less. 2. The method of claim 1, wherein the optical thicknesses of the first components forming the same sea-island complex stream have a deviation within 20% of the average optical thickness. 2. The method of claim 1, wherein the flow control is a T-die or a coat-hanger die. The method according to claim 1,
Further comprising the step of forming a primer layer on at least one side of the core layer between steps (5) and (6). The method according to claim 1,
Wherein the structured surface layer is a fine patterned layer. 8. The method of claim 7,
Wherein the fine pattern is at least one selected from the group consisting of a prism, a lenticular, a microlens, a triangular pyramid, and a pyramid pattern. 7. The method according to claim 1 or 6,
Wherein the step (6) is performed through a pattern-forming mold film. 10. The method of claim 9, wherein step (6)
a) transferring the core layer;
b) transferring the mold film for pattern formation formed on one surface of the reversed phase pattern of the structured surface layer;
c) bringing the one side of the core layer and the one side of the pattern-forming mold film into contact with each other;
d) injecting a fluid material into a region where the core layer and the mold film for pattern formation are in close contact with each other to fill the spaces between the patterns;
e) applying the material to the core layer by curing the material filled between the patterns; And
f) separating the mold film for pattern formation and the core layer coated with the material,
Wherein the steps a) and b) are performed independently of the order. 11. The method of claim 10,
Between step d) and step e)
Further comprising the step of applying pressure to the core layer and the mold film in close contact to fill the material evenly between the second patterns. &Lt; RTI ID = 0.0 &gt; 8. &lt; / RTI &gt; 11. The method of claim 10,
Wherein the step e) includes the step of irradiating heat or UV to the material filled between the patterns. 10. The method of claim 9, wherein step (6)
I) The core layer is closely contacted to a master roll formed on one side of the reversed phase pattern of the structured surface layer, and the melted polymer resin is applied to the pattern side or the core side of the master roll; And
Ii) UV-curing the polymer resin by irradiating UV or heat while the polymer resin is press-formed on the pattern surface of the master roll, and separating the polymer resin. 14. The method of claim 13,
Curing the polymer resin by irradiating UV or heat again after the step ii); &Lt; / RTI &gt; wherein the polymer is dispersed. A plurality of platelike polymers dispersed within the substrate to transmit a first polarized light externally irradiated and to reflect a second polarized light, wherein the plurality of platelike polymers are different in refractive index in at least one axial direction from the substrate , The substrate is elongated in at least one axial direction, The plurality of plate-like polymers each form a group for reflecting a transverse wave (S wave) of a desired wavelength, the plurality of groups are formed, the average optical thickness of the inter-group plate-like polymers is different, A core layer having an aspect ratio of a minor axis to a major axis length of 1/1000 or less based on a vertical cross section of the core layer;
And a structured surface layer formed on at least one side of the core layer. 16. The method of claim 15,
Further comprising a primer layer for enhancing adhesion between the core layer and the structured surface layer. 17. The method according to claim 15 or 16,
Wherein the structured surface layer is a fine patterned layer. 18. The method of claim 17,
Wherein the fine pattern is at least one selected from the group consisting of a prism, a lenticular, a micro lens, a triangular pyramid, and a pyramid pattern. 19. The method of claim 18,
Wherein the prism pattern has a height of 10 to 50 占 퐉 and a pitch of 20 to 100 占 퐉. 19. The method of claim 18,
Wherein the microlens pattern has a height of 10 to 50 占 퐉 and a lens diameter of 20 to 100 占 퐉, and the lenticular pattern has a height of 10 to 50 占 퐉 and a pitch of 20 to 100 占 퐉.

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