KR101931376B1 - Manufacturing method of reflective polizer dispered polymer and device 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) . Also, since the skin layer is formed on at least one surface of the core layer in a molten state, the skin layer is not subjected to a separate adhesion step. 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 The present invention relates to a reflective polarizer and a reflective polarizer,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed and more particularly to a method and an apparatus for producing a reflective polarizer in which a polymer capable of maximizing a light modulation effect is dispersed even when the number of polymer .

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 passes through the reflective polarizer and is transmitted to the liquid crystal assembly. The S polarized light is reflected from the reflective polarizer into the optical cavity, Is transmitted to the reflection type polarizer, and finally S-polarized light is converted into P-polarized light that can pass through the polarizer of the liquid crystal assembly, passes through the reflection type polarizer, and is transmitted to the liquid crystal assembly.

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. When the skin layer of the conventional polycarbonate material is integrated with the core layer alternately laminated with PEN-coPEN, peeling may occur due to the compatibility member, and the degree of crystallization is about 15% There is a high risk of occurrence of birefringence on the axis. Accordingly, in order to apply the polycarbonate sheet of the non-smelting process, an adhesive layer has to be formed between the core layer and the skin layer. 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. In addition, when a multilayer polarizer is manufactured through a feed block and a distributor, it is difficult to control various thicknesses as well as yellowing and carbonization due to an increase in polymer retention time. Therefore, in order to control the visible light region of the wavelength of 380 nm to 780 nm, the reflection polarizing layer having two or more different thicknesses must be extruded and manufactured through the bonding process, since the reflective polarizing function is implemented for one visible light wavelength region Resulting in a defect rate occurrence and a running cost for each process.

Thus, a technical idea has been proposed in which the birefringent polymer stretched in the longitudinal direction in the substrate is arranged to achieve the function of the reflection type polarizer. 2 is a perspective view of a reflective polarizer 20 including a bar-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, there is a problem that the light modulation efficiency is too low as compared with the above-mentioned alternately stacked reflective polarizers. To have a transmittance and a reflectance similar to those of the alternately stacked reflective polarizers, an excessively large number of birefringent polymers 22 There was a problem to be placed. 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 in that it is difficult to produce a spinneret and commercialization is impossible.

In order to overcome this problem, a technical idea including a birefringent sea chart was proposed in the substrate. 3 is a cross-sectional view of a birefringent chart paper included in the inside of the base material. Since 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 a result, the optical characteristics were deteriorated due to light leakage due to pore generation. In addition, due to the structure of the fabric, there is a problem in that reflection and polarization characteristics are limited due to the limitation of the layer structure.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a birefringent polymer having a very small number of birefringent polymers in a substrate as compared with a conventional birefringent polymer, And to provide a method and an apparatus for producing a reflective polarizer having excellent optical properties.

A second problem to be solved by the present invention is to provide a method and apparatus for manufacturing a reflection type polarizer capable of causing modulation of a wide range of light by including a dispersed polymer having a different optical thickness inside a reflection type polarizer.

A third problem to be solved by the present invention is to provide a method and an apparatus for manufacturing a reflective polarizer capable of being integrally formed without forming a separate adhesive layer between a core layer and a skin layer.

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 includes a core layer in which a plurality of first components are dispersed in a second component, and a skin layer formed on at least one surface of the core layer A method of producing a reflective polarizer in which a polymer is dispersed, comprising the steps of: (1) supplying a first component, a second component, and a skin layer component to extruders, respectively; (2) a sea-island complex stream in which a plurality of first components are dispersed in the second component is formed, the sea-island complex stream reflects a transverse wave (S wave) of a desired wavelength and forms an optical thickness of the first components differently The first component and the second component transferred from the extruding section are introduced into a single seawater type extrusion orifice including a separating plate having a part or all of a diameter or a cross sectional area of the component supply paths different from each other, Forming at least one surface of the sea-island composite stream with a skin layer component transferred from the extrusion portion; And (3) inducing spreading in the flow control section such that the first component of the core layer having the skin layer laminated forms a plate-like shape.

According to a preferred embodiment of the present invention, the metal distribution plates may have a plurality of layers and the diameter or cross-sectional area of the conductive partitioning holes forming the same layer may be the same.

According to another preferred embodiment of the present invention, the islands distributing plate may form a plurality of layers of the ingredient supply channels, and the diameter or the cross-sectional area of the conductive partitioning holes forming the same layer may be the same.

According to another preferred embodiment of the present invention, the diameter or cross-sectional area of the conductive bore holes forming the different layers may be different.

According to another preferred embodiment of the present invention, a plurality of layers having the same diameter or cross-sectional area are formed, and the plurality of layers form a group, and the plurality of groups are formed .

According to another preferred embodiment of the present invention, the group may be three, and more preferably, the group may be four or more.

According to another preferred embodiment of the present invention, the aspect ratio of the plate-like shape in the step (4) is 1/300 or less, preferably 1/500 or less, more preferably 1/1000 or less, 2000 or less, more preferably 1/3000 or less, more preferably 1/5000 or less, still more preferably 1/10000 or less, and most preferably 1/20000 or less.

According to another preferred embodiment of the present invention, the first component is at least one selected from the group consisting of polyethylene naphthalate (PEN), co-polyethylene 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) , 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) , 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 skin layer component may be 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 (ABS), polyurethane (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile blend (SAN), ethylene vinyl acetate (EVA), polyamide (PA) ), Phenol, epoxy (EP), urea (UF), melamine (MF), unsaturated polyester (UP), silicone (SI) and cycloolefin polymers.

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

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 pressing unit to the seawater extrusion orifice .

According to another preferred embodiment of the present invention, the partitioning holes of the detachable distribution plate included in the inside of the isometric extrusion opening may be arranged in zigzags.

According to another preferred embodiment of the present invention, at least one or more of the diameter and the cross-sectional area of the bead separation holes of the detachable distribution plate included in the inside of the seawater extrusion orifice may be different.

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 the step (3), the step of stretching the reflective polarizer in which the polymer is dispersed may be included.

According to another preferred embodiment of the present invention, after the stretching step, the aspect ratio of the plate-like shape is 1/1000 or less, preferably 1/2000 or less, preferably 1/3000 or less, preferably 1/5000 or less, Preferably not more than 1/10000, more preferably not more than 1/20000, more preferably not more than 1/30000, more preferably not more than 1/50000, and most preferably not more than 1/70000.

According to a preferred embodiment of the present invention, there is provided a device for manufacturing a reflective polarizer in which a polymer is dispersed, comprising a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer, , Wherein at least three extruding portions into which the first component, the second component and the skin layer component are separately introduced; Type composite stream in which the first component is dispersed in the second component, and the sea-island complex stream is formed by mixing the extruded portion into which the first component is introduced and the second component And a corrugated distribution plate having a part or all of a diameter or a cross-sectional area of the elementary-ingredient supply paths forming the sea-island complex flow into which the first component and the second component transferred from the charged extruded part are introduced, A spin block portion communicating with the extruded portion into which the skin layer component is inserted and having a skin layer laminated on at least one surface of the sea-island composite stream; And a first component of a sea-island composite stream having a skin layer transferred from the spin block part is formed so as to form a plate-like shape having an aspect ratio of 1/200 or less, which is a ratio of a short axis length to a long axis length, And a flow control section for leading the spread.

According to another preferred embodiment of the present invention, the plate-like shape has an aspect ratio of 1/200 or less, 1/300 or less, preferably 1/500 or less, more preferably, Is preferably 1/1000 or less, more preferably 1/2000 or less, still more preferably 1/3000 or less, still more preferably 1/5000 or less, still more preferably 1/10000 or less, and most preferably 1/200 ≪ / RTI >

According to another preferred embodiment of the present invention, the number of layers of the ingredient supply channels of the detachment distribution plate included in the sea-island type push-out unit is 100 or more, preferably 200 or more, more preferably 400 or more, More preferably, it may be 600 or more.

According to another preferred embodiment of the present invention, at least one of the cross-sectional area or the diameter of the ingredient supply channels of the detention distribution plate included in the sea-island extrusion / detachment unit may be different.

According to another preferred embodiment of the present invention, the spin block unit may include first pressing means for discharging the first component transferred from the extrusion unit and supplying the discharged first component to the male-like extrusion orifice.

According to another preferred embodiment of the present invention, the spin block unit may include a second pressing unit that discharges the second component transferred from the extrusion unit and supplies the discharged second component to the male-type extrusion orifice.

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

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) . Also, since the skin layer is formed on at least one surface of the core layer in a molten state, the skin layer is not subjected to a separate adhesion step. 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.

1 is a schematic view for explaining the principle of a conventional reflective polarizer.
2 is a perspective view of a reflection type polarizer including a bar-shaped polymer.
3 is a cross-sectional view showing a path of light incident on a birefringent graphite sheet used for a reflective polarizer.
Figs. 4 and 5 are perspective views showing a coupling structure of the crotch distribution plates of a sea-island type extrusion orifice which can be used in the present invention.
6 is a cross-sectional view of a claw distribution plate according to another preferred embodiment of the present invention.
FIG. 7 and FIG. 8 are cross-sectional views showing an arrangement of a furnace distribution furnace (spinner hole) of a detour distribution plate according to a preferred embodiment of the present invention in detail.
Figs. 9 and 10 are perspective views illustrating a coupling structure of a cowling distribution plate of a sea-island type extrusion cortex that can be used in the present invention.
FIG. 11 is a schematic view including a first pressing means for forming a sea current type complex flow according to a preferred embodiment of the present invention. FIG.
FIG. 12 is a schematic view including a second pressing means for forming a sea-island type combined flow according to a preferred embodiment of the present invention.
Figure 13 is a cross-sectional view of a coat-hanger die in accordance with a preferred embodiment of the present invention, and Figure 14 is a side view.
15 is a cross-sectional view of a reflective polarizer according to an embodiment of the present invention.
16 is a cross-sectional view of a reflective polarizer according to another embodiment of the present invention.
17 is a perspective view of a reflective polarizer according to a preferred embodiment of the present invention.
18 is a cross-sectional view of a sheet-like polymer according to a preferred embodiment of the present invention.
19 is a cross-sectional view of a plate-like polymer according to another preferred embodiment of the present invention.
20 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.
21 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.
22 is an exploded perspective view of a liquid crystal display device including the reflection type polarizer 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 of the present invention is dispersed, comprising the steps of: forming a core layer in which a plurality of first components are dispersed in a second component; (1) supplying a first component, a second component, and a skin layer component to the extrusion units, respectively; (2) a sea-island complex stream in which a plurality of first components are dispersed in the second component is formed, the sea-island complex stream reflects a transverse wave (S wave) of a desired wavelength and forms an optical thickness of the first components differently , A first component and a second component transferred from the extruding section are introduced into a sea-island extrusion port including a separating distribution plate having a part or all of the diameter or cross-sectional area of the component supply channels different from each other, And joining at least one surface of the sea-island composite stream with a skin layer component transferred from the extrusion portion; And (3) inducing the spreading in the flow control section such that the first component of the core layer in which the skin layer is laminated forms a plate-like shape

First, in step (1), the first component, the second component, and the skin layer 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 Monomers such as dimethyl-2,6-naphthalene dicarboxylate, dimethyl terephthalate and ethylene glycol, cyclohexanedimethanol (CHDM) may be suitably polymerized co-PEN.

The skin layer component can be used without limitation as long as it is usually used in a reflective polarizer in which a polymer is dispersed. Preferably, the skin layer component may be a polyethylene terephthalate (PET), a polycarbonate (PC), a polycarbonate (PC) ), Heat resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane ), Polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile blend (SAN), ethylene vinyl acetate (EVA), polyamide (PA), polyacetal (POM) (UF), melamine (MF), unsaturated polyesters (UP), silicon (SI) and cycloolefin polymers. The polycarbonate alloy is preferably made of a polycarbonate and a modified glycol polycyclohexylene dimethylene terephthalate (PCTG), more preferably a polycarbonate and a modified glycol polycyclohexane (PCTG) may be a polycarbonate alloy having a weight ratio of 5:95 to 95: 5. In the meantime, the skin layer of the present invention is preferably made of a material having a small change in refractive index in the spreading and stretching process, more preferably polycarbonate or polycarbonate glass.

Meanwhile, the first component, the second component, and the skin layer component may be separately supplied to the independent extrusion units. In this case, the extrusion unit may be composed of three 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, in step (2), a sea-island complex stream in which a plurality of first components are dispersed is formed in the second component, the sea-island complex stream reflects a transverse wave (S wave) of a desired wavelength, The first component and the second component transferred from the extruding section are introduced into a sea-island extrusion orifice containing a separating plate having a part or all of the diameter or cross-sectional area of the component supply channels different from each other, Type composite stream and at least one side of the sea-island composite stream is interwoven with the skin layer component transferred from the extruding section.

Next, in step (2), a sea-island composite stream in which a plurality of first components are dispersed in the second component is formed, and in order to reflect a transverse wave (S wave) of a desired wavelength, And the first component and the second component transferred from the first component and the second component are introduced into the seawater extrusion port to form a single sea-type complex flow.

4 and 5 are perspective views showing the coupling structure of the cage-shaped distribution plates of the sea-type push-out apparatus, which can be used in the present invention. The first holding distribution plate S1 positioned at the upper end of the sea-island extrusion opening may include a first component supply path 50 and a 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 separate 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. [ In the fourth corrugated distribution plate S4, the number of the component layers is at least 25, more preferably at least 50, more preferably at least 100, even more preferably at least 200, even more preferably at least 400 Or more, and most preferably, 600 or more. 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. 4 and 5 are illustrative examples of the 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 the first component is dispersed in the 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 path in the fourth bundling distribution plate S4 increases, the bonding phenomenon may also occur between the components (first components). In order to prevent this, as shown in FIG. 6, the islands supply channel may be divided and the sea salt supply channels 71 and 72 may be formed on the partition to allow the sea salt to permeate more smoothly between the 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.

FIG. 7 shows an arrangement of the ingredient supply passages which can be included in the fourth pick-up distribution plate, and the ingredient supply passages forming the same layer L1 have the same diameter. On the other hand, the diameter of the islands supply paths forming the other layer L2 and the diameter of the islands supply paths forming another layer L3 are the same. On the other hand, the diameter (a) of the component supply path of L1, the diameter (b) of the component supply path of L2 and the diameter (c) of the component supply path of L3 are in the order of b> The arrangement of these layers can be repeated randomly or randomly. The reflective polarizer manufactured through this method can form the optical thickness of the plate-like polymer contained therein differently for each layer, which is very advantageous in achieving modulation of a wide range of light.

FIG. 8 shows an arrangement of the ingredient supply channels that can be included in the fourth detachable distribution plate according to another preferred embodiment of the present invention. Specifically, layers having the same diameter of the component supply paths are gathered to form four groups 81, 82, 83, 84. In this case, the diameter or the cross-sectional area of the component supply paths included in the same group are substantially the same, but the diameter or the cross-sectional area of the component supply paths included in the different groups may be different from each other. In this case, the cross-sectional areas of the supply lines included in the respective groups 81, 82, 83, and 84 may be arranged in the order of b>c>d> a. Also, the number of layers forming one group may be 100 or more, and preferably 200 or more. The reflection type polarizer manufactured through this method can minimize the aggregation of polymers because the plate type polymers having different optical thicknesses and aspect ratios form a plurality of groups. In addition, the supply lines of the supply lines are arranged in a zigzag manner, thereby minimizing the light leakage phenomenon.

Figures 9 and 10 are views of the detachment of a sea-island extrusion nozzle according to one preferred embodiment of the present invention. Specifically, there are 6 custodial distribution plates (T1 to T6) for the sea-view reflex custody, and the fourth custody distribution plate (T4) and the fifth custody distribution plate (T5) differ from the custody distribution plate of FIG. 4, the fourth holding distribution plate T4 of FIG. 9 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 sea-island composite stream through the fourth pickling distribution plate T4 and the fifth pickling distribution plate T5 in 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.

On the other hand, the above-mentioned sea-island complex streams may have different optical thicknesses of the first component dispersed inside the second component so as to cover the respective wavelength range of the different light. To this end, the diameter, cross-sectional area, shape, and / or number of layers of the ingredient supply path and / or the sea component supply path included in the same isometric extrusion opening may be different. Accordingly, the reflection type polarizer finally manufactured through the spreading and stretching process is very advantageous because the plate-shaped polymers formed therein can have various optical thicknesses and thus include the entire visible light region.

More specifically, the optical thickness means n (refractive index) x d (physical thickness). Therefore, it is possible to cause a variation in the optical thickness of the first component included in the sea-island complex type by differently controlling the cross-sectional area, the diameter, and the like of the captive hole of the sea-island extrusion port, It is possible to reflect the S wave in the wavelength region of the light and to transmit the P wave.

More specifically, 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 soot supply path from one seawater extrusion orifice.

According to another preferred embodiment of the present invention, the first component transferred from the extrusion unit is discharged between the steps (1) and (2) through the first pressing unit as a different isostatic pressing unit . Specifically, FIG. 11 is a schematic view including a first pressing means, in which a first component transferred from an extruding portion (not shown) is supplied to the first pressing means 130, Can be supplied to the extrusion opening 132. For this, the discharge amount of the first pressurizing unit 130 may be 1 to 100 kg / hr, but is not limited thereto.

And the second component transferred from the extruding unit may be discharged through the second pressurizing unit into different seawater extrusion orifices. Specifically, Fig. 12 is a schematic view including a second pressing means, in which a second component transferred from an extrusion portion (not shown) is supplied to the second pressing means 140, And can be supplied to the extrusion opening 142. For this, the discharge amount of the second pressurizing unit 130 may be 1 to 100 kg / hr, but is not limited thereto.

Thereafter, at least one surface of the formed single sea chart type composite stream is joined with the skin layer component transferred from the extrusion portion. Preferably, the skin layer component may be laminated on both sides of the core layer.

Next, as a step (3), the first component of the core layer in which the skin layer is laminated induces a spread in the flow control section to form a plate-like shape. Specifically, Figure 13 is a cross-sectional view of a coat-hanger die, which is one type of preferred flow control that may be applied to the present invention, and Figure 14 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. 13, since the core layer having the skin layer sandwiched therebetween is spread widely from side to side in the coat-hanger die, the first component included therein also spreads to the left and right. Also, as shown in the side view of FIG. 14, 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.

According to a preferred embodiment of the present invention, the step (3) may further include the step of extending the reflection type polarizer, and more particularly, (4) the step of cooling the polarizer And (5) stretching the polarizer through the smoothing step; And (6) opening and fixing the stretched polarizer.

First, as a step of cooling and smoothing the polarizer transferred from the flow control unit as the step (4), it is possible to cool it, solidify it, and then perform a smoothing step through a casting roll process or the like.

Thereafter, a step of stretching the polarizer through the smoothing step is 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, in step (6), the final reflective polarizer can be manufactured through a step of fixing the stretched polarizer. The hot fix may be heat-set through a conventional method, preferably at 180 to 200 ° C for 0.1 to 3 minutes through an IR heater, a ceramic heater, a hot air heater, or the like. When the target optical thickness and 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 unit, and the stretching ratio are appropriately controlled in consideration of the target optical thickness and aspect ratio, You can do it.

The reflection type polarizer in which the polymer produced by the above method is dispersed is characterized in that a skin layer is formed on at least one surface of the core layer and the core layer, and in order to transmit the first polarized light irradiated from the outside and reflect the second polarized light, Wherein the core layer comprises a plurality of polymers dispersed within the substrate (a plurality of discontinuous phases dispersed within the continuous phase), the plurality of polymers having different refractive indices in at least one axial direction from the substrate, A polymer having a light modulating interface formed between the polymer and the substrate and having an aspect ratio of 1/1000 or less which is the ratio of the short axis length to the long axis length based on the vertical cross section of the polarizer. The core layer and the skin layer are integrally formed and do not include an adhesive layer.

15 is a cross-sectional view of a reflective polarizer according to an exemplary embodiment of the present invention. Skin layers 181 and 182 are formed on both sides of a core layer 180. Inside the core layer 180, A plurality of polymers 183, 184, 185, 186 are dispersed. In this case, the dispersed polymers 183, 184, 185, and 186 may be of a plate-like shape having an aspect ratio of 1/1000 or less, which is a ratio of the minor axis length to the major axis length, The polymer may have an appropriate optical thickness to reflect the desired (S wave) wavelength region of light and may have a thickness variation within a suitable range.

 Here, the optical thickness means n (refractive index) x d (physical thickness). 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, if the average optical thickness of the polymers is 150 nm, it is possible to reflect a transverse wave (S wave) of a wavelength of 400 nm by the relational expression (1). In this case, if the thickness deviation is 30%, it is possible to cover the wavelength band of about 420 to 780 nm. When the first component, the plate-like polymer, has optical birefringence, the P wave must be transmitted and the S wave must be reflected, so that the refractive index (n) is set based on the thickness direction (z axis refractive index) can do. Therefore, preferably, the optical thickness of the polymers may be 1/3 to 1/5 of the desired wavelength ([lambda]).

On the other hand, 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 100 or more, preferably 150 or more, more preferably 200 or more, more preferably 400 or more, most preferably 600 or more Or more. In order to maximize the light modulation effect, the polymers forming the adjacent layers may be arranged in zigzags as in FIG.

On the other hand, in order to improve the light modulation effect, the average distance d ₁ of adjacent polymers forming the same layer as the average distance d ₂ of the incoming polymers forming the different layers may be small. This minimizes the distance between the polymers forming the same layer, thereby reducing the light leakage phenomenon and maximizing the light modulation effect.

According to a preferred embodiment of the present invention, the core layer and the skin layer are integrally formed. 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. Further, since the skin layer is produced simultaneously with the core layer and then the stretching process is performed, unlike the conventional adhesion of the core layer after stretching to the unstretched skin layer, the skin layer of the present invention can be stretched in at least one axial direction. As a result, the surface hardness is improved as compared with the non-drawn skin layer, and the scratch resistance is improved and the heat resistance can be improved.

16 is a cross-sectional view of a reflective polarizer according to another embodiment of the present invention. 15, the polymers having different average optical thicknesses inside the core layer are aligned with the groups, which can be achieved through the above-described prism distribution plate of FIG. As a result, it is possible to cover various light wavelength bands, thereby reflecting not only S waves in the entire visible light region but also minimizing the problem of adhesion of polymers.

FIG. 17 is a perspective view of a reflective polarizer according to an embodiment of the present invention, in which a plurality of polymers 211 are stretched in the longitudinal direction inside a second polymer 210, and the cross-sectional shape is a plate-like shape. Skin layers 212 and 213 are formed on both sides of the second polymer 210. 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.

According to a preferred embodiment of the present invention, the aspect ratio of the shape of the vertical cross section in the longitudinal direction of the polymer is the short axis length to the major axis length is 1/1000 or less. 18 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 length of the major axis length a to the minor axis length b (aspect ratio ) 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. 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.

More specifically, in the case of a display having a size of 1580 mm and a height of 400 μm based on a 32-inch reference display based on a vertical cross section of the reflective polarizer, 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, further preferably 1/10000 or less or 1/20000 or less, more preferably 1/30000 or less, still more preferably 1/50000 or less Preferably from 1/70000 to 1/200000.

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 3,000, the number of the plate-like polymers forming one layer is 30 to 1,000, Lt; / RTI > Also, the distance between adjacent plate-shaped polymers forming one layer may be at most 0.001 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 core layer may have a thickness of 20 to 180 탆, and the skin layer may have a thickness of 50 to 300 탆, but the present invention is not limited thereto.

According to a preferred embodiment of the present invention, the polymer may be coated with a third material or further contain another material inside the polymer. Specifically, FIG. 19 may further include a third material 191, such as a filler, metal particles, polymer, etc., inside the polymer 190 as a cross section of the polymer according to a preferred embodiment of the present invention. In this case, the third material 191 included may have different refractive indexes so as to form a birefringent interface with the polymer. For example, when the optical properties of the polymer 190 are birefringent, the third material 191 may have optical isotropy to form a birefringent interface with the polymer 190. The third material 191 may also be an elongated body extending in the longitudinal direction of the polymer. Furthermore, even when the polymer is coated with the third material, it is possible to form the third material such that it can be formed at the birefringence interface between the base material and / or the polymer and the coated third material, The refractive index of the material can be appropriately adjusted.

According to a preferred embodiment of the present invention, there is provided a device for manufacturing a reflective polarizer in which a polymer is dispersed, comprising a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer, , Wherein at least three extruding portions into which the first component, the second component and the skin layer component are separately introduced; Type composite stream in which the first component is dispersed in the second component, and the sea-island complex stream is formed by mixing the extruded portion into which the first component is introduced and the second component And a corrugated distribution plate having a part or all of a diameter or a cross-sectional area of the elementary-ingredient supply paths forming the sea-island complex flow into which the first component and the second component transferred from the charged extruded part are introduced, A spin block portion communicating with the extruded portion into which the skin layer component is inserted and having a skin layer laminated on at least one surface of the sea-island composite stream; And a first component of a sea-island composite stream having a skin layer transferred from the spin block part is formed so as to form a plate-like shape having an aspect ratio of 1/200 or less, which is a ratio of a short axis length to a long axis length, And a flow control section for leading the spread.

20 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. Specifically, the first extrusion part 220 into which the first component is injected, the second extrusion part 221 into which the second component is injected, and the third extrusion part 222 into which the skin layer component is injected. The first extruding part 220 is connected to the spin block part C including the sea-island extrusion opening 223 and supplies the first component in a molten state. The second extruding part 221 is also connected to the spin block part C and supplies the second component to the sea type extrusion orifice 223 contained therein in a molten state. And produces a sea-island complex stream in which the first component is dispersed in the second component through the sea-island extrusion opening 223. The sea-island extrusion port 223 may be one. The seawater extrusion orifice 223 may be a sea-island extrusion orifice as shown in FIG. 4 or FIG. Also, the diameter or the cross-sectional area of the ingredient supply path and / or the sea component supply path included in the sea-island extrusion port may be different. The skin layer component transferred from the third extruding unit 222 may be interwoven with the sea-island composite stream manufactured in the spin block unit C. For this purpose, the spin block part C further includes a separate joint part, or a sea-island complex flow is generated in the sea-likes extrusion opening 223 when the third extrusion part 222 is communicated with the sea-island extrusion opening 223 And the skin layer can be laminated.

Then, the core layer having the skin layer formed thereon is transferred to the flow controller 225, and the spread of the first component is induced to form a plate-like shape. Preferably, the flow control may be a T-die or a coat-hanger die.

21 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. 20, the first extruding unit 220 feeds the first component to the first pushing unit 230. In this case, The first pressurizing means (230) discharges the first component into the seawater extrusion orifice (223). The second extruding portion 221 feeds the second component to the second pressing means 231. The second pressing means 231 discharges the second component to the hydrographic extrusion orifice 223. On the other hand, it is also possible that a plurality of first pressing means and two pressing means exist. A sea-island complex stream in which the first component is dispersed within the second component is produced through the sea-island extrusion opening 223. The first pushing means 230, the second pushing means 231 and the sea-island extrusion opening 223 form a spin block portion C.

According to a preferred embodiment of the present invention, there is provided a liquid crystal display device including the reflective polarizer of the present invention. Specifically, FIG. 22 shows an example of a liquid crystal display device employing the reflective polarizer of the present invention, in which a reflection plate 280 is inserted on a frame 270, a cold cathode fluorescent lamp 290 is mounted on the upper surface of the reflection plate 280, . An optical film 320 is disposed on the upper surface of the cold cathode fluorescent lamp 290. The optical film 320 includes a diffusion plate 321, a light diffusion film 322, a prism film 323, a reflection type polarizer 324 and the absorption polarizing film 325 are stacked in this order, but the order of lamination may be changed depending on the purpose, or a part of the constituent elements may be omitted or a plurality of them may be provided. For example, the diffusion plate 321, the light diffusion film 322, the prism film 323, and the like may be omitted from the overall configuration and may be changed in order or formed at different positions. Further, a phase difference film (not shown) or the like can also be inserted at an appropriate position in the liquid crystal display device. Meanwhile, the liquid crystal display panel 310 may be positioned on the upper surface of the optical film 320 by being inserted into the mold frame 300.

The light emitted from the cold cathode fluorescent lamp 290 reaches the diffuser plate 321 of the optical film 320. The light transmitted through the diffusion plate 321 passes through the light diffusion film 322 in order to advance the proceeding direction of the light perpendicularly to the optical film 320. The film having passed through the light diffusion film 322 reaches the reflection type polarizer 324 after passing through the prism film 323, thereby causing light modulation. Specifically, the P wave passes through the reflection type polarizer 324 without loss, but light modulation (reflection, scattering, refraction, etc.) occurs in the case of the S wave and is reflected again by the reflection plate 280, which is the back surface of the cold cathode fluorescent lamp 290 And the properties of the light are randomly changed into a P wave or an S wave, and then pass through the reflective polarizer 324 again. And then reaches the liquid crystal display panel 310 after passing through the absorption polarizing film 325. [ As a result, when the reflective polarizer of the present invention is inserted into a liquid crystal display device due to the above-described principle, remarkable improvement in luminance can be expected as compared with a general reflective polarizer. Meanwhile, the cold cathode fluorescent lamp 290 may be replaced with an LED.

In the present invention, the use of the reflective polarizer is described mainly with respect to the liquid crystal display, but the present invention is not limited thereto, and can be widely used in flat panel display technologies such as projection display, plasma display, field emission display and electroluminescence display.

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, a refractive index of 1.64 and a refractive index obtained by polymerizing 90 wt% of polycarbonate and 10 wt% of polycyclohexylene dimethylene terephthalate (PCTG) as a skin layer component 1.58 were injected into the first extruding portion, the second extruding portion and the third extruding portion, respectively. The extrusion temperature of the first component and the second component was 295 캜, and Cap. The polymer flow was calibrated through adjustment and the skin layer was subjected to an extrusion process at a temperature level of 280 占 폚. The first component was transferred to the first pressurizing means (Kawasaki gear pump) and the second component was also transferred to the second pressurizing means (Kawasaki gear pump). The discharge amounts of the first pressurizing means are respectively 8.9 kg / h and 8.9 kg / h, respectively. And a sea-island type mixed flow was manufactured by using the sea-island type extrusion-opening as shown in Fig. Specifically, in the fourth corrugated distribution plate T4 of the sea-island type extrusion / taking-off section, the diameter of the retaining hole of the ingredient supply passage of the A group 81 is 0.17 mm, and the diameter of the retaining hole of the ingredient supply passage of the B group 82 is 0.44 mm, and the diameter of the through hole of the component supply path of the C group 83 is 0.38 mm, the diameter of the through hole of the component supply path of the D group 84 is 0.23 mm, The diameter of discharge port of the sixth detention distribution plate was 15 mm × 15 mm. Then, skin layer components flowed through the flow path from the third extruded portion to form a skin layer on the upper and lower surfaces of the sea-island composite stream (core layer polymer). 13 and 14 for correcting the flow velocity and the pressure gradient of the core layer polymer such that the aspect ratio of the sea-island complex flow is 1/117330 for A group, 1/64470 for B group, 1/76590 for C group and 1/94380 for D group, Spreading was induced on a coat hanger die with a width of 1,260 mm.

The spread of the core layer polymer on which the skin layer was formed was induced in the coat hanger die of Figs. 13 and 14 to correct the flow rate and pressure gradient. Specifically, the width of the die inlet is 200 mm, the thickness is 20 mm, the width of the die outlet is 960 mm, the thickness is 2.4 mm, and 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 carried out 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 core layer thickness is 59 占 퐉, and the skin layer thickness is 170.5 占 퐉 at the upper and lower portions.

≪ Example 2 >

The process was carried out as in Example 1. As shown in FIG. 8, four groups are formed, and the number of catalyst layers in each group is 150. The number of elemental supply channels included in one layer is 5625. The intermediate conditions were the same as in Example 1, and the aspect ratios of the sea-island composite streams were changed to 1260 mm coat-hanger so that the aspect ratio of A group was 1/87998, B group 1/48352, C group 1/57443 and D group was 1/70785. The spreading process was performed on the die. Thereafter, the same process as in Example 1 was carried out to prepare a reflective polarizer in which the polymer was dispersed as shown in Fig. The refractive index of the first component of the produced reflection polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.62.

≪ Example 3 >

The process was carried out as in Example 1. Specifically, a PEN having a refractive index of 1.65 as a first component and a PEN having a refractive index of 1.59 as a second component polymerized with 30% by weight of 70% by weight of polycarbonate and 30% by weight of polycyclohexylene dimethylene terephthalate (PCTG) A polycarbonate alloy and polycarbonate pieces having a refractive index of 1.58 obtained by polymerizing 90% by weight of polycarbonate and 10% by weight of polycyclohexylene dimethylene terephthalate (PCTG) as a skin layer component, The second extruding portion, and the third extruding portion. The intermediate conditions were the same as in Example 1, and the coat-hangers were formed at a width of 1260 mm such that the aspect ratio of the sea-island composite streams was 1/455, group B 1/250, group C 1/297, The spreading process was performed on the die. Thereafter, the same process as in Example 1 was carried out to prepare a reflective polarizer in which the polymer was dispersed as shown in Fig. The refractive index of the first component of the manufactured reflection polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.575.

≪ Comparative Example 1 &

A reflection type polarizer for a 32-inch LCD including 25,000 birefringent fibers composed of PEN, which is a first component having a diameter of 0.158 mu m, was manufactured inside the CO-PEN substrate as the second component.

≪ Comparative Example 2 &

The process was performed as in Example 3. Specifically, a PEN having a refractive index of 1.65 as a first component and a PEN having a refractive index of 1.59 as a second component polymerized with 30% by weight of 70% by weight of polycarbonate and 30% by weight of polycyclohexylene dimethylene terephthalate (PCTG) A polycarbonate alloy and polycarbonate pieces having a refractive index of 1.58 obtained by polymerizing 90% by weight of polycarbonate and 10% by weight of polycyclohexylene dimethylene terephthalate (PCTG) as a skin layer component, The second extruding portion, and the third extruding portion. The discharge amount of the first pressurizing means was 4.5 kg / h under the same condition as in Example 1, except that the number of layers of the cage holes included in the fourth cage distribution plate was 800, and the diameters of the cage holes were all 0.17 mm. 2 The discharge amount of the pressurizing means is 8.9 kg / h. The spreading process was performed on a coat-hanger die such that the aspect ratio of the sea-island composite stream was 1/142 under the same conditions as in Example 1. [ Thereafter, the same process as in Example 3 was carried out to prepare a reflective polarizer in which the polymer as shown in FIG. 15 was dispersed. The refractive index of the first component of the manufactured reflection polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.59.

<Experimental Example>

The following properties of the reflective polarizer prepared in Examples 1 to 3 and Comparative Examples 1 and 2 were evaluated, and the results are shown in Table 1.

1. Transmittance

Transmission axis transmittance and reflectance axis transmittance were measured by ASTM D1003 method using COH300A analysis equipment of NIPPON DENSHOKU, Japan.

2. Polarization degree

The degree of polarization was measured using a RETS-100 analyzer from OTSKA.

3. 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.

Relative luminance is a relative value of the luminance of the other Examples 2 to 3 and Comparative Examples 1 and 2 when the luminance of the reflection type polarizer of Example 1 is taken as 100 (standard).

Relative luminance (%) Polarization degree (? = 550 nm) Polarization degree (? = 650 nm) Polarization degree Transmission axis transmittance Reflective axis transmittance Polarization degree Transmission axis transmittance Reflective axis transmittance Example 1 100 85% 88.5% 7% 83% 90% 8% Example 2 96 80% 88.5% 10% 78% 90% 11% Example 3 92 66% 88.5% 18% 65% 90% 19% Comparative Example 1 80 43% 89.5% 35% 35% 90.5% 43% Comparative Example 2 86 56% 89.5% 25% 52% 90.5% 28%

As can be seen from Table 1, it can be confirmed that the reflection type polarizers of Examples 1 to 3 of the present invention have remarkably improved optical properties as compared with the reflection type polarizers of Comparative Examples 1 and 2.

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 (28)

A method for manufacturing a reflective polarizer in which a polymer is dispersed, the method comprising: preparing a reflective polarizer comprising a core layer having a first component dispersed therein and a skin layer formed on at least one surface of the core layer,
(1) supplying the first component, the second component, and the skin layer component to the extruding portions, respectively;
(2) In order to form a sea-island composite stream in which a plurality of first components are dispersed in the second component, a plurality of harvesting distribution boards are laminated and the first component And a second component are added to form a sea-island composite stream, and at least one side of the sea-island composite stream is sandwiched with the skin layer component transferred from the extruded section; And
(3) inducing spreading in the flow control section so that the first component of the sea-island composite stream having the skin layer laminated forms a plate-like shape having an aspect ratio of 1/200 or less as a ratio of the short axis length to the long axis length with respect to the vertical cross section; , &Lt; / RTI &
Said plurality of detent distribution plates comprising an upper detent distribution plate, a seahorse detent distribution plate and a bottom detent distribution plate which are sequentially stacked in a vertical direction,
Wherein the upper detachment distribution plate includes at least two detachment distribution plates stacked in a vertical direction, wherein the detachment distribution plate disposed at the lower one of the at least two detachment distribution plates includes a detent plate The number of the detaching holes through which the first component and the second component respectively flow out is disposed adjacent to and above the first component and the second component so that the flow of the first component and the second component is branched so that the first component and the second component flow out in an increased flow number Is designed to be greater than the number of detention halls of the detention distribution plate,
Wherein the isothermal distribution plate includes a first component supply path assembly portion formed of a plurality of component supply paths for allowing a first component introduced through the upper detachment distribution plate to flow out and forming a plurality of component components flows, And a second component supply path disposed adjacent to the first component supply path assembly part such that two components can permeate between the plurality of component flow streams,
Characterized in that a part or the whole of the diameter or cross-sectional area of the island-shaped compound supply channels is different in order to reflect the transverse waves (S waves) of a desired wavelength and to form the optical thicknesses of the first components differently. Is dispersed. The method according to claim 1,
Wherein the holding distribution plate has a plurality of layers and the diameter or cross-sectional area of the conductive partitioning holes forming the same layer is the same. 3. The method of claim 2,
Characterized in that the diameter or cross-sectional area of the conductive bore holes forming the different layers is different. 3. The method of claim 2,
Wherein a plurality of layers having the same diameter or cross-sectional area of the conductive paste-containing holes contained therein are formed. 5. The method of claim 4,
Wherein the plurality of layers form a group, and a plurality of the groups are formed. 6. The method of claim 5,
Wherein the number of the groups is three or more. 6. The method of claim 5,
Wherein the number of the groups is four or more. 6. The method of claim 5,
Wherein the number of layers included in a single group is 100 or more. 6. The method of claim 5,
Wherein the number of layers included in a single group is 200 or more. The method according to claim 1,
Wherein the aspect ratio of the plate-like shape is 1/1000 or less. The method according to claim 1,
Wherein the aspect ratio of the plate-like shape is 1/5000 or less. The method according to claim 1,
Wherein the aspect ratio of the plate-like shape is 1/20000 or less. The method according to claim 1, further comprising the steps of (1) and (2)
Wherein the first component transferred from the extrusion unit is discharged through a first pressing unit to a seawater extrusion orifice. The method according to claim 1, further comprising the steps of (1) and (2)
And the second component transferred from the extruding unit is discharged through a second pressing unit to a seawater extrusion orifice. 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, wherein, after the step (3)
And a step of stretching the reflective polarizer in which the polymer is dispersed. 17. The method of claim 16,
Wherein the aspect ratio of the plate-like shape after the elongating step is 1/1000 or less. 17. The method of claim 16,
Wherein after the stretching step, the aspect ratio of the plate-like shape is 1/10000 or less. There is provided an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed, the polymer polarizer including a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer,
Three or more extruders into which the first component, the second component and the skin layer component are separately introduced;
And a single sea type extrusion port integrally formed by laminating a plurality of compartmentalization distribution plates for forming a sea-island complex stream in which the first component is dispersed in the second component, Wherein said top detent distribution plate comprises at least two detent distribution plates stacked in a vertical direction, said at least two detent plates being stacked in sequence, said at least two detent plates being stacked vertically, The cocoon distribution plate disposed at the lower part of the distribution plate branches off the flow of the first component and the second component that are introduced from the cocoon distribution plate disposed adjacent to the upper side to divide the first component and the second component downward The number of the detaching holes through which the first component and the second component respectively flow out is designed so as to be larger than the number of the detaching holes of the detachable distribution plate disposed on the upper side in order to allow the first component and the second component to flow out, A first component supply path assembly part formed of a plurality of component supply paths for allowing the first component introduced through the upper holding distribution plate to flow out and forming a plurality of component components flows, And a second component supply path disposed adjacent to the first component supply path aggregation part so that the component can permeate between the plurality of the component flow streams, And the first component and the second component transferred from the extruded portion into which the first component is introduced and the second component are introduced into the extruded portion into which the first component is introduced, A spin block portion in which a skin layer is joined to at least one surface of a sea-island composite stream which is partially or wholly different and communicates with an extruded portion into which the skin layer component is injected; And
And a flow control unit for guiding the spread of the first component of the sea-island complex stream having the skin layer conveyed in the spin block unit to form a plate-like shape having an aspect ratio of 1/200 or less with respect to the vertical cross- Wherein the polymer is dispersed. 20. The method of claim 19,
Wherein the plate-like shape has an aspect ratio of 1/2000 or less that is a ratio of a short axis length to a long axis length with respect to a vertical cross section. 20. The method of claim 19,
Wherein the plate-like shape has an aspect ratio of 1/10000 or less as a ratio of the minor axis length to the major axis length with respect to the vertical cross section. 20. The method of claim 19,
The holding distribution plate is characterized in that the conductive filler holes forming the same layer have the same diameter or cross sectional area and the diameter or sectional area of the conductive paste-making holes forming the different layers are different from each other. Wherein the polymer is dispersed. 23. The method of claim 22,
Wherein the plurality of layers form a group, and a plurality of the groups are formed. 24. The method of claim 23,
Wherein the number of layers included in a single group is 100 or more. 20. The apparatus according to claim 19, wherein the spin block portion includes first pressing means for discharging the first component transferred from the extrusion portion and supplying the discharged first component to the island-shaped extrusion orifice. 20. The apparatus according to claim 19, wherein the spin block portion includes a second pressing means for discharging the second component transferred from the extrusion portion and supplying the second component to the island-like extrusion orifice. 20. The apparatus of claim 19, wherein the flow controller is a T-die. 20. The apparatus of claim 19, wherein the flow control unit is a coat-hanger die.

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