KR102248880B1 - Alignment film, polarizing plate, and retardation plate, method thereof manufacturing, and apparatus therefor - Google Patents

Abstract

The present invention relates to an alignment layer, a polarizing plate, a retardation plate, an alignment layer manufacturing method, and an alignment layer manufacturing apparatus, in particular, comprising a substrate and an alignment layer formed on the substrate, wherein the alignment direction of the alignment layer is parallel to the surface of the substrate and one direction in the plane is It relates to an alignment film that continuously changes along with it. In addition, the present invention relates to a polarizing plate and a retardation plate including the alignment layer, and to a polarizing plate and a retardation plate in which optical axes of the polarizing plate and the retardation plate continuously change.
In addition, the present invention relates to an optical element including the polarizing plate or the retardation plate. And, it relates to an optical filter or window capable of continuously adjusting the amount of light transmitted by using the polarizing plate or the retardation plate.

Description

Alignment film, polarizing plate, and retardation plate, manufacturing method and manufacturing apparatus thereof {ALIGNMENT FILM, POLARIZING PLATE, AND RETARDATION PLATE, METHOD THEREOF MANUFACTURING, AND APPARATUS THEREFOR}

The present invention relates to an alignment film in which the direction of an alignment axis continuously changes, a method for manufacturing an alignment layer, and an apparatus for manufacturing an alignment layer as a technology applied to various optical devices.

In addition, the present invention relates to a polarizing plate including an alignment layer having the continuous orientation, a retardation plate, and a method of manufacturing the same.

In addition, the present invention relates to an optical panel capable of continuously adjusting a light transmission amount using the alignment layer, a polarizing plate, and a retardation plate, and a window including the same.

When forming a thin film by coating a polarizing material including a liquid crystal or a dye on a substrate, an alignment layer is used so that the polarizing material has a certain alignment angle. In order to form an alignment layer and perform alignment treatment, a rubbing method or a light alignment method is generally used. The rubbing method is a method of orientation treatment by rotating a roll on which cotton or rayon is wound on the surface of an alignment layer, and light alignment is a method of treating the alignment layer so that it is oriented according to the polarization direction of the UV by irradiating linearly polarized UV onto the alignment layer.

These methods apply liquid crystal or dye on the alignment layer to form one or multiple alignment directions on the entire surface of the substrate when manufacturing a polarizing plate or a retardation plate, so it is possible to form a liquid crystal of LCD, a film patterned retarder (FPR) of a 3D display, and an OLED. It is used as a method of manufacturing functional films for realizing a high contrast ratio or manufacturing an optical filter or shutter. Therefore, in the manufacture of an optical device using a polarizing film, the alignment treatment technology of the alignment film is being emphasized.

In particular, it is possible to provide a window in which a light filter using a polarizing film is applied to a window or the like to control light transmittance electrically or non-electrically. Specifically, a window to which a polarizing film is applied is arranged so that the two polarizing films face each other and are movable with respect to each other, and each polarizing film is developed in a patterned form having a certain transmission axis or varying the transmission axis according to an area.

Chinese Patent No. 103364943 provides an optical device in which a region of a polarizing plate with different polarization directions is divided into a grid pattern, etc., and Korean Patent No. 1640670 is a polarizing plate having alternately two regions with different absorption axes. It provides an optical element arranged to face each other. In all of the above technologies, an alignment layer subjected to an alignment treatment by dividing an area is used, and in order to manufacture such an alignment layer, an alignment process is performed for each area using a patterned mask.

However, as in the prior art, since a polarizing plate or an optical filter using a retardation plate divided into regions has a boundary between regions, streaks or the like are formed as the light transmittance is adjusted, resulting in poor functionality and aesthetics.

In addition, the conventional method of patterning an alignment layer uses a patterned mask or requires a separate alignment treatment for each area, so the manufacturing process is complicated. In particular, it is difficult to form a pattern in which the alignment direction continuously changes with this method.

Accordingly, there is a need for an alignment layer capable of supplementing these points, an optical device to which the same, and a manufacturing method and a manufacturing device thereof are applied.

Chinese Patent No. 1640670 (BenQ Materials Co., Ltd.) 2015.12.02 Korean Patent Registration No. 1640670 (LG Chemical Co., Ltd.) 2016.07.12

The alignment layer of the present invention has been devised to solve the above problems, and it is an object of the present invention to provide an alignment layer whose alignment direction is parallel to the substrate surface and continuously changes along one direction in the surface, a method of manufacturing the same, and a manufacturing apparatus.

In addition, another object of the present invention is to provide a polarizing plate and a retardation plate including the alignment layer.

In addition, another object of the present invention is to provide an optical panel and a window including the polarizing plate or the retardation plate.

In addition, another object of the present invention is to provide a method of manufacturing the polarizing plate and the retardation plate.

The present invention can also aim to achieve these objects and other objects that can be easily derived by a person skilled in the art from the general description of the present specification in addition to the above-described clear objects.

The alignment layer of the present invention comprises a substrate and an alignment layer formed on the substrate, and the alignment direction of the alignment layer is parallel to the substrate surface and continuously changes along one direction in the plane in order to achieve the object as described above. do.

In addition, the orientation direction may be continuously rotated along one direction in the plane of the substrate.

In addition, the alignment layer may be a photo-alignment layer including a photo-alignment material.

Meanwhile, the polarizing plate of the present invention includes the alignment layer and a polarizing layer formed thereon, and the polarization axis direction of the polarizing plate is parallel to the substrate surface and continuously changes along one direction in the plane.

In addition, the direction of the polarization axis may continuously rotate along one direction in the plane of the substrate.

In addition, the direction of the polarization axis may rotate 1 when moving in one direction in the plane of the substrate from 3 to 1000 mm, preferably from 5 to 950 mm, more preferably from 10 to 500 mm, and even more preferably from 10 to 100 mm.

In addition, the polarizing layer may include a dichroic dye or a dichroic dye and a polymerizable liquid crystal compound.

Meanwhile, the retardation plate of the present invention includes the alignment layer and an optically anisotropic layer formed thereon, and the slow axis direction of the retardation plate is parallel to the substrate surface and continuously changes along one in-plane direction.

In addition, the slow axis direction may continuously rotate along one direction in the plane of the substrate.

In addition, the slow axis direction may rotate 1 when moving in one direction in the plane of the substrate from 3 to 1000 mm, preferably from 5 to 950 mm, more preferably from 10 to 500 mm, and even more preferably from 10 to 500 mm.

In addition, the optically anisotropic layer may include a polymerizable liquid crystal compound.

On the other hand, the optical panel of the present invention includes a first polarizing plate and a second polarizing plate arranged to face each other, and the polarization axis of the first polarizing plate and the second polarizing plate continuously changes along one direction in the plane of the polarizing plate, and the first polarizing plate And at least one of the second polarizing plates is linearly movable with respect to the other polarizing plate, so that the amount of light transmitted can be continuously adjusted.

On the other hand, the optical panel of the present invention,

A first polarizing plate having a first polarization axis,

A second polarizing plate having a second polarization axis, and

Including a first retardation plate positioned between the first polarizing plate and the second polarizing plate,

In the first retardation plate, the slow axis continuously changes along one direction in the plane of the first retardation plate,

At least one of the first retardation plate and the second polarizing plate is linearly movable with respect to the other plate, so that the amount of light transmission can be continuously adjusted.

In addition, the optical panel,

Including a second retardation plate positioned between the first retardation plate and the second polarizing plate,

The second retardation plate has a slow axis continuously changing along one direction in the plane of the second retardation plate,

At least one of the first retardation plate and the second retardation plate is linearly movable with respect to the other retardation plate, so that the amount of light transmitted may be continuously adjusted.

In addition, the first polarization axis and the second polarization axis may be parallel or perpendicular to each other.

Meanwhile, the window of the present invention is characterized in that it includes the optical panel.

On the other hand, the alignment film manufacturing method of the present invention,

(A) transferring the substrate;

(B) forming an alignment layer by applying a mixed solution containing a photo-alignment material on the substrate; And

And (C) irradiating polarized light whose polarization direction continuously rotates on the alignment layer, and aligning the alignment direction of the photo-alignment material to continuously change according to the transfer direction of the substrate; do.

In addition, after step (B) and before step (C), the step of drying the alignment layer coated with the mixed solution may be further included.

On the other hand, the polarizing plate manufacturing method of the present invention,

(A) forming a polarizing layer by applying a dichroic dye or a mixed solution containing a dichroic dye and a polymerizable liquid crystal compound onto the alignment film prepared by the method of manufacturing the alignment film, and

(B) It characterized in that it comprises the step of curing the polarizing layer.

On the other hand, the retardation plate manufacturing method of the present invention,

(A) forming an optically anisotropic layer by applying a liquid crystal mixture containing a polymerizable liquid crystal compound having optical anisotropy on the alignment layer prepared by the alignment layer manufacturing method, and

(B) It characterized in that it comprises the step of curing the optically anisotropic layer.

On the other hand, the alignment film manufacturing apparatus of the present invention,

A transfer unit for continuously transferring a substrate on which an alignment layer including a photo-alignment material is formed, and an exposure unit for irradiating polarized light whose polarization direction continuously rotates on the alignment layer,

The exposure unit,

A light source module emitting active energy rays;

A polarizer positioned under the light source module and polarizing active energy rays generated from the light source module;

A rotating device connected to the polarizer to rotate the polarizer; And

And a mask positioned under the polarizer and having a transmission slit for transmitting the polarized light.

In addition, the wavelength of the active energy ray generated from the light source module may be 150 to 500 nm, preferably 175 to 475 nm, more preferably 200 to 450 nm.

In addition, the rotating device may rotate the polarizer at 1 to 100 rpm, preferably 2 to 90 rpm, more preferably 3 to 80 rpm.

In addition, the polarizer may be a reflective linear polarizer in which a wire grid is formed on a substrate transmitting a wavelength of 100 to 400 nm, preferably 120 to 380 nm, more preferably 140 to 360 nm.

In addition, the transmission slit may be formed along a direction perpendicular to the traveling direction of the substrate.

In addition, the transmission slit may be a fixed slit having a constant width or a variable slit having a variable width.

In addition, the width of the transmission slit may be 10 to 500 μm, preferably 20 to 450 μm, more preferably 50 to 400 μm.

In addition, the polarizer may be a circular polarizer.

In addition, the polarizer may be quartz.

In addition, the alignment film manufacturing apparatus of the present invention may be arranged in a zigzag or diagonally with respect to the conveying direction of the substrate when there are two or more circular polarizers.

In addition, the transmission slit may be formed at a position on the mask corresponding to a diameter of the circular polarizer, which is a diameter perpendicular to the transport direction of the substrate.

In addition, the alignment layer may be manufactured with a contrast index of 15 to 300, preferably 20 to 270, more preferably 25 to 250.

The alignment film according to the present invention continuously changes the orientation direction, and a polarizing plate or slow axis continuously changing the polarization axis by coating a dichroic dye, a polymerizable liquid crystal compound, or a dichroic dye and a polymerizable liquid crystal compound on the alignment film. It is possible to manufacture a variable retardation plate.

In addition, the optical panel and the window according to the present invention may include the polarizing plate or the retardation plate to continuously adjust the amount of light transmitted.

In addition, the method of manufacturing an alignment layer according to the present invention can produce an alignment layer having an alignment direction that continuously rotates according to the progress direction of the substrate by irradiating polarized light whose polarization direction continuously changes. Compared to the method, the manufacturing method has a simple advantage. The method of manufacturing a polarizing plate and a retardation plate of the present invention further comprises a step of coating and curing a dichroic dye and/or a polymerizable liquid crystal compound on the alignment layer manufactured by the above alignment layer manufacturing method. And it is possible to manufacture a retardation plate in which the slow axis continuously changes.

In addition, the alignment film manufacturing apparatus according to the present invention can expose polarized light whose polarization direction continuously changes while transferring the substrate, and can adjust the transfer speed of the transfer unit, the rotational speed of the polarizer, and the width of the slit through which light passes. , The rotation period of the alignment direction with respect to the length direction of the alignment layer may be adjusted. And, it is possible to arrange two or more circular polarizers rotating in engagement, so that the width of the substrate is not limited by the diameter of the circular polarizer.

In addition, the optical device of the present invention can be used for an optical shutter, a smart window having variable transmission characteristics, an optical-based position sensor, and a retardation plate for a display.

1 shows an embodiment of an optical panel according to the present invention.
2 shows another embodiment of an optical panel according to the present invention.
3 shows a method of manufacturing an alignment layer according to the present invention.
4 shows an embodiment of an alignment film manufacturing apparatus according to the present invention.
5 shows an embodiment of an alignment film manufacturing apparatus according to the present invention including a rotating device.
6 is a plan view of an alignment film manufacturing apparatus in which a plurality of polarizers are disposed according to the present invention.
7 shows an embodiment of a method and apparatus for manufacturing an alignment layer in which a plurality of polarizers are disposed according to the present invention.
8 is a photograph of a retardation plate manufactured according to the present invention.
9 and 10 are results of measuring characteristics of an alignment layer manufactured as an embodiment of the present invention.

Hereinafter, a preferred embodiment of the present invention will be described in detail.

However, the following is only for describing in detail by exemplifying specific embodiments, and since the present invention may be variously changed and may have various forms, the present invention is not limited to the specific exemplary embodiments illustrated. It is to be understood that the present invention includes all changes, equivalents, and substitutes included in the spirit and scope of the present invention.

In addition, in the following description, there are many specific details such as specific components, etc., which are provided to help a more general understanding of the present invention, and the present invention can be practiced without these specific details. It will be said that it is self-evident to those who have the knowledge of. Further, in describing the present invention, when it is determined that a detailed description of a related known function or configuration may unnecessarily obscure the subject matter of the present invention, a detailed description thereof will be omitted.

In addition, terms used in the present specification are used only to describe specific embodiments, and are not intended to limit the present invention. Unless otherwise defined, all terms used herein including technical or scientific terms have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Terms as defined in a commonly used dictionary should be interpreted as having a meaning consistent with the meaning in the context of the related technology, and should not be interpreted as an ideal or excessively formal meaning unless explicitly defined in the present application. Does not.

In the present specification, terms such as first and second may be used to describe various components, but the components should not be limited by the terms. The above terms are used only for the purpose of distinguishing one component from another component.

In the present specification, the term'phase difference plate' refers to a retardation plate, a retarder, a waveplate, etc. that corrects a polarization state, and a film, film, plate, etc. Is to refer to all of them.

In this specification, the term'continuously changes' means that the average orientation direction in a specific differential region perpendicular to the substrate transport direction and the average orientation direction in the differential region adjacent to each other coincide with each other when the alignment film, polarizing plate, and retardation plate are manufactured. Indicates to do.

In the present specification, the term'active energy ray' refers to particle rays and electromagnetic waves having energy enough to cure a predetermined resin, and ultraviolet rays, lasers, microwaves, electron beams, X-rays, etc. Includes.

In the present specification, the term'periodic displacement of the optical axis' refers to a displacement in one direction in the plane of the substrate corresponding to one rotation when the direction of the polarization axis or the slow axis periodically rotates along one direction in the plane of the substrate.

In the present specification, the term'contrast displacement index' is a new index related to how much each polarizing plate or retardation plate must be moved in order to adjust the brightness of the optical panel of the present invention, and is defined by the following equation:

[Equation 1]

Contrast displacement index = periodic displacement of the optical axis / (width of the transmission slit × RPM of the rotating device).

The present invention is an alignment film comprising a substrate and an alignment layer formed on the substrate, wherein the alignment direction of the alignment layer is parallel to the surface of the substrate and continuously changes along one direction in the plane.

The alignment layer may include a compound capable of forming an alignment layer, and in particular, may include a photo-alignment material. The photo-alignment material is a generic term for a material in which the direction of the alignment material is aligned according to irradiation of light, and a person skilled in the art may appropriately employ it. In addition, the alignment layer may further include a material for adding an optical function, and may include a photo initiator.

In the alignment layer, the alignment direction of the photo-alignment material in the alignment layer formed by irradiation of light is referred to as the alignment direction, and the alignment layer having the alignment direction is referred to as an alignment-treated alignment layer. The orientation film of the present invention is characterized in that the orientation direction is parallel to the substrate surface and continuously changes according to one in-plane direction.

In this specification, the term'continuously changes' means that the average orientation direction in a specific differential region perpendicular to the substrate transport direction and the average orientation direction in the differential region adjacent to each other coincide with each other when the alignment film, polarizing plate, and retardation plate are manufactured. Indicates to do. This point is the most important feature of the present invention, and is distinguished from the prior art, which is divided into a plurality of regions having different orientation directions.

Specifically, as in Korean Patent No. 1640670, the conventional alignment layer has a plurality of regions perpendicular to the substrate transport direction, the orientation directions within one region are the same, and the orientation directions are the same around the boundary formed with the adjacent region. It has different characteristics. A window made of an alignment layer, a polarizing plate, and a retardation plate made in the prior art has different light transmittances based on the boundary, and thus it is impossible to continuously change the light transmittance. Above all, in order to form a different orientation direction for each region, there is a problem in that the manufacturing process is also performed discontinuously, resulting in a sharp decrease in process efficiency.

On the contrary, the present invention can achieve a continuous change in the orientation direction simply by continuously rotating the polarizer, and thus the process itself is extremely simple and thus process efficiency is very excellent.

As such, when the polarizer rotates, the alignment direction of the alignment layer of the present invention may be continuously rotated along one direction in the plane of the substrate, and one direction in the plane of the alignment layer may be a longitudinal direction of the alignment layer according to the transfer direction of the substrate. Accordingly, an angle formed by the orientation direction and the longitudinal direction of the substrate may be 0 degrees to 360 degrees, and the orientation direction may have a period, and furthermore, a rotation period.

The polarizing plate of the present invention includes a polarizing layer formed on the alignment layer of the alignment layer, and the polarization axis (transmission axis) direction of the polarizing plate is parallel to the substrate surface and continuously changes along one direction in the plane.

Since the material forming the polarization layer stacked in contact with the alignment layer having the alignment direction is aligned along the alignment direction, the polarization axis (transmission axis) is formed in the same direction as the alignment direction. Accordingly, the polarization axis is characterized in that it is parallel to the substrate surface and continuously changes according to the length direction of the substrate in the same manner as the orientation direction. Further, when the polarizer rotates as described above, since the orientation direction of the alignment film of the present invention continuously rotates along one direction in the plane of the substrate, the polarization axis direction may also be continuously rotated along one direction in the plane of the substrate.

The direction of the polarization axis may rotate 1 when moving in one direction in the plane of the substrate from 3 to 1000 mm, preferably from 5 to 950 mm, more preferably from 10 to 500 mm, and even more preferably from 10 to 500 mm. If the moving displacement corresponding to one rotation is less than the above range, the light transmittance rapidly changes even if a small movement is made, and it is difficult to adjust to the desired brightness. Conversely, if it exceeds the above range, the moving displacement for adjusting the desired brightness is excessively large, which is an inconvenient problem.

The polarizing layer may include a dichroic dye, a polymerizable liquid crystal compound, or a dichroic dye and a polymerizable liquid crystal compound.

The retardation plate of the present invention includes an optically anisotropic layer formed on the alignment layer of the alignment layer, and a slow axis of the optically anisotropic layer is parallel to the substrate surface and continuously changes along one direction in the plane.

Since the materials forming the optically anisotropic layer stacked in contact with the alignment layer having the alignment direction are aligned along the alignment direction, the slow axis is formed in the same direction as the alignment direction. Accordingly, the slow axis is characterized in that it is parallel to the substrate surface and continuously changes according to the longitudinal direction of the substrate as in the orientation direction. Further, as described above, when the polarizer rotates, since the orientation direction of the alignment film of the present invention continuously rotates along one direction in the plane of the substrate, the slow axis direction may also continuously rotate along one direction in the plane of the substrate.

The slow axis direction may rotate 1 when moving in one direction in the plane of the substrate from 3 to 1000 mm, preferably from 5 to 950 mm, more preferably from 10 to 500 mm, even more preferably from 10 to 500 mm. If the moving displacement corresponding to one rotation is less than the above range, the light transmittance rapidly changes even if a small movement is made, and it is difficult to adjust to the desired brightness. Conversely, if it exceeds the above range, the moving displacement for adjusting the desired brightness is excessively large, which is an inconvenient problem.

The optically anisotropic layer may include a polymerizable liquid crystal compound, the polymerizable liquid crystal compound may be a liquid crystal material including a polymerizable functional group, and the liquid crystal material may include a reactive mesogen (RM). have.

The optical panel of the present invention includes a first polarizing plate 12 and a second polarizing plate 14 disposed to face each other as shown in FIG. 1, and the first polarizing plate 12 and the second polarizing plate 14 are The polarization axis is characterized in that it continuously changes along one direction in the plane of the polarizing plate, and at least one of the first polarizing plate 12 and the second polarizing plate 14 is linearly movable with respect to the other polarizing plate, so that the amount of light transmitted can be continuously adjusted. It may be an optical panel. It is preferable that the first polarizing plate 12 and the second polarizing plate 14 be, for example, polarizing plates having the same periodic pattern.

1 is a configuration of an embodiment of an optical panel according to the present invention, in which a first polarizing plate 12 and a second polarizing plate 14 whose polarization axes continuously change are arranged to face each other, and at least one polarizing plate is disposed on another polarizing plate. Indicates that it can move linearly.

When the first polarizing plate 12 and the second polarizing plate 14 facing each other are disposed so that the overlapping transmission axes are orthogonal to each other as shown in FIG. 1(a), light incident from the outside of the first polarizing plate 12 is transmitted to the first polarizing plate ( After being polarized at 12), the second polarizing plate 14 cannot be transmitted and is blocked, thereby entering a blocking mode. On the other hand, as shown in FIG. 1(b), when at least one polarizing plate moves parallel to another polarizing plate by a predetermined position, the transmission axes overlapping each other form a predetermined angle, and at this time, from the outside of the first polarizing plate 12 The incident light may be partially transmitted while passing through the first polarizing plate 12 and the second polarizing plate 14. In addition, when at least one polarizing plate further moves with respect to another polarizing plate and the transmission axes overlapping each other become parallel, light incident from the outside of the first polarizing plate 12 passes through the first polarizing plate 12 and the second polarizing plate 14. It is completely transmitted and becomes a transmission mode.

On the other hand, another embodiment of the optical panel for controlling the amount of light transmission of the present invention is a first polarizing plate 16 having a first polarization axis, a second polarizing plate 18 having a second polarization axis, and the first polarizing plate 16 And a first retardation plate 22 positioned between the second polarizing plates 18, wherein the first retardation plate 22 is characterized in that the slow axis continuously changes along one direction in the plane of the retardation plate. At least one of the first retardation plate 22 and the second polarizing plate 18 may be an optical panel capable of linearly movable with respect to the other plate to continuously control a light transmission amount.

Further, another embodiment of the optical panel of the present invention includes a second retardation plate 24 positioned between the first retardation plate 22 and the second polarizing plate 18, as shown in FIG. The second retardation plate 24 has a slow axis continuously changing along one direction in the plane of the second retardation plate, and at least one of the first retardation plate 22 and the second retardation plate 24 is linear with respect to the other retardation plate. It may be an optical panel that can be moved to and continuously adjust the amount of light transmission. It is preferable that the first and second retardation plates 22 and 24 are, for example, retardation plates having the same periodic pattern.

FIG. 2 is an optical panel including a first polarizing plate 16, a first retardation plate 22, a second retardation plate 24, and a second polarizing plate 18 according to the present invention, and disposed in sequence. The polarizing plate 16 and the second polarizing plate 18 have a uniform polarization axis, and the first retardation plate 22 and the second retardation plate 24 have slow axes that change continuously. In addition, FIG. 2 shows that at least one retardation plate can move linearly with respect to another plate.

When the first and second retardation plates 22 and 24 that face each other are disposed so that the overlapping slow axes are orthogonal to each other, as shown in FIG. 2(a), the first polarizing plate 16 from the outside of the first polarizing plate 16 The light incident thereon is blocked without passing through the second polarizing plate 18 through the first retardation plate 22 and the second retardation plate 24, and thus enters a blocking mode. On the other hand, as shown in Fig. 2(b), when at least one retardation plate moves parallel to another retardation plate by a predetermined position, the slow axes overlapping each other form a predetermined angle. In this case, the outer side of the first polarizing plate 16 In the light incident on the first polarizing plate 16, only a portion of the light may pass through the first retardation plate 22, the second retardation plate 24, and the second polarizing plate 18. In addition, when at least one retardation plate further moves with respect to another retardation plate and the slow axes overlapping with each other become parallel, light incident from the outside of the first polarizing plate 16 to the first polarizing plate 16 is transferred to the first retardation plate 22. ), the second retardation plate 24, and the second polarizing plate 18 are transmitted through the transmission mode.

In addition, in the optical panel including the retardation plate, the first polarizing plate and the second polarizing plate are known polarizers such as polyvinyl alcohol (PVA) polarizing films, or are dichroic dyes, polymerizable liquid crystal compounds or dichroic dyes, and polymerizable liquid crystals. It may be a coated polarizing plate coated with a material containing a compound.

In addition, the first and second retardation plates may be 1/4 wavelength plates.

The optical panel of the present invention continuously and gradually increases the amount of light transmitted from the blocking mode to the transmission mode. As the optical shutter, blocking member, or blind using a conventional polarizing film uses a polarizing film patterned by dividing a region, regions having different light transmittances occurred in the intermediate mode between the transmission mode and the blocking mode. A brighter and darker area occurred and the pattern was inevitably formed. However, in the optical panel according to the present invention, since the polarization axis of the polarizing plate is continuously changed, for example, rotated along the direction of the substrate, it is possible to gradually decrease the overall light transmittance while uniformly maintaining the overall light transmittance from the transmission mode to the blocking mode. Therefore, it is possible to prevent the pattern from being formed, so that it is excellent not only aesthetically, but also the light transmittance can be easily adjusted.

In addition, the window of the present invention includes the optical panel, and as an embodiment, the optical panel may be installed between window glasses to be electrically or non-electrically driven, and a person skilled in the art adds an element suitable for the driving. It can be adopted and implemented as an alternative.

On the other hand, in the manufacturing method of the alignment layer of the present invention, an alignment layer is formed by applying a mixed solution containing a photo-alignment material on a substrate to be transferred, and the polarized light continuously rotating in a polarization direction is irradiated on the alignment layer. It is characterized in that the orientation is arranged so that the orientation direction of the photo-alignment material continuously changes according to the transport direction of the substrate.

The step of forming the alignment layer by applying the mixed solution containing the photo-alignment material may include applying and drying the mixed solution.

3 shows an embodiment of the method for manufacturing an alignment layer according to the present invention. In the manufacturing process of the alignment layer 400, the light source module 100 and the transmission slit 310 are fixed, and the alignment layer 400 is rotated while only the polarizer 200 is rotated. When is transferred, the light 320 passing through the transmission slit is irradiated onto the substrate while the linear polarization direction is changed.

According to the method of manufacturing the alignment layer, since the transfer of the alignment layer 400 and the rotation of the polarizer 200 proceed continuously, the alignment layer 400 in which the alignment direction continuously changes with one transfer can be manufactured. Therefore, as in the prior art, it is not necessary to stop the rotation of the polarizer 200 or the transfer of the transfer unit 500 in order to expose to polarized light with a different orientation for each area, which is economically advantageous. Compared to the technology of repeating the transfer or reciprocating the transfer, manufacturing is quick and easy. In addition, since the patterning mask is also unnecessary, the manufacturing apparatus can be simplified.

In addition, after forming the alignment layer on the alignment layer 400, a step of drying the alignment layer may be additionally included. This may be for more rapidly evaporating the solvent in the mixed solution containing the photo-alignment material.

Meanwhile, in the method of manufacturing a polarizing plate of the present invention, a polarizing layer is formed by applying a dichroic dye or a mixed solution containing a dichroic dye and a polymerizable liquid crystal compound on the alignment layer prepared by the above alignment layer manufacturing method, and forming a polarizing layer. It is characterized by hardening.

In addition, the method of manufacturing a retardation plate of the present invention is characterized in that an optically anisotropic layer is formed by applying a mixed solution containing a polymerizable liquid crystal compound on the alignment layer manufactured by the alignment layer manufacturing method, and the formed optically anisotropic layer is cured. .

Curing the polarizing layer or the optically anisotropic layer may be photocuring by ultraviolet rays.

In the method of manufacturing the alignment layer, the polarizing plate, and the retardation plate, coating and coating the mixture may be performed by a spin coating or slot coating method.

Meanwhile, FIGS. 4 and 5 are an embodiment of an alignment layer manufacturing apparatus according to the present invention. A transfer unit 500 for continuously transferring an alignment layer 400 on which an alignment layer including a photo-alignment material is formed, and above the alignment layer. It includes an exposure unit for irradiating the polarized light 320 rotates continuously in a polarization direction.

In addition, the exposure unit is connected to the light source module 100, a polarizer 200 positioned under the light source module 100 and polarizing the active energy ray 110 generated from the light source module 100, and the polarizer 200 Characterized in that it comprises a rotating device 220 for rotating the polarizer 200, and a mask 300 located under the polarizer 200 and having a transmission slit 310 for transmitting the polarized light 210 can do.

In addition, the alignment film manufacturing apparatus of the present invention further includes a coating apparatus for coating a mixture solution containing a photo-alignment material on a substrate prior to the alignment treatment of the alignment film, or a drying apparatus for drying after the alignment treatment of the alignment film. Can include. In addition, a device for applying a material for forming a polarizing layer and a material for forming an optically anisotropic layer may be further included on the prepared alignment layer, or a light irradiation device for photo-curing these materials may be included.

The light source module 100 is a module that generates an active energy ray, and may generate an active energy ray having a wavelength of 150 to 500 nm, preferably 175 to 475 nm, and more preferably 200 to 450 nm. If the wavelength of the active energy ray is less than the above range, orientation in a desired direction is not easily achieved, whereas if the wavelength of the active energy ray exceeds the above range, photocuring is not smoothly achieved. In particular, the light source module may irradiate ultraviolet rays, and the wavelength of the irradiated active energy ray may be adjusted according to the type of the alignment layer.

The rotation device 220 is a device that rotates the polarizer 200 and may further include a control device capable of arbitrarily adjusting the RPM of the polarizer, and the RPM of the polarizer is 1 to 100 rpm, preferably 2 to 90 rpm. rpm, more preferably 3 to 80 rpm.

The polarizer 200 is positioned under the light source module, and a polarizer is disposed on a surface on which the light source module irradiates the active energy ray to polarize the active energy ray generated from the light source module. The polarizer 200 may be a reflective polarizer, and may be a linear polarizer that linearly polarizes incident light. In addition, the polarizer 200 may be a polarizer having a wire grid formed on a substrate transmitting a wavelength of 100 to 400 nm, preferably 120 to 380 nm, more preferably 140 to 360 nm.

The transmission slit 310 is a narrow gap formed on the mask 300 to expose the light polarized by the polarizer 200 to a predetermined portion of the alignment layer 400. The mask 300 including the transmission slit 310 may be disposed under the polarizer 200, and the transmission slit 310 may be formed along a direction perpendicular to the traveling direction of the substrate. In addition, the transmission slit 310 may be a fixed slit having a constant width or a variable slit having a variable width. The width of the transmission slit is 10 to 500 μm, preferably 20 to 450 μm, more preferably 50 to 400 μm, or it is preferable that it can vary within the above range. In addition, in the manufacturing process of the alignment layer 400, the transmission slit 310 may have a fixed position.

In addition, the polarizer 200 may be a circular polarizer, and in particular, may be a quartz plate. However, the type and shape of the polarizer is not limited, and a known polarizer may be appropriately employed.

In addition, the transfer speed of the transfer unit 500 and the rotation speed of the polarizer 200 may or may not be constant, and may be respectively controlled. If a constant speed is maintained, the amount of change in the rotation angle in the orientation direction with respect to the transport length of the substrate per unit time will be constant regardless of the position of the substrate, but it may not be the case if the speed is not constant.

In the alignment layer manufacturing apparatus, when the polarizer 200 is a circular polarizer and two or more polarizers are rotated, the polarizers 200 may be arranged to rotate in engagement with each other when the polarizers rotate. In addition, the arrangement may be arranged in zigzag so that the circular polarizers alternate with each other as shown in FIG. 6(a) or the circular polarizers may be arranged in a diagonal line with respect to the length direction of the alignment layer as shown in FIG. 6(b). However, in consideration of the simplification and economic efficiency of the manufacturing apparatus, it would be desirable to arrange the circular polarizers in a zigzag manner so as to stagger each other.

FIG. 7 shows an apparatus including a plurality of circular polarizers 200 that rotate in engagement with each other as an embodiment of the apparatus for manufacturing an alignment layer of the present invention. In this type of device, the transmission slit 610 for transmitting the polarized light may be formed at a position on the mask 600 corresponding to a diameter of the circular polarizer 200 that is perpendicular to the traveling direction of the substrate. In this case, it is necessary to adjust the rotation of each polarizer 200 so that the pattern formed by each transmission slit 610 has a uniform pattern over the entire alignment layer. When the plurality of circular polarizers 200 are meshed and rotated as described above, patterning is possible with respect to the width of an arbitrary alignment layer 400 regardless of the size (diameter) of the polarizer 200. Therefore, it is possible to manufacture the alignment layer 400 through one alignment treatment, so that the manufacturing process is simple and economically advantageous.

In the present invention, the alignment layer may be prepared with a contrast index of 15 to 300, preferably 20 to 270, more preferably 25 to 250. The'contrast displacement index' is a new index related to how much each polarizing plate or retardation plate must be moved in order to adjust the brightness of the optical panel of the present invention, and is defined by the following equation:

[Equation 1]

Contrast displacement index = periodic displacement of the optical axis / (width of the transmission slit × RPM of the rotating device).

Here, the term'periodic displacement of the optical axis' refers to a displacement in one direction in the plane of the substrate corresponding to one rotation when the direction of the polarization axis or the slow axis periodically rotates along one direction in the plane of the substrate.

If the light-dark displacement index is less than the above range, even if the polarizing plate or the retardation plate of the present invention is slightly moved, the light transmittance of the optical panel changes rapidly, making it difficult to adjust to the desired brightness. There is an inconvenient problem because the displacement of the retardation plate is too large.

Hereinafter, an embodiment of the present invention will be described.

Example

practice Yes 1: Fabrication of the retardation plate (Substrate 1)

Example 1-1: Preparation of alignment layer

The alignment agent (Osaka Yuga Chemical Industries, Japan) is coated on the substrate (TAC film. Hyosung Chemical, Korea) by the slot coating method, but the flow rate of the alignment agent is 0.3 cc/min, and the transfer speed (coating speed) of the substrate is 3.5. The photoalignment film was formed in mm/s. Then, the coated photo-alignment film was dried at 80° C. for 2 minutes.

Using an alignment film manufacturing apparatus including a light source module, a polarizer located under the light source module and connected to a rotating device, a mask located under the polarizer and having a transmission slit through which light can pass, and a substrate transfer unit located under the mask, the alignment The liquid-coated alignment layer was photo-aligned. In the light source module, UV having a wavelength of 310 nm ^{was generated at 10 to 20 mJ/cm 2} , and the rotational speed of the reflective polarizer for polarizing the light was set to 4 rpm. Light transmitted through the polarizer from the light source module was passed through a transmission slit having a width of 100 μm, and was exposed to a substrate transferred at a speed of 100 mm/min to perform light alignment treatment.

Example 1-2: Fabrication of a retardation plate (Substrate 1)

RM (Reactive Mesogen. Osaka Oil Chemical Industries, Japan) was coated on the alignment film prepared according to Example 1-1. The coating was coated by the spin coating method, but the spin coating speed of the RM was 3000 rpm. Then, it dried at 60 degreeC for 2 minutes. After the drying was completed, 365 nm UV was irradiated with 400 mJ/cm ² and photo-cured to prepare a retardation plate.

Test Example 1: Confirmation of the optical axis pattern of Substrate 1

As a result of transmitting light by attaching a polarizing plate to the retardation plate Substrate 1 prepared according to Example 1-2, a gradation pattern was observed (Fig. 8), and from this, the substrate 1 was continuously changed according to the direction of the substrate. It was confirmed that the shaft was formed.

Example 2: Fabrication of a retardation plate (Substrate 2)

Example 2-1: Preparation of alignment layer

An alignment layer was prepared in the same manner as in Example 1-1, but the light transmitted through the polarizer from the light source module was exposed to a substrate transferred at a speed of 300 mm/min to perform light alignment treatment.

Example 2-2: Fabrication of a retardation plate (Substrate 2)

A retardation plate was manufactured in the same manner as in Example 1-2, but the alignment layer prepared according to Example 2-1 was used as the alignment layer, and the spin coating speed of the RM was 2000 rpm.

Test Example 2: Measurement of the optical axis and retardation value of the retardation plate in the moving direction of the substrate

For the retardation plate Substrates 1 and 2 prepared according to Examples 1 and 2, retardation values and optical axis directions were measured at intervals of 0.3 mm with respect to the moving direction of the substrate (FIG. 9).

The retardation value (Re) with respect to the substrate advancing direction showed a constant value within the range of 80 to 100 nm regardless of the position, whereas the angle formed by the substrate advancing direction and the optical axis continuously increased according to the substrate advancing direction. From this, it can be seen that the optical axis continuously rotates according to the moving direction of the substrate, and it was confirmed that the rotation period of the angle is 11 to 12 mm.

Test Example 3: Measurement of the optical axis and retardation values in a direction perpendicular to the substrate traveling direction of the retardation plate

For the retardation plate Substrates 1 and 2 prepared according to Examples 1 and 2, retardation values and optical axis directions were measured at intervals of 0.3 mm with respect to the direction perpendicular to the substrate traveling direction (FIG. 10).

The retardation value (Re) with respect to the direction perpendicular to the substrate traveling direction showed a constant value within 80 to 100 nm regardless of the position. In addition, it was confirmed that the angle formed by the optical axis and the direction perpendicular to the moving direction of the substrate represents a constant value within the range of ±10 degrees regardless of the position.

In the above, preferred embodiments of the present invention have been described, but the present invention is not limited to the specific embodiments described above, and those of ordinary skill in the art can implement various modifications without departing from the gist of the present invention. Of course it is possible. Therefore, the scope of the present invention should not be construed as limited to the above embodiments, and should be defined by the claims and equivalents to the claims to be described later.

100: light source module
110: active energy ray generated from the light source module
200: polarizer
210: polarized light
220: rotating device
300: mask
310: transparent slit
320: polarized light passing through the transmission slit
400: alignment layer
410: alignment film before alignment treatment
420: moving direction of the substrate
430: alignment layer after alignment treatment
500: transfer unit
600: mask including at least one or more slits
610: transmission slit for each polarizer

Claims (21)

A substrate and an alignment layer formed on the substrate, wherein the alignment direction of the alignment layer is parallel to the substrate surface and continuously changes along one in-plane direction,
The continuous change in the orientation direction is characterized in that the average orientation direction in the specific differential region perpendicular to the one direction in the plane and the average orientation direction in the differential region adjacent thereto are coincident with each other. The method according to claim 1,
The alignment layer is an alignment layer, characterized in that the photo-alignment layer containing a photo-alignment material. It includes the alignment layer of claim 1 and the polarization layer formed on the alignment layer, the polarization axis direction of the polarization layer is parallel to the substrate surface and continuously changes along one direction in the plane,
Wherein the polarization axis direction is continuously changed, the average polarization axis direction in a specific differential region perpendicular to the one direction in the plane and the average polarization axis direction in a differential region adjacent thereto are coincident with each other. The method of claim 3,
The polarizing layer is characterized in that it comprises a dichroic dye, or a dichroic dye and a polymerizable liquid crystal compound, a polarizing plate. It includes the alignment layer of claim 1 and the optically anisotropic layer formed on the alignment layer, wherein the direction of the slow axis of the optically anisotropic layer is parallel to the substrate surface and continuously changes along one direction in the plane,
The retardation plate characterized in that that the slow axis direction continuously changes is characterized in that the average slow axis direction in the specific differential region perpendicular to the one direction in the plane and the average slow axis direction in the differential region adjacent thereto coincide with each other. The method of claim 5,
The optically anisotropic layer is characterized in that it comprises a polymerizable liquid crystal compound, retardation plate. Including a first polarizing plate and a second polarizing plate arranged to face each other,
In the first polarizing plate and the second polarizing plate, a polarization axis continuously changes along one direction in the plane of the polarizing plate,
At least one of the first polarizing plate and the second polarizing plate is linearly movable with respect to the other polarizing plate, so that the amount of light transmitted can be continuously adjusted,
The continuous change of the polarization axis is characterized in that the average polarization axis direction in the specific differential region perpendicular to the one direction in the plane and the average polarization axis direction in the differential region adjacent thereto coincide with each other. A first polarizing plate having a first polarization axis,
A second polarizing plate having a second polarization axis, and
Including a first retardation plate positioned between the first polarizing plate and the second polarizing plate,
The first retardation plate has a slow axis continuously changing along one direction in the plane of the first retardation plate,
At least one of the first retardation plate and the second polarizing plate is linearly movable with respect to the other plate to continuously adjust the amount of light transmission,
The continuous change of the slow axis is characterized in that the average slow axis direction in the specific differential region perpendicular to the one direction in the plane and the average slow axis direction in the differential region adjacent thereto coincide with each other. The method of claim 8,
Including a second retardation plate positioned between the first retardation plate and the second polarizing plate,
The second retardation plate has a slow axis continuously changing along one direction in the plane of the second retardation plate,
At least one of the first retardation plate and the second retardation plate is linearly movable with respect to the other retardation plate, so that the amount of light transmission can be continuously adjusted,
The continuous change of the slow axis is characterized in that the average slow axis direction in the specific differential region perpendicular to the one direction in the plane and the average slow axis direction in the differential region adjacent thereto coincide with each other. The method of claim 8,
The optical panel, characterized in that the first polarization axis and the second polarization axis are parallel or perpendicular to each other. A window comprising the optical panel of any one of claims 7 to 10. (A) transferring the substrate;
(B) forming an alignment layer by applying a mixed solution containing a photo-alignment material on the substrate; And
(C) irradiating polarized light whose polarization direction continuously rotates on the alignment layer, and aligning the photo-alignment material so that the alignment direction of the photo-alignment material continuously changes according to the transfer direction of the substrate.
Including,
The continuously rotating polarized light is generated by rotating a polarizer positioned between a light source and an alignment layer. The method of claim 12,
After the step (B) and before the step (C), further comprising the step of drying the alignment layer coated with the mixed solution. (A) forming a polarizing layer by applying a dichroic dye or a mixed solution containing a dichroic dye and a polymerizable liquid crystal compound onto the alignment film prepared by the manufacturing method of claim 12 or 13, and
(B) comprising the step of curing the polarizing layer, polarizing plate manufacturing method. (A) forming an optically anisotropic layer by applying a liquid crystal mixture containing a polymerizable liquid crystal compound having optical anisotropy on the alignment layer prepared by the manufacturing method of claim 12 or 13, and
(B) A method of manufacturing a retardation plate comprising the step of curing the optically anisotropic layer. A transfer unit for continuously transferring a substrate on which an alignment layer including a photo-alignment material is formed, and an exposure unit for irradiating polarized light whose polarization direction continuously rotates on the alignment layer,
The exposure unit,
A light source module emitting active energy rays;
A polarizer positioned under the light source module and polarizing active energy rays generated from the light source module;
A rotating device connected to the polarizer to continuously rotate the polarizer; And
A mask located under the polarizer and having a transmission slit for transmitting the polarized light
Including,
The rotating device is characterized in that rotating the polarizer at 1 to 100 rpm, the alignment film manufacturing apparatus. The method of claim 16,
The alignment film manufacturing apparatus, characterized in that the wavelength of the active energy ray generated from the light source module is 150 to 500 nm. delete The method of claim 16,
The transmission slit is characterized in that formed along a direction perpendicular to the traveling direction of the substrate, the alignment film manufacturing apparatus. The method of claim 16,
The polarizer is a circular polarizer, characterized in that, the alignment film manufacturing apparatus. The method of claim 20,
When there are two or more circular polarizers, the alignment film manufacturing apparatus is characterized in that arranged in a zigzag or diagonally with respect to the transport direction of the substrate.

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