KR102323196B1 - Method and apparatus for fabricating pattern sheet - Google Patents

Abstract

A method for manufacturing a patterned sheet and an apparatus for manufacturing a patterned sheet are provided. A method of manufacturing a pattern sheet includes forming a first pattern layer including a first surface asperity on an upper surface of a first substrate, and forming a second pattern layer on the first pattern layer in a continuous process. Forming a second pattern layer so that the sum of the thicknesses of the pattern layer and the second pattern layer is uniform, wherein the second pattern layer includes a second surface unevenness having a complementary shape engaged with the first surface unevenness, and , the first pattern layer includes a first pattern region, and a second pattern region in which the first surface asperity and the second surface asperity have a cross-sectional structure different from that of the first pattern region.

Description

Pattern sheet manufacturing method and pattern sheet manufacturing apparatus {Method and apparatus for fabricating pattern sheet}

The present invention relates to a method and apparatus for manufacturing a patterned sheet in which a plurality of patterned layers having complementary shapes are laminated.

Laminated pattern sheets are used in display devices. Due to the recent enlargement of the display, there is a lot of demand for a pattern sheet having a size of 55 inches or more. However, in the case of a pattern sheet corresponding to 55 inches or more, a plurality of patterns having a width of 1300 mm or more and a minimum diameter of several micrometers are formed on the front surface. It may be necessary to manufacture a roll, and when the plurality of patterns are linear and the pattern roll needs to be processed in the width direction, not in the circumferential direction of the pattern roll, or in the direction tilted at a large angle in the circumferential direction, the manufacturing time is shortened due to high difficulty Since it is long, the yield is low, and it is very expensive, the manufacturing cost may be significantly increased when forming a laminated pattern sheet having a width of 1300 mm or more.

In addition, in order to form a pattern sheet, a pattern sheet semi-finished product having a first pattern layer formed on a first substrate by a pattern roll and a primary pattern resin is manufactured, and then a secondary pattern is formed on the surface of the first pattern layer. After the resin is applied, a second pattern layer having a shape complementary to the first pattern layer is formed by physically pressing the second substrate to cover the first pattern layer and the second pattern layer, respectively, in separate processes. Defects formed on the first pattern layer during manufacturing may be recognized on the laminated pattern sheet, or as a stain on the laminated pattern sheet due to non-uniform thickness of the first and/or second pattern layers. As an alternative to the pattern roll, a method of forming a pattern by a soft mold is known, but the soft mold includes a joint connecting both ends, and the pattern to which the joint is transferred shows a thickness non-uniformity. When each of the plurality of pattern layers has a high light transmittance of 90% or more, it is inevitably more sensitive to an appearance defect.

Laid-Open Patent Publication No. 10-2016-0057904

The problem to be solved by the present invention relates to a method of manufacturing a pattern sheet in which defects due to the first pattern layer are not visually recognized in the laminated pattern sheet.

Another problem to be solved by the present invention relates to an apparatus for manufacturing a pattern sheet in which defects due to the first pattern layer are not visually recognized in the laminated pattern sheet.

The problems of the present invention are not limited to the problems mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the following description.

A method of manufacturing a pattern sheet according to an embodiment for solving the above problems includes forming a first pattern layer including a first surface asperity on an upper surface of a first substrate, and on the first pattern layer in a continuous process Forming a second pattern layer, comprising forming the second pattern layer so that the sum of the thicknesses of the first pattern layer and the second pattern layer is uniform, wherein the second pattern layer includes the first pattern layer a second surface asperity having a complementary shape engaged with the surface asperity, wherein the first pattern layer has a first pattern area, and a cross section in which the first surface asperity and the second surface asperity are different from the first pattern area and a second pattern region having a structure.

An apparatus for manufacturing a pattern sheet according to an embodiment for solving the other problem is a pattern sheet manufacturing apparatus including a first pattern forming unit and a second pattern forming unit, wherein the first pattern forming unit is a soft mold and a first resin supply a unit, and a first substrate providing unit, wherein the second pattern forming unit includes a lamination unit, a second resin supply unit, and a second substrate providing unit, wherein the first pattern forming unit and the second pattern forming unit are a continuous process is connected to

The details of other embodiments are included in the detailed description and drawings.

According to embodiments, it is possible to improve productivity and reduce manufacturing costs by manufacturing in a continuous process using a film mold with high productivity and low cost.

In addition, it is possible to prevent the occurrence of defects due to the joint of the first pattern layer produced from the film mold, and to make the thickness of the laminated pattern uniform when manufacturing the laminated pattern sheet, and to apply the film mold and perform a continuous process using the same This can reduce the manufacturing cost. In particular, it is possible to improve the productivity of a large laminated pattern sheet with a width of 1300 mm or more. Furthermore, thickness uniformity of the first and/or second pattern layers may be improved.

The effect according to the present invention is not limited by the contents exemplified above, and more various effects are included in the present specification.

1 is a cross-sectional view of a pattern sheet according to an embodiment.
2 to 4 are cross-sectional views of pattern sheets according to various embodiments.
5 is a cross-sectional view of a pattern sheet according to another embodiment.
6 is a cross-sectional view of a pattern sheet according to another embodiment.
7 is a cross-sectional view of a roll-shaped pattern sheet according to an embodiment.
8 is a perspective view of a soft mold according to an embodiment.
9 is a cross-sectional view taken along line IX-IX' of FIG. 8 .
10 is a cross-sectional view illustrating a process of manufacturing a pattern sheet using the soft mold of FIG. 8 .
11 is a perspective view of a soft mold according to another embodiment.
12 is a cross-sectional view taken along line XII-XII' of FIG. 11 .
13 is a cross-sectional view of a roll-shaped pattern sheet formed using the soft mold of FIG. 11 .
14 is a perspective view of a soft mold according to another embodiment.
15 is a cross-sectional view taken along line XV-XV' of FIG. 14 .
16 is a cross-sectional view taken along line XVI-XVI' of FIG. 14 .
17 is a perspective view of a roll-shaped pattern sheet formed using the soft mold of FIG. 14 .
18 is a flowchart of a method of manufacturing a pattern sheet according to an exemplary embodiment.
19 is a schematic diagram illustrating an apparatus and process diagram for manufacturing a pattern sheet according to an embodiment.
20 is a schematic diagram illustrating an apparatus and process diagram for manufacturing a pattern sheet according to another embodiment.

Advantages and features of the present invention and methods of achieving them will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in a variety of different forms, and only these embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention belongs It is provided to fully inform the possessor of the scope of the invention, and the present invention is only defined by the scope of the claims.

Reference to an element or layer “on” another element or layer includes any intervening layer or other element directly on or in the middle of another element. On the other hand, when an element is referred to as "directly on", it is indicated that there are no intervening elements or layers intervening. Like reference numerals refer to like elements throughout. “and/or” includes each and every combination of one or more of the recited items.

Although the first, second, etc. are used to describe various elements, these elements are not limited by these terms, of course. These terms are only used to distinguish one component from another. Accordingly, it goes without saying that the first component mentioned below may be the second component within the spirit of the present invention.

The terminology used herein is for the purpose of describing the embodiments and is not intended to limit the present invention. As used herein, the singular also includes the plural unless specifically stated otherwise in the phrase. As used herein, “comprises” and/or “comprising” does not exclude the presence or addition of one or more other components in addition to the stated components.

Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used with the meaning commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, terms defined in a commonly used dictionary are not to be interpreted ideally or excessively unless clearly defined in particular.

Spatially relative terms "below", "beneath", "lower", "above", "upper", etc. It can be used to easily describe the correlation between a component and other components. A spatially relative term should be understood as a term that includes different directions of components during use or operation in addition to the directions shown in the drawings. For example, when a component shown in the drawings is turned over, a component described as “beneath” or “beneath” of another component may be placed “above” of the other component. can Accordingly, the exemplary term “below” may include both directions below and above. Components may also be oriented in other orientations, and thus spatially relative terms may be interpreted according to orientation.

The terms "~ sheet", "~ film", "~ layer", etc. used herein may be used interchangeably with the same meaning. In addition, the term functional optical sheet as used herein may be used in the sense of including an optical film, an optical plate, an optical film package, and the like.

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

1 is a cross-sectional view of a pattern sheet according to an embodiment.

For convenience of description, a surface placed in an upper direction in the drawing among the surfaces of the sheet, film, or layer is referred to as an upper surface, and a surface placed in a lower direction is referred to as a lower surface. However, terms such as the upper surface, the lower surface, etc. are only used to refer to one surface or the other surface of the structure to be relatively distinguished, and depending on the application or arrangement direction of the pattern sheet 10 , the surface referred to as the upper surface faces downward or It can face in various directions, such as facing the side.

In the drawing, the first direction D1 and the second direction D2 are directions perpendicular to each other. A side of the pattern sheet 10 may be parallel to any one of the first direction D1 and the second direction D2 , but is not limited thereto.

Referring to FIG. 1 , a pattern sheet 10 may be used as an optical sheet of a display device. For example, the pattern sheet 10 may be used as an optical sheet of a backlight unit of a liquid crystal display. Specifically, the pattern sheet 10 may be used as a wavelength conversion sheet, a prism sheet, a diffusion sheet, a protective sheet, and the like of the backlight unit. As another example, the pattern sheet 10 may be used as a liquid crystal display panel or an optical sheet disposed on the organic light emitting display panel. Specifically, the pattern sheet 10 may be used as a privacy sheet, a sheet for reducing color change to increase color reproducibility at a viewing angle, a bright-room contrast-ratio improving sheet with excellent contrast even in a bright place, and an electromagnetic wave shielding sheet.

The pattern sheet 10 may be a laminated pattern sheet in which a plurality of layers are stacked. The pattern sheet 10 includes a first substrate 100 , a first pattern layer 310 disposed on the upper surface of the first substrate 100 , and a second pattern layer disposed on the first pattern layer 310 ( 320). The pattern sheet 10 may further include a second substrate 200 disposed on the second pattern layer 320 . In an embodiment, the lower surface of the first substrate 100 that is the outer surface of the pattern sheet 10 and the upper surface of the second substrate 200 are flat, and may be exposed to the outside without disposing another layer. In another embodiment, a functional coating layer (not shown) may be disposed on the lower surface of the first substrate 100 and/or the upper surface of the second substrate 200 . Examples of the functional coating layer include, but are not limited to, a hard coating layer, an antireflection layer, an antifouling layer, and the like.

The first substrate 100 and the second substrate 200 face each other. The first substrate 100 and the second substrate 200 may each have a uniform thickness.

The first substrate 100 and the second substrate 200 may each include a transparent resin. For example, the first substrate 100 and the second substrate 200 may include polyethylene terephthalate (PET), polycarbonate (PC), polyethylene (PE), polypropylene (PP), polysulfone (PSF), and polymethyl It may be made of a material conventionally applied to an optical film, such as methacrylate (PMMA), triacetyl cellulose (TAC), cycloolefin polymer (COP) or cycloolefin copolymer (COC). The light transmittance of the first substrate 100 and the second substrate 200 may be 90% or more. The first substrate 100 and the second substrate 200 may be made of the same material, but are not limited thereto.

A first pattern layer 310 is disposed on the upper surface of the first substrate 100 . The upper surface of the first pattern layer 310 may include a first surface unevenness (or a first pattern portion, an upper portion of a dotted line inside '310' in the drawing) including a concave portion and a convex portion. The first pattern layer 310 may further include a first base portion (or a first relief layer, a lower portion of a dotted line inside '310' in the drawing) that integrally connects each convex portion.

A second pattern layer 320 is disposed on the first pattern layer 310 . The lower surface of the second pattern layer 320 may directly contact the upper surface of the first pattern layer 310 . The lower surface of the second pattern layer 320 may include a second surface asperity including convex portions and concave portions (or a second pattern portion, a lower portion of the dotted line inside '320' in the drawing). The first surface irregularities of the first pattern layer 310 and the second surface irregularities of the second pattern layer 320 may have complementary shapes that engage with each other. That is, the convex portion of the first surface asperity has substantially the same shape as the convex portion of the second surface asperity and may be engaged. The concave and convex portions of the first surface asperity have substantially the same shape as the convex and convex portions of the second surface concavo-convex and engage with each other. A specific shape of the first surface asperity will be described later.

The upper surface of the second pattern layer 320 may be in contact with the lower surface of the second substrate 200 . The upper surface of the second pattern layer 320 may be substantially flat, but is not limited thereto.

In an embodiment, the second pattern layer 320 may not include a base portion unlike the first pattern layer 310 . In this case, each pattern of the second pattern layer 320 may be divided or divided by the convex portions of the first surface asperity of the first pattern layer 310 . In addition, at least a portion of the convex and convex portions of the first surface asperity of the first pattern layer 310 may contact the lower surface of the second substrate 200 .

In another embodiment, the second pattern layer 320, like the first pattern layer 310, is a second base portion (or second alleviation layer, '320' in the drawing) connecting each convex portion of the second pattern layer 320. The inner dotted line upper portion) may be further included. The thickness of the second base may be equal to, smaller than, or larger than the thickness of the first base. When the thickness of the second base is smaller than the thickness of the first base, the maximum thickness of the second pattern layer 320 may also be smaller than the maximum thickness of the first pattern layer 310 . On the other hand, as will be described later, when the first pattern layer 310 has only light modulation characteristics and the second pattern layer 320 has not only light modulation characteristics but also adhesion characteristics, the thickness of the second base is the first It may be greater than the thickness of the base, and in this case, the maximum thickness of the second pattern layer 320 may also be greater than the maximum thickness of the first pattern layer 310 .

The combined thickness of the first pattern layer 310 and the second pattern layer 320 may be uniform. In some embodiments, the height t10 of the convex portion of the first pattern layer 310 may not be uniform. For example, the height of the first pattern region PTR1 and the second pattern region PTR2 to be described later may be different from each other. In addition, a height difference may occur between the convex portions belonging to the first pattern region PTR1 . In this case, the second pattern layer 320 formed on the upper surface of the first pattern layer 310 may perform a planarization function. That is, in a region where the thickness (or height) t10 of the convex portion of the first pattern layer 310 is large, the thickness (or height) t21 of the concave portion of the second pattern layer 320 is relatively small, and the first pattern In a region where the thickness t10 of the convex portion of the layer 310 is small, the thickness t21 of the concave portion of the second pattern layer 320 is relatively large, and thus the first pattern layer 310 and the second pattern layer 320 are generally large. The combined thickness can be maintained uniformly. As the sum of the thicknesses of the first pattern layer 310 and the second pattern layer 320 is uniform, the distance between the upper surface of the first substrate 100 and the lower surface of the second substrate 200 opposite thereto may also be uniform. have. Similarly, the sum of the thickness t11 of the concave portion of the first pattern layer 310 and the corresponding thickness t20 of the convex portion of the second pattern layer 320 is uniform, and the convex portion of the first pattern layer 310 is uniform. It may be the same as the sum of the thickness t10 and the thickness t21 of the corresponding concave portion of the second pattern layer 320 .

In a state in which the pattern sheet 10 is spread in a flat plate shape, the first substrate 100 and the second substrate 200 may be arranged in parallel.

The first pattern layer 310 and the second pattern layer 320 may each include a transparent resin. The first pattern layer 310 and the second pattern layer 320 are photocurable resins such as epoxy acrylate-based resins, urethane acrylate-based resins, and silicone acrylate-based resins, acrylic resins, urethane-based resins, and polyester-based resins, respectively. It may include a thermosetting resin, such as. The resin constituting the first pattern layer 310 and the second pattern layer 320 may each have a light transmittance of 95% or more.

The second pattern layer 320 may further have an adhesive property. When the pattern sheet 10 includes the second substrate 200 and the second pattern layer 320 has high adhesive properties, the lamination quality of the pattern sheet 10 itself may be improved. In addition, when laminating the second pattern layer 320 with the second substrate 200 or laminating the pattern sheet 10 without the second substrate 200 with an additional adherend, a separate bonding member may be omitted. have. In this case, the adhesive force of the second pattern layer 320 may be 500 g/25 mm or more, and more preferably 1000 g/25 mm or more. For example, when the second pattern layer 320 is attached to non-alkali glass (Corning Eagle XG Glass 0.7t), the adhesive force between the glass and the second pattern layer 320 is 1500 g/25 mm or more. , when using the pattern sheet 10 as a surface film, it is possible to implement a strong bonding force without using a separate bonding member.

The refractive index of the first pattern layer 310 and the second pattern layer 320 may be about 1.4 to 1.7 or about 1.5 to 1.6, but is not limited thereto. In an embodiment, the first pattern layer 310 and the second pattern layer 320 may have the same refractive index. In this case, since a substantial optical interface is not formed at the interface between the first pattern layer 310 and the second pattern layer 320 , light passing through the interface may travel straight without being refracted. In another embodiment, the refractive indices of the first pattern layer 310 and the second pattern layer 320 may be different. For example, when the difference in refractive index between the first pattern layer 310 and the second pattern layer 320 is 0.1 or more, the interface between the first pattern layer 310 and the second pattern layer 320 is an optical interface. It can perform a light modulation function such as refracting or reflecting the propagation direction of light.

In an embodiment, the first pattern layer 310 and the second pattern layer 320 may include the same material. In another embodiment, the first pattern layer 310 and the second pattern layer 320 may include different materials. In some embodiments, the first pattern layer 310 and the second pattern layer 320 may have different components, but may have substantially the same refractive index. Here, the fact that the refractive indices are substantially the same may be used to include not only the case in which the refractive indices are completely identical, but also the case in which the difference in refractive indices is 0.01 or less.

In some embodiments, the second pattern layer 320 may have a smaller Young's modulus value than that of the first pattern layer 310 . When the second pattern layer 320 has a relatively smaller Young's modulus value, it has a relatively good restoring force, and the first pattern layer 310 or the second pattern layer 320 of the adjacent pattern sheet 10 during winding. Even when pressing occurs due to a minute step, deformation caused by it can be reduced.

1 illustrates a case in which the first pattern layer 310 is formed directly on the upper surface of the first substrate 100 and the second pattern layer 320 is formed directly on the lower surface of the second substrate 200, but the first A functional coating layer such as a release layer may be further disposed between the upper surface of the substrate 100 and the first pattern layer 310 and/or between the lower surface of the second substrate 200 and the second pattern layer 320 . In this case, the adhesive force of the release layer to the pattern layer 300 is smaller than the adhesive force of the above-described second pattern layer 320 , and may be, for example, 5 g/25 mm to 30 g/25 mm, but is not limited thereto.

In some embodiments, between the upper surface of the first substrate 100 and the first pattern layer 310 and/or between the lower surface of the second substrate 200 and the second pattern layer 320 , a functional coating layer having opposite functions can be placed. For example, on the upper surface of the first substrate 100 , that is, between the first substrate 100 and the first pattern layer 310 , a primer layer for increasing adhesion with the first pattern layer 310 is further provided. and on the lower surface of the second substrate 200 , that is, between the second substrate 200 and the second pattern layer 320 , a release layer for lowering the adhesion with the second pattern layer 320 may be further provided. have. Conversely, the release layer may be disposed on the upper surface of the first substrate 100 and the primer layer may be disposed on the lower surface of the second substrate 200 .

Hereinafter, the surface uneven shape of the first pattern layer 310 and the second pattern layer 320 will be described in detail with reference to FIGS. 1 to 4 .

2 to 4 are cross-sectional views of pattern sheets according to various embodiments.

First, referring to FIG. 1 , the first surface unevenness of the first pattern layer 310 may have a prism shape having an isosceles triangular cross-section. Here, the equilateral side of the isosceles triangle becomes the surface of the first pattern layer 310 , and the base side becomes an imaginary line connecting the valleys of the first pattern layer 310 . The prism shape of the first pattern layer 310 may extend in a first direction, and convex portions and concave portions may be alternately arranged along a second direction intersecting the first direction. In this case, the convex portion of the first pattern layer 310 may be the ridge of the prism, and the concave portion of the first pattern layer 310 may be the valley of the prism. In the cross-sectional view, an isosceles triangle of the convex portion of the first surface of the first pattern layer 310 and an isosceles triangle of the concave portion may have the same shape. In this case, the shape of the concave and convex portions of the second surface asperity of the second pattern layer 320 may be the same isosceles triangle in cross-sectional view.

As an example of the pattern layer 301 of the other pattern sheet 10_1 , the first surface asperity of the first pattern layer 311 may have a prism shape having an asymmetric triangular cross-section as shown in FIG. 2 . The cross-sectional shape of the first surface unevenness of the first pattern layer 311 may be a right-angled triangle having one side of the convex portion as the hypotenuse. The cross-sectional shape of the second surface unevenness of the second pattern layer 310 may also be the same right-angled triangle.

As another example of the patterned layer 302 of the patterned sheet 10_2 , the first surface asperity of the first patterned layer 312 may have a trapezoidal shape as illustrated in FIG. 3 . The convex portion of the first surface unevenness may have an isometric trapezoidal shape in which a base (imaginary line connecting valleys) is longer than an upper side, and a hypotenuse (lateral side) has the same slope. The cross-sectional shape of the second surface unevenness of the second pattern layer 322 may also be an isometric trapezoidal shape.

As another example of the pattern layer 303 of the pattern sheet 10_3 , the first surface asperity of the first pattern layer 313 may have a rounded side surface as shown in FIG. 4 . The embodiment of FIG. 4 corresponds to the case of the hypotenuse curve in the embodiment of FIG. 3 . In FIG. 4 , the hypotenuse of the first surface unevenness is convex and the hypotenuse of the second surface unevenness of the second pattern layer 314 complementary thereto forms a concave curve. On the contrary, the hypotenuse of the first surface unevenness is concave. and the hypotenuse of the second surface asperity may be convex.

5 is a cross-sectional view of a pattern sheet according to another embodiment. The embodiment of FIG. 5 illustrates that at least one of the first patterned layer 314 and the second patterned layer 324 of the patterned layer 304 of the patterned sheet 10_4 may further include particles therein. . Specifically, a case in which the pattern sheet 10_4 is applied as a wavelength conversion sheet is exemplified in which the first pattern layer 314 and the second pattern layer 324 include wavelength conversion particles and scattering particles as examples of the particles. Unlike the example, the wavelength conversion particles WCP1 and WCP2 and the scattering particles SCP may be disposed on only one of the first pattern layer 314 and the second pattern layer 324 .

Referring to FIG. 5 , the first pattern layer 314 and the second pattern layer 324 may include wavelength conversion particles WCP1 and WCP2 therein. The wavelength conversion particles WCP1 and WCP2 are particles that convert the wavelength of incident light, and may be, for example, quantum dots (QDs), particles of a fluorescent material, or a phosphorescent material. Quantum dots, which are examples of wavelength conversion particles (WCP1, WCP2), are described in detail. Quantum dots are materials having a crystal structure of several nanometers in size, and are composed of hundreds to thousands of atoms. Since quantum dots are very small in size, quantum confinement effects appear. The quantum confinement effect refers to a phenomenon in which an energy band gap of an object becomes larger when an object becomes smaller than a nano size. Accordingly, when light having a wavelength higher than that of the bandgap is incident on the quantum dot, the quantum dot absorbs the light and enters an excited state, and falls to a ground state while emitting light of a specific wavelength. Light of the emitted wavelength has a value corresponding to the band gap. By controlling the size and composition of quantum dots, the light emission characteristics due to the quantum confinement effect can be controlled.

Quantum dots that can be applied to this embodiment are not particularly limited as long as they are commonly used, but for example, II-VI compounds, II-V compounds, III-VI compounds, III-V compounds, IV-VI compounds. It may include at least one of a group compound, a group I-III-VI compound, a group II-IV-VI compound, and a group II-IV-V compound.

The quantum dots may include a core and a shell over-coating the core. Cores include, but are not limited to, for example, CdS, CdSe, CdTe, ZnS, ZnSe, ZnTe, GaN, GaP, GaAs, GaSb, AlN, AlP, AlAs, AlSb, InP, InAs, InSb, SiC, Ca, It may be at least one of Se, In, P, Fe, Pt, Ni, Co, Al, Ag, Au, Cu, FePt, Fe2O3, Fe3O4, Si, and Ge. Shells include, but are not limited to, for example, ZnS, ZnSe, ZnTe, CdS, CdSe, CdTe, HgS, HgSe, HgTe, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, GaSe, InN, It may include at least one of InP, InAs, InSb, TlN, TlP, TlAs, TlSb, PbS, PbSe, and PbTe.

The wavelength conversion particles WCP1 and WCP2 may include a plurality of wavelength conversion particles that convert incident light into different wavelengths. For example, the wavelength conversion particle may include a first wavelength conversion particle (WCP1) that converts incident light of a specific wavelength into a first wavelength and emits it, and a second wavelength conversion particle (WCP2) that converts and emits a second wavelength. have. In an exemplary embodiment, the incident light may be light of a blue wavelength, the first wavelength may be a green wavelength, and the second wavelength may be a red wavelength. For example, the blue wavelength may be a wavelength having a peak at 420 nm to 470 nm, the green wavelength may be a wavelength having a peak at 520 nm to 570 nm, and the red wavelength may be a wavelength having a peak at 620 nm to 670 nm. However, it should be understood that the blue, green, and red wavelengths are not limited to the above examples, and include all wavelength ranges that can be recognized as blue, green, and red in the art.

In the exemplary embodiment, a portion of the blue light incident on the pattern layer 304 passes through the pattern layer 304 and enters the first wavelength conversion particle WCP1, is converted into a green wavelength, and is emitted, and the other portion is emitted. The second wavelength conversion particles WCP2 are incident on the WCP2, are converted into red wavelengths, and are emitted, and the remaining portion may be emitted without being incident on the first and second wavelength conversion particles WCP1 and WCP2. Accordingly, the light passing through the pattern layer 304 includes all of blue wavelength light, green wavelength light, and red wavelength light. If the ratio of the emitted light of different wavelengths is appropriately adjusted, white light or emitted light of a different color can be displayed. Lights converted to the pattern layer 304 are focused within a specific wavelength in a narrow range, and have a sharp spectrum with a narrow half maximum width. Accordingly, color reproducibility may be improved when color is realized by filtering light of such a spectrum with a color filter.

The ratio of the emitted light may be controlled by the ratio of the content of the first wavelength conversion particles WCP1 to the content ratio of the second wavelength conversion particles WCP2. For example, when the content of the first wavelength conversion particles (WCP1) is relatively large, more light of the first wavelength is emitted, and when the content of the second wavelength conversion particles (WCP2) is relatively large, the light of the second wavelength is more A lot is emitted In an exemplary embodiment, the content ratio of the first wavelength conversion particle WCP1 related to the green wavelength and the second wavelength conversion particle WCP2 related to the red wavelength may be 5:1 to 14:1, and further 8:1 to 12:1.

Unlike the above exemplary embodiment, incident light is ultraviolet light, and three types of wavelength conversion particles that convert it into blue, green, and red wavelengths, respectively, are inside the first pattern layer 314 and the second pattern layer 324 . It may be disposed to emit white light.

The first pattern layer 314 and the second pattern layer 324 may further include scattering particles (SCP) therein. The scattering particle (SCP) is a non-quantum dot particle, and may be a particle having no wavelength conversion function. The scattering particles (SCP) scatter the incident light so that more incident light is incident toward the wavelength conversion particle. In addition, the scattering particles (SCP) may play a role of uniformly controlling the emission angle of light for each wavelength. In detail, when some incident light is incident on the wavelength conversion particles WCP1 and WCP2 and the wavelength is converted and emitted, the emission direction has a random scattering characteristic. If there are no scattering particles (SCP) in the pattern layer 304, green and red wavelengths emitted after the collision of the wavelength conversion particles (WCP1, WCP2) have scatter emission characteristics, but without collision of the wavelength conversion particles (WCP1, WCP2) Since the emitted blue wavelength does not have a scattering emission characteristic, the emission amount of the blue/green/red wavelength may be different depending on the emission angle. Accordingly, the scattering particles (SCP) do not collide with the wavelength conversion particles (WCP1, WCP2) by imparting a scattering emission characteristic to the emitted blue wavelength, it is possible to similarly control the emission angle of light for each wavelength.

In order to effectively exhibit wavelength conversion efficiency and scattered emission characteristics, the content of the scattering particles (SCP) is preferably greater than or equal to the content (total) of the first and second wavelength conversion particles (WCP1, WCP2). However, if the content of the scattering particles (SCP) is too large, the transmittance of the pattern layer 304 may be reduced. For example, when the content of the scattering particles (SCP) exceeds 6 times the content of the first and second wavelength conversion particles (WCP1, WCP2), it is inappropriate to apply as a backlight assembly due to a decrease in transmittance. In this regard, the content of the scattering particles (SCP) is equal to or greater than the content (total) of the first and second wavelength conversion particles (WCP1, WCP2) or the content (total) of the first and second wavelength conversion particles (WCP1, WCP2) It may have a range of 6 times or less of

The scattering particles (SCP) may have a larger size than the wavelength conversion particles (WCP1, WCP2). For example, SiO2, TiO2, ZnO, etc. having a size of several tens of nm to several tens of um may be used as the scattering particles (SCP). In the case of SiO2, it may have a size of 0.1 μm to 20 μm, and in one embodiment, it may have a size of 1.5 μm to 3.5 μm. TiO2 may have a size of 0.05um to 5um, and in one embodiment, may have a size of 0.19um to 0.48um. In the case of ZnO, it may have a size of 0.1 μm to 2 μm.

6 is a cross-sectional view of a pattern sheet according to another embodiment. 6 illustrates a case in which the second pattern layer 325 of the pattern layer 305 of the pattern sheet 10_5 includes light absorbing particles LAP therein. The pattern sheet 10_5 having such a structure may be applied as a privacy sheet or a contrast enhancement sheet.

Referring to FIG. 6 , the first concave-convex surface of the first pattern layer 315 and the second concave-convex surface of the second pattern layer 325 each have an isometric trapezoidal shape in cross section. The light absorbing particles LAP are disposed inside the second pattern layer 325 . The light absorbing particles LAP are not disposed inside the first pattern layer 315 . In this case, it may be preferable that the second pattern layer 325 does not have a second base portion. Unlike the example, the light absorbing particles LAP are disposed inside the first pattern layer 315 and may not be disposed inside the second pattern layer 325 .

7 is a cross-sectional view of a roll-shaped pattern sheet according to an embodiment.

Referring to FIG. 7 , the pattern sheet 10R1 may be manufactured in a roll shape. When the pattern sheet 10R1 is applied to a display device, it may be cut from the roll-shaped pattern sheet 10R1 to have a predetermined shape. The cut pattern sheet may have a rectangular shape, but is not limited thereto.

In the roll-shaped pattern sheet 10R1, the longitudinal direction is a direction to be wound or unwound, and the width direction is a direction perpendicular to the longitudinal direction. The longitudinal direction may also be referred to as a longitudinal direction or MD (Machine Direction) direction because it corresponds to the traveling direction of the sheet when the roll-shaped pattern sheet 10 is manufactured. The width direction is a direction transverse to the MD direction, and may also be referred to as a transverse direction or a TD (Transverse Direction) direction. In an exemplary embodiment, the prism-shaped extension directions of the first patterned layer 310 and the second patterned layer 320 of the patterned sheet 10 are the TD directions of the roll-shaped patterned sheet 10 . The TD direction width of the roll-shaped pattern sheet 10 may be 1300 mm or more, but is not limited thereto.

The roll-shaped pattern sheet 10 may include a first pattern region PTR1 and a second pattern region PTR2 . The first pattern region PTR1 is a normal pattern region (or effective pattern region) in which the first surface irregularities of the first pattern layer 310 and the surface irregularities of the second pattern layer 320 described with reference to FIGS. 1 to 6 are normally formed. ) can be The second pattern region PTR2 is a region having a cross-sectional structure in which the first surface irregularities of the first pattern layer 310 and the second surface irregularities of the second pattern layer 320 have different cross-sectional structures, and may be a dummy pattern region. The second pattern region PTR2 of the roll-shaped pattern sheet 10 may not be applied to the display device. That is, when the pattern sheet 10 applied to the display device is formed, the roll-shaped pattern sheet 10R1 may be cut to include only the first pattern region PTR1 excluding the second pattern region PTR2 . In the second pattern region PTR2 , the shapes of the first pattern layer 310 and the second pattern layer 320 are different from those of the first pattern region PTR1 , but between the first substrate 100 and the second substrate 200 . The height (or the total thickness of the pattern layer 300 combined with the first pattern layer 310 and the second pattern layer 320) may be uniform in both the first pattern region PTR1 and the second pattern region PTR2. have.

The second pattern region PTR2 may be a result of forming the roll-shaped pattern sheet 10R1 using a soft mold including a joint portion. Hereinafter, the second pattern region PTR2 will be described in more detail through the description of the process of forming the first pattern layer 310 using the soft mold.

8 is a perspective view of a soft mold according to an exemplary embodiment, and FIG. 9 is a cross-sectional view taken along line IX-IX' of FIG. 8 and is a cross-sectional view of a joint of the soft mold. 10 is a cross-sectional view illustrating a process of manufacturing a pattern sheet using the soft mold of FIG. 8 .

8 to 10 , the first surface unevenness of the first pattern layer 310 may be formed using the soft mold 20 . The soft mold 20 has a pattern complementary to a target pattern to be formed on its surface. The first pattern layer ('310' in FIG. 1) having the first surface asperity is pressed so that the surface pattern of the soft mold 20 having the complementary shape of the first surface asperity is in contact with the first resin layer (imp tint). ), by curing the first resin layer. As another example, a first resin layer is formed by supplying a first resin to the surface pattern of the soft mold 20 having a complementary shape of the first surface unevenness, and then cured to form the first pattern layer 310 having the first surface unevenness. ) can also be formed. The first resin may be supplied on the surface pattern of the soft mold 20 or supplied on the upper surface of the first substrate 100 , and both the surface pattern of the soft mold 20 and the upper surface of the first substrate 100 . may be supplied simultaneously or sequentially. The soft mold 20 may be manufactured by duplicating a cylindrical or plate-shaped metal mold that is a hard mold.

Unlike the hard mold, the soft mold 20 may itself have a sheet shape. The soft mold 20 may include a mold substrate 21 and a mold pattern 22 disposed on the mold substrate 21 . Both ends of the soft mold 20 in the longitudinal direction may be connected to each other to form a loop shape. The loop-shaped soft mold 20 may rotate over the guide roll GR. That is, a specific position of the soft mold 20 may be moved in the longitudinal direction along the loop shape. A specific position of the soft mold 20 passes through the first resin supply unit RPD1 and moves in a state in which the first resin layer is supplied on the surface, and then, in the first lamination parts PRR1 and DRR, the first substrate ( 100) and the first resin layer may be transferred to the first substrate 100 side.

On the other hand, the surface shape of the soft mold 20 has a uniform repeating pattern along the longitudinal direction, but may have a different pattern in the joint portion (CNR) formed to make the loop shape. Specifically, the soft mold 20 may further include the first adhesive tape 23 disposed on the joint portion CNR. Both ends of the sheet-type soft mold 20 may be attached and connected through the first adhesive tape 23 . The first adhesive tape 23 may be disposed on the upper surface of the mold pattern 22 of the soft mold 20 . Since the first adhesive tape 23 is disposed on the mold pattern 22 , the surface of the first adhesive tape 23 may protrude more in the thickness direction than the ridge of the mold pattern 22 . Accordingly, the surface shape of the soft mold 20 may further protrude from the joint portion CNR in the thickness direction. In the imprint process, the convex portions of the soft mold 20 are transferred to the convex portions of the first pattern layer 310 and the convex portions of the soft mold 20 are transferred to the convex portions of the first pattern layer 310 , so the soft mold 20 When imprinting is performed using , the first pattern layer 310 pressed by the joint portion CNR may have a thinner concave portion.

In some embodiments, the soft mold 20 may further include a second adhesive tape 24 disposed on the lower surface of the mold substrate 21 . The second adhesive tape 24 may be omitted.

The first pattern layer 310 pressed by the joint portion CNR of the soft mold 20 corresponds to the second pattern region PTR2 of FIG. 7 , and in the second pattern region PTR2, the first pattern layer ( The thickness (thickness of the recess) of the 310 may be smaller than the thickness of the recess (valley) of the first pattern layer 310 in the first pattern region PTR1 . The length (width in the longitudinal direction) of the second pattern region PTR2 is greater than the repeat pattern pitch of the first pattern region PTR1, for example, 100 to 500 times the unit prism width (width in the MD direction). can be a range. In the roll-shaped pattern sheet 10R1 of FIG. 7 , the first pattern region PTR1 and the second pattern region PTR2 may be alternately arranged at a constant cycle along the longitudinal direction.

11 is a perspective view of a soft mold according to another embodiment, and FIG. 12 is a cross-sectional view taken along the line XII-XII' of FIG. 11 and is a cross-sectional view of a joint. 13 is a cross-sectional view of a roll-shaped pattern sheet formed using the soft mold of FIG. 11 .

11 and 12 , the soft mold 20_1 according to the present embodiment is different from the embodiment of FIG. 8 in that the joint CNR is formed by laser welding. At the joint CNR, both ends of the mold substrate may be fused through laser welding. The laser used for the laser welding may include, but is not limited to, an Alexandrite laser, a diode laser, an Nd:YAG laser, and the like. A predetermined section of the mold pattern 22 is completely removed from the upper surface of the mold base 21 at the joint CNR, or the residual layer of the mold pattern 22 is smaller than the thickness of the ridge of the mold pattern 22 as shown in the figure. This may be placed. The residual layer of the mold pattern 22 may be a residual layer remaining by laser welding the mold pattern 22 and the mold base 21 . A second adhesive tape 24 may be disposed on the lower surface of the mold base 21 at the joint portion CNR. The second adhesive tape 24 may be removed after laser welding is completed.

The joint portion CNR of the soft mold 20_1 of FIG. 12 is different from the joint portion CNR of the soft mold 20 of FIG. 9 , the residual layer of the mold pattern 22 may be recessed from the surrounding mold pattern 22 have. In one embodiment, the thickness of the remaining layer of the mold pattern 22 of the soft mold 20_1 may be smaller than the thickness of the ridges of the mold pattern 22 and may be greater than or equal to the thickness of the valleys of the mold pattern 22, but is limited thereto. no.

Referring to FIG. 13 , when the roll-shaped pattern sheet 10R2 is manufactured using the soft mold 20_1 of FIG. 11 , the shape of the first pattern layer 310 of the first pattern region PTR1 is shown in FIG. 7 . Although the same as the embodiment of , the shape of the first pattern layer 310 of the second pattern region PTR2 may have a predetermined thickness by transferring the shape of the recessed joint portion CNR, unlike the embodiment of FIG. 7 . have. The thickness of the first pattern layer 310 of the second pattern region PTR2 may be greater than the thickness of the valleys of the first pattern layer 310 of the first pattern region PTR1 and less than or equal to the thickness of the peaks. As another example, the thickness of the first pattern layer 310 of the second pattern region PTR2 may be greater than the thickness of the peaks of the first pattern region PTR1 . The length (width in the longitudinal direction) of the second pattern region PTR2 is greater than the prism repeat pattern pitch of the first pattern region PTR1 , for example, 5 to 50 times the unit prism width (width in the MD direction). may be in the range of

14 is a perspective view of a soft mold according to another embodiment. 15 is a cross-sectional view taken along line XV-XV' of FIG. 14 . 16 is a cross-sectional view taken along line XVI-XVI' of FIG. 14 . 17 is a cross-sectional view of the roll-shaped pattern sheet 10 formed using the soft mold of FIG. 14 .

This embodiment exemplifies a case in which the prism-shaped extension directions of the first pattern layer 310 and the second pattern layer 320 of the pattern sheet 10R3 are the MD directions of the roll-shaped pattern sheet 10 . Referring to FIG. 17 , the roll-shaped pattern sheet 10R3 includes a first pattern region PTR1 and a second pattern region PTR2 , and each prism pattern is formed along the length direction of the first pattern region PTR1 . After extending, the second pattern region PTR2 may be disconnected. The length (width in the longitudinal direction) of the second pattern region PTR2 is greater than the prism repeat pattern pitch of the first pattern region PTR1 , for example, 5 to 50 times the unit prism width (width in the TD direction). may be in the range of

Referring to FIG. 14 , both ends of the soft mold 20_2 are connected through a joint CNR. The prism shape of the mold pattern 22 of the soft mold 20_2 extends along the loop direction. 14 illustrates a case in which both ends of the soft mold 20_2 are attached and connected through the first adhesive tape 23 and the second adhesive tape 24 . However, the present invention is not limited thereto, and may be fused by a laser as in the embodiment of FIG. 12 .

Unlike the illustration, the prism-shaped extension directions of the first pattern layer 310 and the second pattern layer 320 of the pattern sheet 10R3 are inclined with respect to the MD and TD directions of the roll-shaped pattern sheet 10R3. may be lost For example, the prism shape extending direction may have an angle of 1° to 30° or an angle of 60° to 89° with respect to the MD direction.

As described above, the roll-shaped pattern sheets 10R1, 10R2, and 10R3 are formed on the upper surface of the first substrate 100 using the soft molds 20, 20_1, and 20_2 as described above for the first pattern layer 310. , and then forming the second pattern layer 320 and the second substrate 200 on the upper surface of the first pattern layer 310 may be completed. When the coating or pattern forming process is discontinuously performed in the manufacturing process of the sheets, the intermediate coating-finished sheet may be transported or stored in a rolled-up state. For example, by using the soft molds 20, 20_1, 20_2 as described above, the intermediate structure in which the first pattern layer 310 is formed on the upper surface of the first substrate 100 is wound in a roll shape to transport and / Or you can keep it. In this case, in the wound roll-shaped sheet, the upper surface of the first pattern layer 310 and the lower surface of the first substrate 100 may face each other in the wound portion. During the winding process, the sheet may be subjected to pressure in the thickness direction, and the portion corresponding to the second pattern region PTR2 has a smaller length (width in the longitudinal direction) than the first pattern region PTR1, as well as the pattern shape. Since they are different, the first pattern layer 310 of the second pattern region PTR2 may overlap and affect the opposite lower surface of the first substrate 100 by winding, and thus the first substrate 10 during winding ) may also affect the upper surface of the first pattern layer 310 opposite to the lower surface.

For example, when the first pattern layer 310 shown in FIG. 7 is formed and wound, the lower surface of the first substrate 100 opposite to the protruding portion of the second pattern region PTR2 is pressed by pressing the first pattern layer 310 when winding. It may cause a pressing defect in the first pattern layer 310 facing the lower surface of the first substrate 100 . When the first pattern layer 310 shown in FIG. 13 is formed and wound, the lower surface of the first substrate 100 is pressed toward the recessed portion of the second pattern region PTR2 so that the first substrate 100 is wound during winding. A pressing defect may be caused in the first pattern layer 310 facing the lower surface. The second pattern region PTR2 is removed and not used when applied to the pattern sheet 10 of the display device, but may affect the first pattern region PTR1 having a normal pattern during the winding process, and as a result, the first pattern region PTR2 is not used. The pattern region PTR1 may be bent or deformed, and a linear unevenness defect of the pattern sheet 10 may occur.

In order to minimize the influence of the joint portions CNR of the soft molds 20 , 20_1 , and 20_2 , the second pattern layer 320 is formed in a continuous process without the process of forming the first pattern layer 310 and then winding the second pattern layer 320 . ) is proposed.

18 is a flowchart of a method of manufacturing a pattern sheet according to an exemplary embodiment. As shown in FIG. 18 , the method for manufacturing a patterned sheet includes a step (S1) of forming a first pattern layer 310 on the upper surface of the first substrate 100, and a first pattern layer (S1) in a continuous process without a winding process. The step (S2) of forming the second pattern layer 320 on the 310 may be included.

19 is a schematic diagram illustrating an apparatus and process diagram for manufacturing a pattern sheet according to an embodiment.

Referring to FIG. 19 , the apparatus 50 for manufacturing a pattern sheet according to an exemplary embodiment includes a first pattern layer forming unit PTS1 and a second pattern layer forming unit PTS2 .

The first pattern layer forming part PTS1 may include a soft mold 20 , a first resin supply unit RPD1 , and first curing devices PCR1 and MCR1 . The first pattern layer forming part PTS1 may further include a guide roll GR, first lamination parts PRR1 and DRR, and/or a first substrate providing part SPD1. The first substrate of the first substrate providing unit SPD1 may be a finished product in which one or more patterned layers or functional layers are formed on the other surface of the first substrate, or another patterned sheet manufactured by the apparatus 50 for manufacturing a patterned sheet. , in this case, a configuration corresponding to the above-described first pattern layer, the second pattern layer, and the second substrate may be formed on the other surface of the first substrate.

The soft mold 20 may form a loop shape with the lower surface of the mold base 21 spanning the guide roll GR and the drum roll DRR.

The first resin supply unit RPD1 may be disposed on the traveling path of the soft mold 20 . The first resin supply unit RPD1 supplies the first resin onto the mold pattern 22 of the soft mold 20 . The first resin supply unit RPD1 may include at least one first water tank BTH1 and at least one first coating roll SMR1. The first coating roll SMR1 may have an elastic layer made of a rubber or urethane material on its surface. The first water tank BTH1 may contain the first resin. The first resin may include a photocurable material. In the case of the embodiment in which the first pattern layer 310 includes particles therein, the first resin may also include the particles.

The first coating roll SMR1 may be disposed between the first water tank BTH1 and the soft mold 20 . Specifically, the first water tank (BTH1) is disposed at the lower portion, the first coating roll (SMR1) is disposed on the upper surface, and the upper surface of the mold pattern 22 is first coated on the first coating roll (SMR1) The soft mold 20 may be disposed to face the roll SMR1. The first coating roll SMR1 may be installed to be rotatable. The first coating roll SMR1 is disposed to be in contact with the mold pattern 22 of the soft mold 20 and the first resin of the first water tank BTH1, and the first resin from the first water tank BTH1 on the surface It is supplied and rotates in the same direction as the transport direction of the soft mold 20 , and may serve to transfer it to the upper surface of the mold pattern 22 .

The first coating roll SMR1 may be plural. The plurality of first coating rolls SMR1 may be disposed adjacently. The soft mold 20 may sequentially receive the first resin from each of the first coating rolls SMR1 while sequentially passing through the plurality of first coating rolls SMR1 . When the soft mold 20 receives a small amount of the first resin from several first coating rolls SMR1, bubble generation is suppressed compared to receiving a large amount of the first resin from one first coating roll SMR1 at once. can be

The first substrate providing unit 100 includes a first substrate roll. The first substrate 100 unwound from the first substrate roll is transferred along the guide roll GR and moved to the first lamination units PRR1 and DRR. The first lamination unit may include a first pressing roll PRR1 and a drum roll DRR. The first substrate 100 is a soft mold moving on the drum roll DRR while passing through the space between the drum roll DRR and the first pressing roll PRR1 disposed at a predetermined distance from the drum roll DRR at the top thereof. 20 , and may come into contact with the first resin disposed on the mold pattern 22 of the soft mold 20 . The contacted first resin may be transferred from the soft mold 20 to the upper surface of the first substrate 100 , and the first pattern layer 310 may be formed through a plurality of curing processes to be described later. In addition, the lowermost end of the first pressing roll (PRR1) may be disposed similarly to each other so as to be positioned at a lower height than the uppermost end of the drum roll (DRR), although not shown in the drawings, the first pressing roll (PRR1) and the drum By providing two dams (gaskets) and one or more suctions at intervals narrower than the width of the soft mold 20 between the rolls DRR, the first resin remaining when the first pattern layer 310 is formed is transferred to the soft mold. It is possible to prevent a defect from occurring in the soft mold 20 or the first pattern layer 310 by leaking to the side of (20). The thickness t10 of the first pattern layer 310 may be adjusted by the distance between the drum roll DRR and the first compression roll PRR1. Specifically, the thickness t11 of the first base may be adjusted according to the interval between the drum roll DRR and the first pressing roll PRR1. For smooth circulation of the soft mold 20, an elastic layer made of rubber or urethane may be provided on the surface of the drum roll DRR.

The first resin transferred from the soft mold 20 may be cured through the first curing devices PCR1 and MCR1. The first curing devices PCR1 and MCR1 may include a first temporary curing device PCR1 and a first main curing device MCR1 . The first provisional curing device PCR1 may irradiate low-pressure UV, and the first main curing device MCR1 may irradiate high-pressure UV with a higher light quantity. The first temporary curing device PCR1 may be disposed near the drum roll DRR to temporarily cure the first resin at the same time or immediately after the first resin is transferred to the upper surface of the first substrate 100 . The first main curing device MCR1 is disposed on the travel path of the first substrate 100 to completely cure the pre-cured first resin to form the first pattern layer 310 . Accordingly, the first substrate 100 and the first pattern sheet in which the first pattern layer 310 is formed on the upper surface may be manufactured. The first pattern sheet completed by forming the first pattern layer 310 is transferred to the second pattern layer forming unit PTS2 without being wound. The shape of the first pattern layer 310 of the primary pattern sheet may be different from each other in the first pattern region PTR1 and the second pattern region PTR2 as described above. However, in the state of the primary pattern sheet, it is not wound and directly transferred to the step of forming the second pattern layer 320 , so that the pattern sheet 10 overlaps and a press defect occurs by the second pattern region PTR2 . can be prevented.

The second pattern layer forming unit PTS2 may include a second resin supply unit RPD2 and second curing devices PCR2 and MCR2 . The second pattern layer forming part PTS2 may further include a guide roll GR, lamination parts PRR2 and BKR, a blade BLD, and/or a second substrate providing part SPD2.

The second resin supply unit RPD2 may be disposed on a traveling path of the primary pattern sheet. The second resin supply unit RPD2 supplies the second resin on the upper surface of the first pattern layer 310 of the primary pattern sheet. The second resin supply unit RPD2 may include at least one second water tank BTH2 and at least one second coating roll SMR2. The second coating roll SMR2 may have an elastic layer made of a rubber or urethane material on its surface. The second water tank BTH2 may contain a second resin. The second resin may include a photocurable material. In the case of an embodiment in which the second pattern layer 320 includes particles therein, the second resin may also include the particles.

When the second resin does not contain a solvent, the viscosity of the second resin may be 300 cps to 3000 cps. If the viscosity of the second resin is too low, less than 300 cps, bubbles may be generated inside during the coating process of the second resin, resulting in poor appearance, and high fluidity of the second resin may make it difficult to control the thickness. On the other hand, when the viscosity of the second resin exceeds 3000 cps, the second resin is not well filled into the valleys (concave portions) of the first pattern layer 310 , and thus the production rate may be reduced. Accordingly, the preferred viscosity of the second resin is 300 cps to 3000 cps, and more preferably 500 cps to 1500 cps. When the second resin contains a solvent, it may have a viscosity of 300 cps or less or less than 300 cps.

The second coating roll SMR2 may be disposed between the second water tank BTH2 and the first pattern sheet. Specifically, the second water tank (BTH2) is disposed at the lower portion, the second coating roll (SMR2) is disposed on the upper surface, and the upper surface of the first pattern layer (310) is the first on the second coating roll (SMR2). The first pattern sheet may be disposed to face the second coating roll (SMR2). The second coating roll SMR2 may be installed to be rotatable. The second coating roll SMR2 is disposed to be in contact with the upper surface of the second resin and the first pattern layer 310 of the second water tank BTH2, and receives the second resin supplied from the second water tank BTH2 on the surface. It rotates in the same direction as the transport direction of the first pattern sheet and may serve to transfer it to the upper surface of the first pattern layer 310 .

The second coating roll SMR2 may be plural. The plurality of second coating rolls SMR2 may be disposed adjacently. The first pattern sheet may sequentially receive the second resin from each of the second coating rolls SMR2 while sequentially passing through the plurality of second coating rolls SMR2. When the first pattern sheet is supplied with the second resin in small amounts from several second coating rolls (SMR2), bubble generation is suppressed compared to receiving a large amount of the second resin from one second coating roll (SMR2) at once. can

The first pattern sheet supplied with the second resin is transferred to the second lamination units PRR2 and BKR, and a blade BLD is installed in the middle to perform a squeezing process. The blade BLD may be installed to at least partially contact the surface of the second resin. When the first pattern sheet supplied with the second resin is passed through the blade BLD, it is possible to control the thickness of the surface as well as to make the non-uniform surface uniform. In addition, when supplying the second resin to the first pattern sheet, the second resin may be partially unfilled on the valleys of the first pattern layer 310, and such an unfilled space can be filled through a squeezing process. have.

The second substrate providing unit 200 includes a second substrate 200 roll. The second substrate 200 unwound from the roll of the second substrate 200 is transferred along the guide roll GR. The second substrate 200 comes close to the first pattern sheet supplied with the second resin from the second lamination units PRR2 and BKR, passes through the second lamination units PRR2 and BKR, and may be laminated while in contact with each other. have.

The second lamination parts PRR2 and BKR may include a second pressing roll PRR2 (or a gap roll) and a support roll BKR (or a back roll). The second pressing roll (PRR2) and the support roll (BKR) may be disposed to face each other at regular intervals in the horizontal direction. The first pattern sheet and the second substrate 200 supplied with the second resin may be laminated while passing between the second pressing roll PRR2 and the support roll BKR in a vertical or vertical direction. The thickness of the pattern sheet 10 may be controlled by adjusting the interval between the second pressing roll PRR2 and the support roll BKR. The thickness t20 of the second pattern layer 320 may be adjusted by the interval between the second pressing roll PRR2 and the support roll BKR, and specifically, the thickness t21 of the second base may be adjusted. have. Although not shown in the drawing, between the second pressing roll (PRR2) and the support roll (BKR), two dams (gaskets) and one or more suctions are formed at intervals narrower than the width of the first pattern sheet and the second substrate. By providing the second pattern layer 320, it is possible to prevent the second resin from leaking to both sides when the second pattern layer 320 is formed, thereby preventing a defect from occurring.

The second resin may be cured through the second curing devices PCR2 and MCR2. The second curing devices PCR2 and MCR2 may include a second temporary curing device PCR2 and a second main curing device MCR2. The second provisional curing device PCR2 may irradiate a low-pressure UV, and the second main curing device MCR2 may irradiate a higher high-pressure UV than that. In the case of the second temporary curing device PCR2, it may be disposed on the side of the second substrate 200 provided from the second substrate providing unit SPD2, but the second substrate 200 includes a material that blocks or absorbs UV. In this case, it may be disposed on the side of the primary pattern sheet, and the same may be applied to the embodiments described below. The second curing devices PCR2 and MCR2 are disposed adjacent to or adjacent to the second lamination portions PRR2 and BKR to temporarily cure the second resin at the same time or immediately after the second resin and the second substrate 200 are laminated. can get angry The second main curing device MCR2 may be disposed on the travel path of the second substrate 200 to completely cure the second pre-cured resin to form the second pattern layer 320 . The secondary pattern sheet on which the lamination and the second pattern layer 320 are formed may be wound in a roll shape as the completed pattern sheet 10R. In the pattern sheet 10R to be wound, the second pattern layer 320 is already formed on the second pattern region PTR2 , so that when viewed as a whole of the pattern layer 300 , the first pattern region PTR1 and the second pattern region PTR2 . The region PTR2 may have a uniform thickness, and the lower surface of the first substrate 100 and the upper surface of the second substrate 200 may also have flat surfaces without protrusions. Accordingly, even if the pattern sheets 10R overlap by winding, a pressing defect or the like can be prevented. When the second pattern layer 320 is formed of the second resin having a predetermined modulus value after complete curing, it may be more advantageous to prevent a pressing defect. In this case, the thickness t21 of the second base formed on the second pattern layer 320 may be greater than the thickness t11 of the first base formed on the first pattern layer 310 . In addition, the second pattern layer 320 may further have an adhesive property.

20 is a schematic diagram illustrating an apparatus and process diagram for manufacturing a pattern sheet according to another embodiment.

Referring to FIG. 20 , in the apparatus 50_1 for manufacturing a pattern sheet according to the present embodiment, the arrangement of the second lamination units PRR2 and BKR is different from the embodiment of FIG. 19 . That is, the second lamination part (PRR2, BKR) including the second pressing roll (PRR2) (or gap roll) and the support roll (BKR) (or back roll) is the same as the embodiment of FIG. 19 , but the second pressing roll It is different from the embodiment of FIG. 19 in that the PRR2 and the support roll BKR are disposed to face each other at regular intervals in the vertical direction (or in the vertical direction). In the present embodiment, the first pattern sheet and the second substrate 200 supplied with the second resin may be laminated while passing between the second pressing roll PRR2 and the support roll BKR in a horizontal direction. Also in this embodiment, the thickness of the pattern sheet 10R can be controlled by adjusting the interval between the second pressing roll PRR2 and the support roll BKR.

Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those of ordinary skill in the art to which the present invention pertains may be embodied in other specific forms without changing the technical spirit or essential features of the present invention. you will be able to understand Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive.

10: pattern sheet
100: first substrate
200: second substrate
300: pattern layer
310: first pattern layer
320: second pattern layer

Claims (15)

Forming a first pattern layer comprising a first surface unevenness on the upper surface of the first substrate unwound from the first substrate roll;
Forming a second pattern layer on the first pattern layer in a continuous process without a process of winding the first substrate on which the first pattern layer is formed, wherein the thickness of the first pattern layer and the second pattern layer is forming the second pattern layer so that the sum is uniform; and
Comprising the step of disposing a second substrate unwound from a second substrate roll on the second pattern layer after the step of forming the second pattern layer,
The second pattern layer includes a second surface unevenness having a complementary shape engaged with the first surface unevenness,
The first pattern layer includes a first pattern region and a second pattern region in which the first surface irregularities and the second surface irregularities have a cross-sectional structure different from that of the first pattern region,
The first pattern layer is formed from a first resin,
The second pattern layer is formed from a second resin that does not contain a solvent and has a viscosity of 300 to 3000 cps,
The second pattern layer has a smaller Young's modulus value than the first pattern layer,
The second pattern layer is an adhesive layer having an adhesive strength with glass of 1500 g/25 mm or more,
The step of forming the second pattern layer further comprises the step of sequentially supplying the second resin on the first pattern layer through a plurality of second coating rolls disposed adjacently,
The first pattern layer includes a first base for integrally connecting the convex and convex portions of the first surface,
The second pattern layer includes a second base portion integrally connecting the convex and convex portions of the second surface unevenness,
The thickness of the second base portion is greater than the thickness of the first base portion manufacturing method of the pattern sheet. According to claim 1,
The first pattern layer is formed by a soft mold including a joint,
The method of manufacturing a pattern sheet in which the second pattern region is formed by the joint portion. delete According to claim 1,
The method of manufacturing a pattern sheet having a refractive index difference of 0.1 or more between the first pattern layer and the second pattern layer. delete delete According to claim 1,
The first pattern layer is a method of manufacturing a pattern sheet having a prism shape having a cross section of a triangle or a trapezoid. 8. The method of claim 7,
At least one of the first pattern layer and the second pattern layer is a method of manufacturing a pattern sheet including particles therein. 9. The method of claim 8,
The particle is a method of manufacturing a pattern sheet comprising wavelength conversion particles and scattering particles. 9. The method of claim 8,
The particles include light absorbing particles,
The light absorbing particles are disposed inside the second pattern layer, the manufacturing method of the pattern sheet is not disposed inside the first pattern layer. delete delete A pattern sheet manufacturing apparatus including a first pattern forming unit and a second pattern forming unit, the apparatus comprising:
The first pattern forming unit includes a first substrate providing unit including a soft mold, a first resin supply unit, and a first substrate roll,
The second pattern forming unit includes a lamination unit, a second resin supply unit, and a second substrate providing unit including a second substrate roll,
The first pattern forming part and the second pattern forming part are connected in a continuous process,
The second pattern forming part is disposed on the traveling path of the pattern sheet on which the pattern is formed in the first pattern forming part,
The soft mold includes a joint,
The lamination part is disposed between the second substrate providing part and the second resin supply unit,
There is no means for winding the first substrate provided by the first substrate providing unit between the first pattern forming unit and the second pattern forming unit,
The first resin supply unit supplies a first resin,
The second resin supply unit supplies a second resin having a viscosity of 300 to 3000 cps,
The second resin has a smaller Young's modulus value than the first resin in a cured state
The second resin has an adhesive strength of 1500 g/25 mm or more with glass in a cured state,
The second resin supply unit is disposed adjacent to the manufacturing apparatus of a pattern sheet including a plurality of coating rolls configured to supply the second resin. delete 14. The method of claim 13,
The lamination part is an apparatus for manufacturing a pattern sheet including a second pressing roll and a support roll disposed to face the second pressing roll at a predetermined interval.

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