KR20040025815A - Method for manufacturing reflective object having prominence and depression surface and method for manufacturing liquid crystal display having the reflective object - Google Patents

Abstract

PURPOSE: To provide a method of highly efficiently manufacturing a reflector having a random recessed and projected shape at an excellent yield. CONSTITUTION: The manufacturing method of the reflector is provided with a process of using a mother die 15 for which a fine recessed and projected shape is formed on the surface of a roughly columnar mother die base material, rotating the mother die 15 while pressurizing it on a transfer resin film 17 and transferring the surface shape of the mother die 15 to the transfer resin film 17. The reflector can be constituted by forming a metal reflection film on the transfer resin film 17 as well and the shape can be transferred to an organic film by the plate of Ni obtained by performing Ni electrocasting once or more to the transfer resin film 17 as well.

Description

METHODS FOR MANUFACTURING REFLECTIVE OBJECT HAVING PROMINENCE AND DEPRESSION SURFACE AND METHOD FOR MANUFACTURING LIQUID CRYSTAL DISPLAY HAVING THE REFLECTIVE OBJECT}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a reflector having a fine concavo-convex shape on a reflective surface, and a method of manufacturing a liquid crystal display device.

In portable electronic devices such as mobile phones and portable game consoles, since the battery driving time greatly affects convenience in use, a display unit is provided with a reflective liquid crystal display device that can reduce power consumption. The reflective liquid crystal display device includes a reflective film for reflecting external light incident from the front surface thereof, and in such a form, a reflective film is incorporated between two substrates constituting the liquid crystal panel, or the back of the transmissive liquid crystal panel. It is known to arrange | position the reflector provided with the transflective film at the side.

For example, in the reflection type liquid crystal display device described in Japanese Patent No. 3019058, the reflection band for reflecting the light transmitted through the liquid crystal layer is composed of two or more kinds of regions having different directivities when scattering the light. The largest dimension of an area | region is set to 5 mm or less in width and length. That is, necessary reflection characteristics are obtained by mixing regions having different diffusivity in one pixel or in pixel units.

As a method of forming the uneven structure on the surface of the reflecting band having such diffuse reflectivity, as described in Japanese Patent No. 3019058 or Japanese Patent Application Laid-Open No. 9-54318, etc., sand blasting, etching with an etchant, a photo Lithography or the like is used, and embossing or the like is used for the film substrate.

However, the reflecting band having a fine concavo-convex shape formed by the above-described forming method has a problem that it is very difficult to control the reflecting property to a desired state. In order to impart anisotropy or asymmetry to the reflection and diffusion characteristics of the reflection band, the uneven shape must be appropriately controlled. In the above-described method, it is easy to give randomness to the uneven part distribution, but the uneven part has an isotropic shape. Because it must be.

In addition, in order to control the reflection diffusion characteristics, the irregularities of the reflection bands may be individually controlled to be formed. However, problems such as prolongation of the processing lead time, a decrease in the yield of the product, and a large increase in the manufacturing cost caused by these are caused. have.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a method for producing a reflector having a random uneven shape with high efficiency and high yield.

Another object of the present invention is to provide a method of forming a fine concavo-convex shape applicable to the formation of a reflective layer of a liquid crystal display device.

1 is a partial perspective view showing an example of the configuration of a reflector according to the present invention.

FIG. 2: A is a planar block diagram of the recessed part formed in the reflector shown in FIG. 1, B of FIG. 2 is sectional block diagram along the G-G line shown to A of FIG.

FIG. 3 irradiates light to the reflector 10 shown in FIG. 1 at an incidence angle of 30 ° on the right side of the illustration in FIG. 2, and centers the light-receiving angle at 30 ° which is the direction of normal reflection with respect to the reflecting surface (the surface of the reflective film 12). The graph which shows the result of having measured the reflectance (%) of the reflector 10 by rotating in the range of +/- 30 degree (0 degrees-60 degrees; 0 degrees correspond to the normal direction of the liquid crystal panel 20).

4 is a perspective configuration diagram showing a model for forming the uneven shape of the reflector in the manufacturing method of the present embodiment.

FIG. 5 is a cross-sectional configuration diagram showing a step of manufacturing a roll plate using the model shown in FIG. 4. FIG.

The figure which shows the cross-sectional structure of the roll board produced by the process shown in FIG.

FIG. 7 is a perspective configuration diagram showing a step of forming the uneven shape of the reflector using the roll plate shown in FIG. 6. FIG.

8 is a perspective configuration diagram showing another example of the organic film processing step by the manufacturing method of the present embodiment.

FIG. 9 is a process diagram showing an embodiment of a model production apparatus for producing the model 15 shown in FIG. 4. FIG.

The cross-sectional block diagram which shows an example of the tip shape of the indenter with which the model manufacturing apparatus shown in FIG. 9 was equipped.

11A and 11B are explanatory views for explaining the manufacturing process at the time of changing the uneven | corrugated arrangement pattern formed in the organic film in the manufacturing method of this embodiment.

12 is a perspective configuration diagram showing an example in which the reflector according to the present invention is applied to a reflective layer of a liquid crystal display device.

FIG. 13 is a partial cross-sectional view of the liquid crystal display shown in FIG. 12;

* Explanation of symbols for the main parts of the drawings *

10: reflector

11: organic film

12: metal reflective film

13: recess

15: Model

17: transfer resin film

30: Ni plate

31: Ni film

35: roll plate

32: cushioning material

41: model description

47: Indenter

In order to achieve the above object, the present invention adopts the following configuration.

The manufacturing method of the reflector which concerns on this invention comprises an organic film and the metal reflecting film formed on this organic film, and when manufacturing the reflector in which the many concave part or convex part was continuously formed in the surface of the said organic film, it is a substantially cylindrical shape. Using a model having a fine concavo-convex shape formed on the surface of the model substrate, the model is rotated while pressing on the transfer resin film to transfer the model surface shape to the transfer resin film.

The manufacturing method of the above constitution provides a fine concavo-convex shape to the metal reflecting film that reflects light, scatters the reflected light, prevents the reflected light brightness from a specific direction from protruding, and at the same time obtains a high brightness in a wide angle range. It is a preferable manufacturing method for manufacture. In this manufacturing method, a model in which a fine uneven shape is formed on a surface of a substantially cylindrical columnar base material for forming a fine uneven shape on the surface of an organic film made of a resin material or the like is used. That is, by pressing and rotating the model on the transfer resin film, the transfer of the fine concavo-convex shape of the model to the transfer resin film is carried out efficiently, and the transfer resin film is used as the organic film, or the transfer resin film is used as the transfer type, so The organic film in which the fine concavo-convex shape was formed in the surface can be obtained by methods, such as forming a shape. Since the model is roughly cylindrical, the pressing force is applied to the contact surface of the columnar shape substantially, so that the processing accuracy is improved as compared with the case of pressing against the flat surface, and the pressure is the length of the transfer resin film in the previous direction of the model. There is no restriction | limiting in this and it can apply to manufacture of the reflector using a large board | substrate very easily, and the formation of the fine uneven | corrugated shape of a reflector can be performed very efficiently.

Next, in the manufacturing method of the reflector which concerns on this invention, a reflector can be manufactured by forming the said metal reflecting film on the said transfer resin film surface to which the fine uneven | corrugated shape of the said model was transferred.

The manufacturing method of the said structure uses a transfer resin film | membrane as mentioned above as an organic film, and comprises a reflector. According to this manufacturing method, a metal reflective film can be produced on the organic film provided with the said model surface and the fine uneven | corrugated shape of inverse uneven | corrugated shape by a process with few steps.

Next, the manufacturing method of the reflector which concerns on this invention is Ni by the process of forming a metal film on the transcription | transfer resin film to which the said fine uneven | corrugated shape of the said model was transferred, and Ni electroforming using the said metal film as an electrode. It can also be set as the structure which has a process of producing a board | plate, and the process of transferring the fine uneven shape transferred to the said Ni board | plate to an organic film.

In the manufacturing method of the said structure, Ni plate | board is produced by Ni electroplating, making the transfer resin film | membrane in which the model fine uneven | corrugated shape was formed circularly, and using this Ni board | substrate, organic film processing is performed. Therefore, the reflector in which the said model and the uneven | corrugated shape were formed in the organic film surface can be manufactured. In such a manufacturing method, since the large-size Ni plate can be manufactured with an approximately cylindrical shape, and an organic film process can be performed, the manufacturing efficiency especially in the process of forming a fine uneven shape on the surface of an organic film can be improved. .

Next, the manufacturing method of the reflector which concerns on this invention is a process of forming a metal film on the transfer resin film | membrane in which the fine uneven | corrugated shape of the said model was transferred, and producing a Ni plate by Ni electroplating which used the said metal film as an electrode. A step of performing Ni electroforming with the Ni plate as an electrode, forming a Ni film on the metal film on the Ni plate, peeling the Ni film from the metal film, and fine unevenness transferred to the Ni film. It can be set as the structure which has a process of transferring a shape to an organic film.

In the manufacturing method of the above configuration, a Ni plate is produced by using a transfer resin film made as a model, and a Ni film having a fine concavo-convex shape of a model and inverse irregularities is formed by performing a Ni electroplating which makes the Ni plate circular. The organic film is processed using the Ni film. Therefore, according to this manufacturing method, since an organic film having a fine uneven shape substantially the same as that of the model can be formed, it is easy to feed back the reflection characteristics of the produced reflector to the model, thereby making it possible to respond quickly to changes in the reflection characteristics.

Next, the manufacturing method of the reflector which concerns on this invention is a process of forming a metal film on the transfer resin film | membrane in which the fine uneven | corrugated shape of the said model was transferred, and producing a Ni plate by Ni electroplating which used the said metal film as an electrode. Performing a Ni electroforming with the Ni plate as an electrode, forming a Ni film on the metal film on the Ni plate, peeling the Ni film from the metal film, and a buffer material on the back side of the Ni film. Forming a roll plate by wrapping the Ni film around the gas circumferential surface of the substantially cylindrical shape with the buffer material inwardly; and pressing and rotating the roll plate on the organic film to simultaneously rotate the fine film of the outer surface of the Ni film. It can also be set as the structure which has a process of transferring a shape to the said organic film surface.

The manufacturing method of the said structure performs an organic film process using the roll plate which wound and wound the Ni film | membrane which has a fine concavo-convex shape of a model and an inverse unevenness | corrugation throughout substantially cylindrical shape. Therefore, according to this manufacturing method, the reflector provided with the fine uneven | corrugated shape substantially the same as a model surface can be obtained. According to this manufacturing method, as in the case of pressing a plate-like Ni plate onto an organic film to transfer its shape, the organic film processing, the organic film and Since separation of a plate is performed, the shape transfer process to an organic film can be performed very efficiently.

In addition, in the above structure, since the buffer material is formed between the Ni film and the substantially cylindrical gas, the pressing force to the organic film is easily controlled when the organic film is processed, and the Ni film or organic It is possible to effectively prevent the film from being over-pressured and damaged, thereby realizing the long life of the roll plate and improving the product yield of the organic film to be produced.

Next, in the manufacturing method of the reflector which concerns on this invention, it is preferable that the fine concavo-convex shape of the said model is a shape in which many concave parts containing a part of spherical surface are arranged continuously.

With the above configuration, it is possible to provide a reflector in which light incident on the reflector is reflected at a wide angle, whereby a high reflection luminance can be obtained in a wide angle range.

Next, the liquid crystal display device according to the present invention, when the liquid crystal layer is sandwiched between the upper substrate and the lower substrate disposed opposite, and the liquid crystal display device having a reflective layer on the liquid crystal side of the lower substrate is described above, The reflective layer is formed on the lower substrate by the method of manufacturing a reflector of the present invention.

According to the manufacturing method of such a liquid crystal display device, by applying the above-described manufacturing method of the reflector, it is possible to form the reflecting layer very efficiently, and it is easy to change the model surface shape for the change of the reflecting property of the reflector, A liquid crystal display device having reflective characteristics can be easily manufactured.

Embodiment of the invention

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described with reference to drawings.

(Method of manufacturing reflector)

First, the reflector which can be manufactured by the manufacturing method of the reflector which concerns on this invention is demonstrated. 1 is a partial perspective view showing an example of the configuration of a reflector according to the present invention, A in FIG. 2 is a plan configuration diagram of a recess formed in the reflector shown in FIG. 1, and B in FIG. 2 is GG shown in A of FIG. 2. It is a cross-sectional block diagram along a line.

As shown in FIG. 1, the reflector 10 is made of a metal reflecting film 12 having a high reflectance such as Al or Ag, and an organic film made of acrylic resin material or the like for imparting a predetermined surface shape to the metal reflecting film 12 ( 11) is provided. A plurality of recesses 13 are formed on the surface of the organic film 11, and reflectivity is obtained by the metal reflective film 12 formed on the recesses 13.

As shown in FIG. 2, the inner surface of the recessed part 13 contains the 1st curved surface 13a which is a part of two spherical surfaces, respectively different in radius, and the 2nd curved surface 13b, These curved surfaces 13a and 13b are shown. of the center (O _1, O ₂₎ is part of a spherical surface of radius (R1) centered on the are arranged on a normal to the first surface (13a) of the deepest point (O) are O ₁ of the concave portion 13 and, a second surface (13b) is part of a spherical surface of radius (R2) of the center O _2. In the plan view shown in FIG. 2A, the first curved surface 13a and the second curved surface 13b are roughly divided in the vicinity of the straight line H passing through the deepest point O of the recess 13 and orthogonal to the GG line. It is.

FIG. 3 shows light reflecting on the reflector 10 having the above-described configuration at an angle of incidence of 30 ° on the right side of the drawing in FIG. It is a graph which shows the result of measuring the reflectance (%) of the reflector 10 by rotating in (0 degree-60 degree; 0 degree corresponds to the normal direction of the liquid crystal panel 20).

As shown in this figure, according to the reflector 10 having the above constitution, since the absolute value of the inclination angle of the second curved surface 13b having a relatively small radius is relatively large, the reflected light is scattered at a wide angle and is about 15 degrees. A high reflectance can be obtained in a wide light receiving angle range of from 50 ° to 50 °, and a narrower range in a specific direction than the second curved surface 13b due to reflection on the first curved surface 13a having a relatively large spherical surface. Since the reflection scattered by the film | membrane generate | occur | produces, the reflectance becomes the maximum at the angle smaller than 30 degrees which is a specular reflection as a whole, and the reflectance in the vicinity of the peak also becomes high. As a result, since the peak of the light incident on the reflector 10 and reflected is shifted to the side closer to the normal line direction of the reflector 10 than the normal reflection direction, the reflection luminance in the front direction of the reflector 10 can be increased. Therefore, for example, when the reflector 10 of the present embodiment is applied to the reflective layer of the liquid crystal display device, the reflection luminance in the front direction of the liquid crystal display device can be improved, and the luminance in the observer direction of the liquid crystal display device can be increased. have.

Next, the method of manufacturing the reflector of the said structure is demonstrated below with reference to drawings.

4 is a perspective configuration diagram showing a model for forming the uneven shape of the reflector in the manufacturing method of the present embodiment. FIG. 5 is a cross-sectional configuration diagram showing a step of producing a roll plate using the model shown in FIG. 4. 6 is a view showing a cross-sectional structure of a roll plate produced by the step shown in FIG. 5, and FIG. 7 is a perspective configuration diagram showing a step of forming the uneven shape of the reflector using the roll plate shown in FIG. 6.

First, the model 15 shown in FIG. 4 is a cylindrical member having a region where a large number of fine recesses are formed in the machining region 16 on the circumferential surface thereof, and is composed of lead, copper, brass, solder, stainless steel, or the like. The recessed part formed in the peripheral surface of this model 15 is a shape substantially the same as the recessed part 13 shown in FIG. 1, and this peripheral surface shape corresponds to the surface shape of the organic film 11 shown in FIG. . Next, as shown in FIG. 5A, the surface shape of the model 15 shown in FIG. 4 is transferred to the transfer resin film 17. In this process, the model 15 is arranged vertically parallel to these rollers 19 and 20 between the lower feed roller 19 and the upper feed roller 20 formed as needed. Further, the substrate 18 coated on the surface of the transfer resin film 17, which is a workpiece, is allowed to pass between the master 15 and the lower feed roller 19, and the master 15 and the lower feed roller ( Means are provided for allowing 19) to rotate without slipping from each other. The resin supply part 22 which apply | coats and forms the transfer resin film 17 on the board | substrate 18 is formed in the conveyance direction upstream of the said board | substrate 18, and is located above the downstream substrate 18 rather than the model 15. The ultraviolet irradiation part 24 is formed in an array. Further, in order to adjust the viscosity and the hardness of the transfer resin film 17 in the pressurization by the model 15, auxiliary ultraviolet irradiation means may be formed above the substrate 18 between the resin supply section 22 and the model 15. It may be.

As the said board | substrate 18, a glass substrate, a plastic substrate, a resin film substrate, etc. can be used. In addition, although the transfer resin film 17 apply | coated and formed on the board | substrate 18 by the resin supply part 22 uses ultraviolet curable resin in this embodiment, a thermosetting resin may be sufficient and in that case, an ultraviolet irradiation part ( 24) may be used as a heat source such as a heat lamp. The feed rollers 19 and 20 are formed to rotate the master 15 without slipping on the substrate 18, and may be made of any material unless slippage of the master 15 or breakage of the transfer resin film 17 occur. do.

In the process shown in FIG. 5A of the above structure, the substrate 18 is inserted between the master 15 and the lower transfer roller 19 while the master 15 is rotated by rotating the transfer rollers 19 and 20. While moving the 18 in the right direction, the transfer resin film 17 on the substrate 18 is pressed against the surface of the model 15 to transfer the surface shape of the model 15 to the transfer resin film 17, thereby transferring the transfer resin film ( 17) The uneven surface 25 is formed in the surface. The transfer resin film 17 is formed by sequentially applying the resin material by the resin supply unit 22 while moving the substrate 18 in the right direction as shown in the figure, and if necessary before performing the shape processing by the model 15. The preliminary curing by the ultraviolet irradiation means is carried out, the final curing by the ultraviolet irradiation section 24 is carried out after processing by the model 15, and the surface shape thereof is maintained. By the above process, the resin plate 26 in which the model 15 and the uneven surface 25 of the unevenness | corrugation were formed in the transfer resin film 17 surface is obtained.

Next, as shown to FIG. 5B, the metal film 27 is formed on the uneven surface 25 of the resin plate 26 obtained by the process shown to FIG. 5A. Next, the Ni film 28 is formed by electroplating using the metal film 27 as an electrode (Ni pole). It is preferable that the said metal film 27 is a gold plated film, and by forming these metal films, peeling of the metal film 27 and the Ni film 28 can be performed easily so that damage may not occur to the Ni film 28. .

Although the film thickness of the said metal film 27 and the Ni film 28 is not specifically limited, What is necessary is just to set the metal film 27 about 5 nm-about 50 nm, and the Ni film 28 about 30 micrometers-about 200 micrometers.

Next, if the Ni film 28 was formed on the metal film 27 as shown in FIG. 5B, the thin film of these metals and the resin plate 26 were peeled off, and it was almost the same as the surface of the model 15 on one surface side. The Ni plate 30 which consists of the Ni film | membrane 28 in which the uneven | corrugated shape was formed, and the metal film 27 which conforms to the uneven | corrugated shape of the Ni film | membrane 28 is obtained.

Next, as shown to FIG. 5C, the Ni film | membrane 31 is formed by Ni electroforming on the metal film 27 of the Ni board 30 obtained by the said process. In forming the Ni film 31, the same formation method as that of the Ni film 28 shown in Fig. 5B can be applied. Moreover, the film thickness of the Ni film 31 is not specifically limited, What is necessary is just to be 30 micrometers-200 micrometers. Next, the Ni film 31 formed above is peeled from the metal film 27 to obtain a Ni plate having a surface of the master 15 surface and a surface irregularity. Peeling of this metal film 27 and Ni film 31 is performed by using the thermal expansion difference of each thin film. Therefore, by using gold etc. with a small thermal expansion coefficient as the metal film 27, peeling of the metal film 27 and Ni film 31 can be performed more easily.

Next, as shown to FIG. 5D, the shock absorbing material 32 which consists of elastic bodies, such as rubber | gum, is stuck to the surface on the opposite side to the uneven surface of the Ni board (Ni film 31) obtained by the said process. And as shown in FIG. 6, the roll board 35 which has the model 15 and the surface shape of back unevenness | corrugation is obtained by winding the buffer material 32 inside the cylindrical base 34. As shown in FIG.

As shown in FIG. 7, an ultraviolet ray-curing resin or a thermosetting resin is applied to the workpiece region 38 of the product substrate 37 made of glass, plastic, or the like to form an organic film, and then produced by the above-described process. The surface shape of the Ni film 31 of the roll plate 35 is transferred to the organic film surface of the to-be-processed area 38 by pressing into the to-be-processed area 38, rotating the rolled plate 35 which was made. Next, the processed organic film is cured by ultraviolet irradiation or heating, and a metal reflecting film having a high reflectance such as Al or Ag is formed on the surface of the organic film to obtain a reflector according to the present embodiment shown in FIG. 1.

In addition, in the manufacturing method of the reflector which concerns on this embodiment, the roll board 35 used for the organic film process, and the to-be-processed area | region 38 have the uneven shape of the process surface (Ni surface 31 surface of the roll board 35). The width W1 of the formed region 35a is wider than the width W2 of the region to be processed 38, and the circumference of the roll plate 35 is combined to be longer than the length L of the region to be processed 38. This results in a seam formed by rolling the Ni film 31 shown in FIG. 5D together with the cushioning material 32 in a roll shape on the circumference of the roll plate 35 shown in FIG. 6, and the width of the Ni film 31 is finite. By that. That is, in the process shown in FIG. 7, the seam of the said roll plate 35 should not pass through the process area | region 38, and the edge part of the width direction of the process area | region 35a also enters into the process area 38 Because you should not go.

In the manufacturing method of this embodiment, the to-be-processed area | region 38 shown in FIG. 7 may be comprised with the organic film of one reflector, and may be comprised including the organic film of multiple reflectors. In addition, as shown in FIG. 8, using the product board 37A in which the several to-be-processed area | region 38A which has the width W2 smaller than the width W1 of the roll board 35 is arranged, the roll board 35 is used. Machining using this may be performed for each of the workpiece regions 38A. That is, if the area of the area | region which can be processed by rotating the roll plate 35 and the area of the to-be-processed area | region 38 and 38A have the above-mentioned relationship, the organic film formed in the to-be-processed area | region 38 and 38A will be carried out. There are no restrictions on the dimensions of the compartments and the product substrates 37 and 37A.

In addition, in the above description, the case where the model 15 and the roll plate 35 of the concave-convex and concave-convex are produced, and the concave-convex of approximately the same shape as the model 15 is formed on the organic film of the product substrate 37 is explained. In the manufacturing method according to the present invention, various forms can be adopted at the time of processing the product substrate 37. For example, the organic film processing of the product board | substrate 37 can also be performed directly using the model 15, In that case, the reflector which has a surface shape of inverse unevenness with the reflector 10 shown to FIG. 1 and FIG. Can be prepared. In addition, the product substrate 37 may be processed by pressing the Ni film 31 on the organic film while keeping the Ni film 31 in the form of a plate rather than in the form of a roll plate 35. In addition, Ni film 28 can also be applied to the same process.

(Production method of model)

Next, the manufacturing method of the model 15 shown in FIG. 4 is demonstrated. FIG. 9: is a process which shows one Embodiment of the model manufacturing apparatus for manufacturing the model 15 shown in FIG. The model manufacturing apparatus 40 shown in this figure is arrange | positioned above the model base material 41 of a column shape, and the model base material 41, and is for angle | cornering the indentation indentation to the model base material 41 surface. The indenter 47 is provided as the main part, and the said model base material 41 is rotated about the axis by the base material drive part 45 connected through the engaging part 44 to the one end surface (left side figure shown). This is free. In addition, the indenter drive unit (indenter drive unit) 48 is supported by the slider 56 to move freely in the longitudinal direction (shown in the left and right directions) of the model base material 41, and the indenter drive unit 48 and the slider 56 are free. ) To form a processing head for processing the base material 41. As the model base material 41, a base material of a metal material having a relatively easy plastic working process such as lead, brass, solder, stainless steel, or the like is used.

The engaging portion 44 is connected to the substrate driving part 45 and at the same time fixes one end side of the model substrate 41 so that the model substrate 41 can be rotated by the substrate driving part 45. It is. Moreover, the said base material drive part 45 is able to control the position around the axis of the master base material 41 in the pitch of several micrometers-several hundred micrometers. Therefore, the drive means which can control micro rotation amount, such as a servo motor and a stepping motor, is used for the base material drive part 45. As shown in FIG.

In addition, the said model base material 41 is axially supported by the means for maintaining the center position precision of a circumference, for example, auxiliary support means 50, such as a roller. This auxiliary support means 50 is comprised so that a movement to the axial direction of the model base material 41 is possible. The auxiliary supporting means 50 may also have a function of finely adjusting the height in the vertical direction of the model base material 41.

As described above, the indenter 47 is free to move in the radial direction of the master substrate 41 by the indenter driving unit 48, and is formed to have a thin end toward the tip portion (lower side shown), and the tip 47a. ) Is processed into an indentation shape that is stamped onto the model base material 41. That is, when manufacturing the model for manufacturing the reflector 10 of FIG. 1 which has the recessed part 13 of the shape shown in FIG. 2, the indenter 47 and the recessed and recessed shape shown in FIG. Is formed in the tip portion 47a. FIG. 10: is sectional drawing which shows the shape of the tip part 47a of the indenter suitable for preparation of the model 15 for forming the reflector which has the recessed part 13 of the shape shown in FIG. The indenter 47 shown in this figure has shown the example comprised in which the front-end | tip part 47a comprised the 1st curved surface 47A which forms a part of spherical surface which respectively protrudes outward from a radius, and the 2nd curved surface 47B. . That is, the inner surface of the 1st curved surface 13a of the recessed part 13 shown in FIG. 2, and the outer surface of the 1st curved surface 47A shown in FIG. 10 become substantially corresponded, and the inner surface of the 2nd curved surface 13b and the 2nd curved surface are (47B) The outer surface is almost in shape.

In addition, the shape of the tip portion can be appropriately changed according to the shape of the concave portion (or the convex portion) of the reflector to be produced. The indenter 47 can use what formed the diamond processed to the predetermined shape at the front-end | tip of a stainless steel main body, for example, may be cemented carbide, ceramic, tungsten, etc. The material of the tip 47a of the indenter 47 can be appropriately selected depending on the material of the model base material 41.

As the indenter drive unit 48, any drive means capable of driving the indenter 47 in the vertical direction to process the master substrate 41 can be used without any problem. For example, a solenoid, a piezo element (piezoelectric element), or the like is preferable. For example.

In Fig. 9, the processing head moving means 57 supports the processing head (indenter drive unit 48 and slider 56) to be movable along the axial direction of the model substrate 41, and also the radial positioning control. It engages with the means 55, and the position control of the model base material 41 radial direction of a processing head is also enabled. And the processing head can move to the axial direction of the model base material 41 with the pitch of 0.1 micrometer-several 100 micrometers by the processing head moving means 57. As shown in FIG.

In order to process the model base material 41 by the model manufacturing apparatus 40 provided with the above structure, as shown in FIG. 9, the auxiliary support means 50, such as a roller, carries out the cylindrical base material 41 as shown in FIG. It is mounted on the top and fixed to the engaging portion 44. In addition, the indenter driving part 48 and the indenter 47 supported by the slider 56 are moved to the initial position above the central axis of the said model base material 41 (for example, the right end part of the model base material 41). The model base material 41 is selected to have a length W in the substrate axial direction that is larger than the width of the transfer resin film 17 in the region where the concave portion 42 is formed. Moreover, although the diameter of the model base material 41 is not specifically limited, When the diameter of the base material 41 is too small, since the curvature of the to-be-processed surface angled by the indenter 47 may become large and processing precision may fall, it is practical It is preferable to set it as about 10 mm (phi) or more.

Next, the indenter drive part 48 is operated to move the indenter 47 below illustration, and the recessed part 42 is formed in the surface of the base material 41 by the tip 47a of the indenter. After that, the indenter 47 is moved upward to be spaced apart from the model substrate 41, and then the substrate driving unit 45 is operated to rotate the model substrate 41 by a predetermined pitch. In addition, the radial positioning control means 55 connected to the processing head moving means 57 is operated to move the slider 56 (and the indenter 47) in the axial direction of the model substrate 41 by a predetermined pitch. . When the movement of the master substrate 41 and the indenter 47 is completed in this manner, the indenter driving unit 48 is operated in the same manner as described above, and the recess 42 to the surface of the master substrate 41 by the indenter 47 is operated. Perform the rudder angle of.

And the said process is repeated sequentially and as shown in FIG. 9, the recessed part 42 is formed in substantially spiral shape on the model base material 41 surface. By this step, a large number of concave portions 42 having a predetermined range of pitches and depths are formed in the region of the surface of the master substrate 41, and a model 15 having the machining region 16 shown in FIG. 4 is obtained. Lose.

As the model 15 produced by the model manufacturing apparatus 40, as shown in FIG. 9, since the recessed part 42 is continuously formed in substantially spiral shape, there is no seamless in the circumferential direction of the model base material 41. FIG. It is a model and it has the advantage that a process can be performed continuously if it is the rotation direction of the model 15 in the shape transfer using this model 15. Therefore, the fine concavo-convex shape can be formed repeatedly and reproducibly, and the fine concavo-convex shape on the surface of the reflector can be formed very largely and efficiently with a large area of the workpiece to be processed in one processing. In addition, even when manufacturing the roll plate 35 shown in FIG. 6 used for manufacture of the reflector mentioned above, since the model 15 does not have a seamless, even if it is necessary to enlarge the diameter of the roll plate 35, the model 15 is made into the model 15. FIG. By lengthening the process length of the transfer resin film 17 by this, it can respond easily.

Moreover, according to the manufacturing method using the said model manufacturing apparatus 40, the recessed part 42 of arbitrary shape is formed in the circumferential surface of the model base material 41 only by changing the shape of the tip part 47a of the indenter 47 suitably. Since it can be made, it can respond very easily to the change of the reflecting surface shape of the reflector produced by the manufacturing process shown to FIGS. 5-7. Therefore, the lead time according to the design change of a reflector can be shortened significantly, and the reflector which has an optimal surface shape can be manufactured efficiently.

In addition, when applying the reflector 10 shown in FIG. 1 as a reflecting layer of a liquid crystal display device, for example, the arrangement pattern of the recessed part 13 of the reflecting surface of the reflector 10, and the pattern shape of a liquid crystal display device (for example, a pixel) The arrangement pattern of the concave portion 13 of the reflector 10 is changed in accordance with the pattern shape of the liquid crystal display device in order to avoid the occurrence of a moire shape by interfering with an electrode, a color filter, or a pattern of a black mask). Should be. Conventionally, in order to prevent such a war, the transfer type for each type of liquid crystal display device is prepared, and the organic film processing of the reflector is carried out, but the model 15 produced by the model manufacturing apparatus 40, and this According to the manufacturing method of the reflector used, the reflector 10 by which the Mwar countermeasure was implemented while using the same model 15 or the roll plate 35 can be manufactured. This manufacturing method is demonstrated below with reference to FIG.

11A and 11B are explanatory views for explaining the manufacturing process in the case of changing the arrangement pattern of the uneven | corrugated shape formed in the organic film in the manufacturing method of this embodiment, Comprising: Product using the model 15 or the roll plate 35 The process of processing the organic film 38a arrange | positioned at the board | substrate 37 is shown. In addition, although illustration and description are abbreviate | omitted, processes other than what is shown in FIG. 11 shall be based on the manufacturing method of the reflector and model shown to FIG. 5, FIG. 6, and FIG.

In the manufacturing method according to the present embodiment, when manufacturing a reflector (or a liquid crystal display device) in which the irregularities of the reflectors are arranged differently, for example, in one product, as shown in FIG. 11A, the long side of the product substrate 37 is parallel. When the model 15 or the roll plate 35 is rotated while pressing against the organic film 38a in one direction, the machining is performed, and the other type of product substrate 37 is processed, as shown in Fig. 11B. (15) or by rotating the axis of the roll plate 35, for example by the angle (θ), by turning the master 15 or the roll plate 35 in a direction inclined with respect to the piece of the product substrate 37 to perform the machining The organic film 38a having a different arrangement pattern of irregularities can be obtained very easily. By adopting such a manufacturing method, it is possible to take a countermeasure to a moire from a plurality of kinds of reflectors (liquid crystal display devices) with little change in the manufacturing process, and the reflector can be manufactured very efficiently.

(Liquid crystal display)

12 is a perspective configuration diagram showing an example in which the reflector according to the present invention is applied to the reflective layer of the liquid crystal display, and FIG. 13 is a partial cross-sectional configuration diagram of the liquid crystal display shown in FIG.

12 and 13, the liquid crystal display device of the present embodiment includes a front light (illumination device) 110 and a reflective liquid crystal panel 120 disposed on its rear side (lower surface side). It is.

As shown in FIG. 12, the front light 110 includes a substantially flat transparent light guide plate 112, an intermediate light guide 113 arranged along the side cross-section 112a, and the intermediate light guide 113. A light-shielding case deposited on the side of the intermediate light guide 113 so as to cover the light emitting elements 115 arranged in one end surface portion and the side ends of the intermediate light guide 113, the light emitting device 115, and the light guide plate 112. A sieve 119 is provided. That is, the light emitting element 115 and the intermediate light guide 113 serve as the light source of the front light 110, and the side end surface 112a of the light guide plate serves as the light incident surface of the light guide plate. 12, the plurality of prism grooves 114 are extended so as to extend in a direction inclined with respect to the light incident surface 112a in which the intermediate light guide 113 is arranged on the outer surface side (upper surface side) of the light guide plate 112. ) Is arranged in an array.

The liquid crystal panel 120 includes an upper substrate 121 and a lower substrate 122 that are disposed to face each other, and the rectangular region 120D indicated by a dotted line in FIG. 12 serves as a display region of the liquid crystal panel 120. In 120D, the pixels of the liquid crystal panel are actually arranged in a matrix.

In the liquid crystal display device having the above-described configuration, the light guide plate 112 is disposed on the display area 120D of the liquid crystal panel 120, and the display of the liquid crystal panel 120 can be visually recognized through the light guide plate 112. . In a dark place where no external light is obtained, the light emitting element 115 is turned on, and the light is introduced into the light guide plate from the light incidence surface 112a of the light guide plate 112 through the intermediate light guide 113, and then the light guide plate 112 is turned on. ) Is emitted toward the liquid crystal panel 120 from the lower surface 112b to irradiate the liquid crystal panel 120.

The light guide plate 112 of the front light 110 is disposed on the display area of the liquid crystal panel 120 and is a flat acrylic member that flattens the light emitted from the light emitting element 115 to the liquid crystal panel 120. It consists of resin etc. As shown in the partial sectional view of FIG. 13, the upper surface of the light guide plate 112 (the surface opposite to the liquid crystal panel 120) is formed in a stripe shape in which the wedge-shaped prism grooves 114 are parallel to each other and viewed in plan view. It is a reflecting surface 112c, and when it shows in figure (the surface which opposes the liquid crystal panel 120), it becomes the emitting surface 112b which the illumination light for illuminating the liquid crystal panel 120 is radiate | emitted. The prism groove 114 is constituted by a pair of slope portions formed to be inclined with respect to the reference plane N of the reflection surface 112c, one of these slope portions is a slope surface portion 114a, and the other is the slope surface portion 114a. A steep slope 114b formed at a more steep inclination angle. The gentle slope 114a can increase the uniformity of the inclination angle of the light guide plate 112 as the length of the light guide plate 112 becomes shorter, and decrease the inclination angle of the light guide plate 112 as the length of the light guide plate 112 increases the luminance uniformity of the front light 110. And the liquid crystal panel arrange | positioned at the back side of the light-guide plate 112 by reflecting the light which propagates inside the light-guide plate 112 from the right side to the left side to the exit surface 112b side by the sudden-surface part 114b of the reflection surface 112c. It is made to exit toward 120.

The liquid crystal panel 120 is a reflective matrix matrix liquid crystal panel capable of color display, and is formed by sandwiching the liquid crystal layer 123 between the upper substrate 121 and the lower substrate 122 which are arranged to face each other as shown in FIG. And a plurality of rectangular transparent electrodes 126a and an alignment film 126b formed on the transparent electrodes 126a in a planar view extending in the left-right direction on the inner surface side of the upper substrate 121, and having a lower substrate 122. ), A reflective layer 125, a color filter layer 129, a plurality of rectangular transparent electrodes 128a, and an alignment film 128b are formed in sequence on the inner surface side.

The transparent electrode 126a of the upper substrate 121 and the transparent electrode 128a of the lower substrate 122 are both formed in a rectangular planar shape and are arranged in a stripe view in plan view. And the extending direction of the transparent electrode 126a and the extending direction of the transparent electrode 128a are arrange | positioned so that they may mutually orthogonally cross in plan view. Accordingly, one dot of the liquid crystal panel 120 is formed at a position where one transparent electrode 126a and one transparent electrode 128a intersect, and three colors (red, green, blue) described later corresponding to each dot are formed. The color filter of 1 color is arrange | positioned among the color filters of (). And three dots which generate | occur | produce in R (red), G (green), and B (blue) comprise one pixel of the liquid crystal panel 120. FIG.

The color filter layer 129 has a configuration in which the red, green, and blue color filters 129R, 129G, and 129B are periodically arranged, and each color filter is formed below the corresponding transparent electrode 128a, A pair of color filters 129R, 129G, and 129B is disposed for each pixel. The pixel display color is controlled by driving control of the electrodes corresponding to the respective color filters 129R, 129G, and 129B.

Next, the reflective layer 125 formed on the inner surface side of the lower substrate 122 shown in FIG. 13 has the configuration shown in the perspective configuration diagram of FIG. 1, and as shown in FIG. The metal reflecting film 12 and the organic film 11 which consists of acrylic resin materials etc. for giving a predetermined surface shape to this metal reflecting film 12 are comprised. A plurality of recesses 13 are formed on the surface of the organic film 11, and predetermined reflectivity is obtained by the metal reflective film 12 formed on the recesses 13. Therefore, the concave portion 13 of the reflective layer 125 of the liquid crystal display device according to the present embodiment has the shape shown in FIG. 2 and the reflection characteristic shown in FIG. At the same time, since the peak of the reflected luminance is shifted in the panel normal direction rather than the specular reflection direction, the luminance in the panel front direction in which the observer of the liquid crystal display device is normally arranged can be increased, and a substantially bright display can be obtained.

The organic film 11 with which the liquid crystal panel 120 which concerns on this embodiment can be manufactured can be manufactured by the manufacturing method which concerns on this invention, and can be manufactured easily and reproducibly by the manufacturing method of the reflector described above. In addition, according to the manufacturing method of the reflector according to the present invention, since the arrangement direction of the concave-convex shape of the reflecting surface can be arbitrarily changed, the pitch of the electrodes 126a and 128a and the color filter layer 129 can be changed by applying the manufacturing method. Even if it occurs, it is possible to change the arrangement pattern of the unevenness of the reflective layer 125 very easily to effectively prevent the moire shape from occurring.

In the above description, the example applied to the passive matrix reflective liquid crystal display device has been described, but the method of manufacturing the reflector and the liquid crystal display device of the present invention can be applied to a reflective or transflective liquid crystal display device. The present invention can also be applied to an active matrix liquid crystal display device. When applied to these active matrix liquid crystal display devices, the substrate fabrication cost can be reduced, which is effective.

As described in detail above, the method for manufacturing a reflector of the present invention includes an organic film and a metal reflecting film formed on the organic film, and a reflector having a plurality of concave portions or convex portions continuously formed on the surface of the organic film can be manufactured. In this case, by employing a model having a roughly cylindrical model substrate surface having irregularities formed thereon, and adopting a configuration in which the model is rotated while being pressed on the transfer resin film to transfer the model surface shape to the transfer resin film. By pressing and rotating the model on the transfer resin film, the fine concavo-convex shape of the model can be efficiently transferred to the transfer resin film. The transfer resin film may be used as an organic film to form a reflector, or by using a transfer resin film as a transfer type to form an organic film having a fine concavo-convex shape on the surface by a method such as forming a fine concavo-convex shape on the organic film. You can also make. In addition, since the model is substantially cylindrical in shape, there is no limitation on the length of the transfer resin film in the previous direction of the model, and it can be easily used for the manufacture of the reflector using a large substrate, thus forming the fine concavo-convex shape of the reflector very efficiently. can do.

Next, the manufacturing method of the liquid crystal display device of the present invention, when sandwiching the liquid crystal layer between the opposing upper substrate and the lower substrate, and manufacturing a liquid crystal display device having a reflective layer on the inner surface side of the lower substrate, According to the configuration of forming the reflective layer on the lower substrate by the method of manufacturing the reflector of the present invention, it is possible to form a reflective layer having excellent reflective characteristics very efficiently and reproducibly, and to manufacture a liquid crystal display device having high manufacturing efficiency. To make it possible.

Claims (7)

When manufacturing the reflector provided with the organic film and the metal reflective film formed on this organic film, and in which the several concave part or convex part was continuously formed in the said organic film surface, And having a step of transferring the model surface shape to the transfer resin film by rotating the model while pressing and rolling the model on the transfer resin film by using a model having an uneven shape formed on the surface of the roughly base material model. Method for producing a reflector. The method of claim 1, A method for manufacturing a reflector, characterized in that the metal reflective film is formed on the transfer resin film surface on which the fine concavo-convex shape of the model is transferred to produce one or a plurality of reflectors. The method of claim 1, Forming a metal film on the transfer resin film to which the fine concavo-convex shape of the model is transferred; A step of producing a Ni plate by a Ni electric pole using the metal film as an electrode; And And a step of transferring the fine concavo-convex shape transferred to said Ni plate to an organic film. The method of claim 1, Forming a metal film on the transfer resin film to which the fine concavo-convex shape of the model is transferred; A step of producing a Ni plate by a Ni electric pole using the metal film as an electrode; Performing Ni electroforming with the Ni plate as an electrode and forming a Ni film on the metal film on the Ni plate; Peeling the Ni film from the metal film; And And a step of transferring the fine concavo-convex shape transferred to said Ni film to an organic film. The method of claim 1, Forming a metal film on the transfer resin film to which the fine concavo-convex shape of the model is transferred; A step of producing a Ni plate by a Ni electric pole using the metal film as an electrode; Performing Ni electroforming with the Ni plate as an electrode and forming a Ni film on the metal film on the Ni plate; Peeling the Ni film from the metal film; A step of forming a roll plate by arranging a buffer material on the back side of the Ni film, and winding the Ni film on a substantially circumferential gas circumferential surface with the buffer material inward; And And rolling the roll plate onto the organic film while simultaneously rotating the fine plate on the outer surface of the Ni film to the surface of the organic film. The method of claim 1, A method of manufacturing a reflector, characterized in that the fine concavo-convex shape of the model is a shape in which a plurality of concave portions including a part of a spherical surface are continuously arranged on an inner surface thereof. When manufacturing a liquid crystal display device having a liquid crystal layer interposed between the upper substrate and the lower substrate disposed oppositely, and having a reflective layer on the liquid crystal side of the lower substrate, A method for manufacturing a liquid crystal display device, wherein the reflective layer is formed on the lower substrate by the method for manufacturing a reflector according to any one of claims 1 to 6.