KR20070066645A - Manufacturing method of display device - Google Patents

Abstract

A manufacturing method of a display apparatus is provided to easily treat aqueous curing materials by means of a dry photosensitive film or a film. A dry type photosensitive film is arranged so that the photosensitive material is coated on a base film. The dry type photosensitive film is attached on a mold so that the photosensitive material is contacted with prominence and depression patterns formed at the mold. Thereafter, the base film is separated from the dry photosensitive film. The photosensitive materials is contacted with at least a surface of an optical plate(100) and thereafter the prominence and depression patterns are transferred. The photosensitive material is cured by ultraviolet rays and thereafter the mode is removed from the optical plate.

Description

Manufacturing method of display device {MANUFACTURING METHOD OF DISPLAY DEVICE}

1 is a view for explaining a method of manufacturing a display device according to a first embodiment of the present invention;

2 is a view for explaining a method of manufacturing a display device according to a second embodiment of the present invention;

3 is a view for explaining a method of manufacturing a display device according to a third embodiment of the present invention;

4 is a view for explaining a method of manufacturing a display device according to a fourth embodiment of the present invention.

Explanation of symbols on the main parts of the drawings

10: dry photosensitive film 20: mold

30a, 30b: roller 40: film

50: liquid ultraviolet curable material 100: optical plate

The present invention relates to a method for manufacturing a display device, and more particularly, to a method for manufacturing a display device having an optical plate having irregularities formed therein.

The liquid crystal display device includes a lower substrate on which a thin film transistor is formed, an upper substrate on which a color filter layer is formed, and a liquid crystal panel on which a liquid crystal layer is positioned. Since the liquid crystal panel is a non-light emitting device, a backlight unit for irradiating light may be located at the rear of the upper panel. Light transmitted from the backlight unit is controlled according to the arrangement of the liquid crystal layer.

The backlight unit includes a plurality of light adjusting members to uniformly transmit the light emitted from the light source to the liquid crystal panel. Such a light control member generally has a concave-convex pattern on its surface in order to promote light diffusion and scattering. In the case of a plate-shaped light guide plate, which is not a sheet, among the light adjusting members, a molding process is generally performed to form a fine uneven pattern. The most commonly used UV molding includes a coating process for forming a pattern and coating a cured material, a molding process for forming an uneven pattern, and a curing process for curing an uneven pattern by irradiating UV light.

Coating methods can also be further classified into spin coating, screen coating and doctor blade methods. When using a liquid cured material, there is a problem that the cured material flows to the outside, and there are differences in advantages and disadvantages in the process depending on which coating method is used.

Accordingly, it is an object of the present invention to provide a method for manufacturing a display device capable of easily forming an uneven pattern on an optical plate.

The object is to provide a dry photosensitive film so that the photosensitive material is applied to the base film according to the present invention; Attaching the dry photosensitive film to the mold such that the photosensitive material contacts the uneven pattern formed on the mold; Separating the base film from the dry photosensitive film; After contacting the photosensitive material to at least one surface of the optical plate, and is achieved by the manufacturing method of the display device comprising the step of transferring the concave-convex pattern.

UV curing the photosensitive material further.

The method may further include removing the mold from the optical plate after the ultraviolet curing step, and may further include removing the mold from the optical plate before the ultraviolet curing step.

The uneven pattern may be formed on both surfaces of the optical plate.

In order to transmit ultraviolet rays, the mold is preferably transparent.

In the preparing of the dry photosensitive film, the photosensitive material may be formed by soft curing.

Transferring the uneven pattern is preferably performed by a rolling method using a roller.

On the other hand, the object of the present invention comprises the steps of forming the first and second films of a predetermined height on the one surface of the optical plate and the edge of the first mold having the uneven pattern; Providing a liquid ultraviolet curable material on the optical plate and the first mold on which the first and second films are formed, respectively; Stacking the optical plate on the first mold; Providing a second mold having an uneven pattern, and contacting the uneven pattern with an ultraviolet curable material on the optical plate; Pressurizing the first and second molds, and irradiating the optical plate with ultraviolet rays; It may be achieved by a method of manufacturing a display device comprising the step of removing the first and second mold from the optical plate.

Preferably, the first and second molds are transparent.

The predetermined height of the first and second films is preferably greater than the height of the uneven pattern from the first mold and the second mold to cope with the fluidity of the liquid cured material.

On the other hand, the object, according to the present invention (a) forming a film of a predetermined height on the edge of one surface of the optical plate; (b) providing a liquid ultraviolet curable material on the optical plate on which the film is formed; (c) contacting the UV curable material on the optical plate with the concave-convex pattern of the mold; (d) pressing the mold and irradiating the optical plate with ultraviolet rays; (e) can also be achieved by a method of manufacturing a display device comprising removing the mold from the optical plate.

The method may further include forming an uneven pattern on the other surface of the optical plate by repeating the steps (a) to (e). In this case, the mold may be opaque.

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

In various embodiments, like reference numerals refer to like elements, and like reference numerals refer to like elements in the first embodiment and may be omitted in other embodiments.

1 is a view for explaining a manufacturing method of a display device according to a first embodiment of the present invention, and more particularly, a manufacturing method of an optical plate provided integrally with a light guide plate or a diffusion plate used as a light adjusting member. will be.

First, as shown in FIG. 1A, a mold 20 in which the dry photosensitive film 10 and the uneven pattern 21 are formed is provided. The dry photosensitive film 10 is coated with an ultraviolet photosensitive material 12, for example, a resin, on the base film 11, and then soft cured. The dry photosensitive film 10 is used instead of the liquid photosensitive material in the photolithography patterning process. It is a film that is widely used when forming patterns on PCB boards. The base film 11 is about 50 to 100 mm, and the ultraviolet photosensitive material 12 is formed on the base film 11 to a thickness of about 10 to 200 mm. In the case of using the dry photosensitive film 10 in which the photosensitive material 12 is softly cured, the display device may be prevented from flowing down when the liquid resin is used and the resin having limited fluidity may be handled. There is an advantage in that the production of easy. In addition, by using one dry photosensitive film 10, the existing coating process and molding process can be performed in one process, thereby reducing the effort required in the manufacturing process.

The mold 20 includes an uneven pattern 21 in which fine unevenness is formed, and the unevenness according to the present embodiment has a prism shape having an acid and a valley. Concave-convex pattern 21 is not limited to the shape, such as hemispherical, lattice-like, various shapes that can be transferred to the optical plate is possible.

As shown, the dry photosensitive film 10 is attached to the mold 20 such that the photosensitive material 12 contacts the uneven pattern 21 formed in the mold 20. This process is performed by the rolling method using the rollers 30a and 30b, and the pressure is applied through the rollers 30a and 30b in both directions of the contacted mold 20 and the dry photosensitive film 10.

By this rolling, the uneven pattern 21 formed in the mold 20 is transferred to the photosensitive material 12. In this case, since the dry photosensitive film 10 is soft cured, air bubbles are less likely to be generated during the transfer process, but air bubbles may be generated due to insufficient fluidity of the photosensitive material 12. In order to prevent this, the transfer process may be performed in a low vacuum chamber.

Then, the base film 11 is separated from the dry photosensitive film 10 as shown in Figure 1b. That is, the base film 11 is removed, leaving only the uneven pattern 12a of the photosensitive material 12 formed to correspond to the protruding and recessed portions of the uneven pattern 21.

Next, the base film 11 is removed to contact the uneven pattern 12a of the photosensitive material 12 exposed to the outside of the optical plate 100. The optical plate 100 has a transparent rectangular plate shape having a predetermined thickness. The optical plate 100 is made of a material such as polymethylmethyl acrylate (PMMA) or polycarbonate (PC).

 Thereafter, as shown in FIG. 1C, the uneven pattern 12a contacted on the optical plate 100 is transferred to the optical plate 100 using the rollers 30a and 30b.

Finally, as shown in FIG. 1D, ultraviolet rays are irradiated from the upper direction of the mold 20 to cure the concave-convex pattern 12a of the photosensitive material 12, and then the mold 20 is removed from the optical plate 100.

The mold 20 according to the present embodiment may be made of a transparent plastic material. In this case, ultraviolet rays may be irradiated from the upper part of the mold 20 or the lower direction of the optical plate 100, and the mold 20 may be removed after the ultraviolet curing step is completed. It is also possible to remove the mold 20 first and then perform UV curing. However, if the mold 20 is made of a metal material and is opaque, ultraviolet rays cannot penetrate the mold, and thus, the mold is first removed and then an ultraviolet curing step is performed, or ultraviolet rays must be irradiated in the lower direction of the optical plate 100.

2 is a view for explaining a method of manufacturing a display device according to a second embodiment of the present invention. In the optical plate 100 according to the present embodiment, a plurality of uneven patterns 12a and 12b are formed on both surfaces thereof. Mostly similar to the manufacturing method of the optical plate 100 shown in FIG.

By providing two dry photosensitive films and molds 20 and 25 coated with an ultraviolet photosensitive material on the base film, respectively, the uneven patterns 12a and 12b are easily formed on both surfaces of one optical plate 100. Since the uneven patterns 12a and 12b may be formed on both sides of the optical plate 100 at the same time through a single process, the manufacturing process may be simplified and the flow of the resin may be prevented by using a dry photosensitive film.

3 is a view for explaining a method of manufacturing a display device according to a third embodiment of the present invention.

First, as shown in FIG. 3A, first and second films 40 and 41 having a predetermined height d are formed on an edge of the first mold 20 having one surface of the optical plate 100 and the uneven pattern 21. .

The first and second films 40 and 41 formed at the edges of the optical plate 100 and the first mold 20 are made of a material having elasticity and capable of thermocompression bonding. Each film 40, 41 is formed at the edges of the optical plate 100 and the first mold 20 through thermocompression, and has a predetermined height d so that the liquid photosensitive material to be contained thereafter will not flow out. It plays a role. In addition, the optical plate 100 and the first mold 20 to maintain a constant interval through the height. The height d of the first and second films 40 and 41 should be at least greater than the height (about 20 to 50 mm) of the uneven pattern 21 formed in the first mold 20, and the liquid photosensitive material. It is preferable to have a value obtained by adding a certain height (less than 50 mm) in consideration of the fluidity of the. The additional height may be spread to the edge portion by pressing the liquid photosensitive material in the molding process, it is preferable to maintain a constant height in consideration of the movement of the photosensitive material. In addition, since the film has an elastic force, it is possible to prevent scratches that may occur when the optical plate 100 is in contact with the molds 20 and 25, and more flexibly when using a liquid cured material.

After the films 40 and 41 are formed, the liquid ultraviolet curable material 50 is provided inside the rectangular films 40 and 41. Then, as shown in FIG. 3B, the optical plate 100 is stacked on the first mold 20, and the uneven pattern of the ultraviolet curable material 50 and the second mold 25 of the liquid crystal provided on the optical plate 100 are formed. The second mold 25 is laminated so that (26) abuts.

After this, a process similar to the first and second embodiments is repeated. That is, the two molds 20 and 25 are pressed to irradiate ultraviolet rays in both directions of the first and second molds 20 and 25 to cure the cured material 50. In the present embodiment, the molds 20 and 25 should be made of a transparent material to transmit ultraviolet rays. If the mold is formed of an opaque material including a metal, it is impossible to irradiate ultraviolet rays in both directions, so that the uneven pattern is formed on both sides of the optical plate 100 using the curable material 50 in the liquid phase with fluidity. Because you can't.

Air bubbles may be generated in the process of pressurizing the molds 20 and 25, and a molding process may be performed in a vacuum chamber of about 1 toll to prevent such air bubbles.

Finally, when the molds 20 and 25 and the films 40 and 41 are removed from the optical plate 100, the optical plate 100 having concave-convex patterns on both sides is completed.

Of course, it is also possible to sequentially form the concave-convex pattern on each side instead of both sides of the optical plate 40 through the above process.

4 is a view for explaining a method of manufacturing a display device according to a fourth embodiment of the present invention. The optical plate 100 according to the present embodiment is the same as the third embodiment to form the uneven pattern on both surfaces, but differs in that it uses an opaque mold.

First, a film 40 having a predetermined height is formed at an edge of one surface of the optical plate 100, and a liquid ultraviolet curable material is provided inside a rectangular edge. Thereafter, as shown in FIG. 4A, the cured material and the third mold 27 are brought into contact with each other, and then ultraviolet rays are irradiated from the rear surface of the optical plate 100, that is, in a direction opposite to the third mold 27.

Since the third mold 27 and the fourth mold 28, which will be described later, are made of a metal material, the third mold 27 and the fourth mold 28 are opaque and cannot transmit ultraviolet rays. Therefore, when the molds 27 and 28 are used, the optical plate 100 needs to form an uneven pattern on one surface and repeat the same.

Therefore, as shown in FIG. 4B, the optical plate 100 on which the uneven pattern 50a is formed is placed upside down. Next, the film 42 is again formed, the liquid cured material is laminated, and a molding process is performed through the fourth mold 28. In this case, the film 40 formed on the rear surface of the optical plate 100 serves to support the optical plate 100.

When the mold 28 and the films 40 and 42 are finally removed, the optical plate 100 having the uneven pattern formed on both surfaces is completed.

As described above, it is possible to form the uneven pattern on both sides of the optical plate 100 by various methods, and to use the dry photosensitive film 10 or the film 40 to more easily form the uneven pattern. In this way, the liquid cured material 50 may be easily processed.

Although some embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that modifications may be made to the embodiment without departing from the spirit or spirit of the invention. . It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

As described above, according to the present invention, there is provided a method of manufacturing a display device capable of easily forming an uneven pattern on an optical plate.

Claims (14)

Preparing a dry photosensitive film to apply a photosensitive material to the base film; Attaching the dry photosensitive film to the mold such that the photosensitive material contacts the uneven pattern formed on the mold; Separating the base film from the dry photosensitive film; And transferring the concave-convex pattern after contacting the photosensitive material to at least one surface of the optical plate. The method of claim 1, The method of manufacturing a display apparatus further comprising the step of ultraviolet curing the photosensitive material. The method of claim 2, And removing the mold from the optical plate after the ultraviolet curing step. The method of claim 2, And removing the mold from the optical plate before the ultraviolet curing step. The method of claim 1, The uneven pattern is a manufacturing method of the display device, characterized in that formed on both sides of the optical plate. The method of claim 1, And the mold is transparent. The method of claim 1, In the step of providing the dry photosensitive film, the manufacturing method of the display device, characterized in that the soft curing the photosensitive material. The method according to claim 1, wherein The transferring of the uneven pattern may be performed by a rolling method using a roller. Forming first and second films, each having a predetermined height, on one surface of the optical plate and on an edge of the first mold having the uneven pattern; Providing a liquid ultraviolet curable material on the optical plate and the first mold on which the first and second films are formed; Stacking the optical plate on the first mold; Providing a second mold having an uneven pattern, and contacting the uneven pattern with an ultraviolet curable material on the optical plate; Pressurizing the first and second molds, and irradiating the optical plate with ultraviolet rays; And removing the first and second molds from the optical plate. The method of claim 9. And the first and second molds are transparent. The method of claim 9, And a predetermined height of the first and second films is greater than a height of the uneven pattern from at least the first mold and the second mold. (a) forming a film having a predetermined height at an edge of one surface of the optical plate; (b) providing a liquid ultraviolet curable material on the optical plate on which the film is formed; (c) contacting the UV curable material on the optical plate with the concave-convex pattern of the mold; (d) pressing the mold and irradiating the optical plate with ultraviolet rays; (e) removing the mold from the optical plate. The method of claim 12, Repeating the steps (a) to (e) to form a concave-convex pattern on the other surface of the optical plate further comprising the manufacturing method of the display device. The method according to claim 12 or 13, The mold is a method of manufacturing a display device, characterized in that the opaque.

Images