KR20100019650A - Method of manufacturing an multifunction optical filter as plasma display panel using roll stamper - Google Patents

Abstract

PURPOSE: A method of manufacturing and multifunction optical filter as plasma display panel using roll stamper is provided to implement a micro waveguide without using a high price mask. CONSTITUTION: An optical filter for a display comprises an anti-reflective layer, a transparent substrate, an external light barrier layer, an electromagnetic wave-blocking layer, a near infrared blocking, and a color correction layer. A groove is processed by transferring the micro-pattern. The pattern surface of a processed groove is exposed to the scattered light and is hardened. The hardened groove is filled by a conductive absorption material through a blade. An ultraviolet ray is projected on the filled groove and electromagnetic waves shielding pattern is obtained. The UV hardened resin is coated on the electromagnetic waves shielding pattern.

Description

Method of manufacturing an multifunction optical filter as plasma display panel using roll stamper}

The present invention relates to a method for manufacturing a multifunctional optical filter for a plasma display panel using a roll stamper, and more particularly, by using a roll stamper to form a groove in a substrate and then using a blade to fill a conductive light absorbing material. The present invention relates to a method of manufacturing a multifunctional optical filter in a simplified process by forming an electromagnetic wave shielding pattern.

The display panel generally adopts an optical filter with electromagnetic wave blocking, near infrared ray blocking, surface antireflection, and color purity improvement to reduce surface reflection and improve color purity as well as to prevent electromagnetic waves and near infrared rays, and to prevent malfunction of precision instruments. .

The electromagnetic wave shielding pattern forming method used to manufacture the display panel is a general method using an exposure process using a photo mask. Thus, a pattern formed through a general pattern forming method using a photolithography process is used in the etching process of a metal film or an inorganic layer. It can be used as an etch resistant film or as a shadow mask in a lift-off process and then removed or left on the device to form a structure.

Therefore, the method of forming a pattern using a photolithography process is easy to apply to a sphere of a general two-dimensional pattern, but as the substrate becomes larger, the cost increases enormously, and a complex process is required to form a three-dimensional pattern or a multilayer structure. There is a problem, and technical realization is not easy.

In order to solve the problem of the photolithography process, nano imprint lithography method and soft lithography method have been proposed.

Here, in the nanoimprint lithography method, a rigid mold (mold), such as silicon (Si), in which a desired pattern is prepared, is prepared to face a substrate coated with a thermoplastic polymer thin film, placed between press plates, and treated at a high temperature and high pressure, and then cast. The pattern is transferred to the polymer thin film of the substrate by separating the substrate from the substrate. The nanoimprint lithography method has the advantage of easily realizing ultra-fine patterns because it uses a rigid mold such as Si, but has a problem that it is difficult to separate the mold and the substrate after performing a high temperature and high pressure process. Due to the high process pressure, the mold and the substrate may be damaged, and the patterning is performed by using the fluidity of the polymer material heated to a high temperature. Therefore, in the case of a large size pattern, the time required for perfect patterning is very large and the process is delayed. There is a problem that can not be repeated.

In addition, in the case of the soft lithography method, a three-dimensional pattern can be realized, but due to the nature of the process using the fluidity of the residual solvent, the process time is limited, it is difficult to apply in large areas, and the residue remains. Can be.

In order to solve this problem, molding methods can be used, and molds include hard molds and soft molds, and hard molds can be used to directly pattern a metal roll or plate using diamond cutting, copper etching, or NC machining. It is processing.

The soft mold is a lithography method in which a polymer mold is directly manufactured or NC processed, and a soft transparent or translucent polydimethylethyliloxane (PDMS), epoxy, urethane, alkyd, phenol, melamine, urea resin, etc. After fabrication, a plate-type stamper or a roll-type stamper is manufactured using the same, and the pattern is duplicated by stamping the substrate. In Patent No. 0634092, a process of forming a temporary pattern for forming a fine pattern by pressing action of a mold means corresponding to a photosensitive organic film formed on a substrate is described.

In the continuous mass production of fine optical members, the optical member manufacturing apparatus which improves handleability and yield and enables formation of an enlarged pattern is generally made of a material in which the base film 1 is wound, as shown in FIG. Guide rolls 3a, 3b, 3c, 3d and 3e for conveying one roll 2, the second roll 5 on which the manufactured optical member 8 is wound, the base film 1 and the optical member 8 And a pattern molding part 4 including a master roll 4a and 4b for transferring a molding mold, and a coating liquid injection device 6 and a curing device 7, wherein the pattern molding part 4 is a film-shaped substrate. It is composed of a master mold (4a, 4b) is applied to the base film (1) by pattern molding the coating liquid according to the pattern embodied in the molding mold by pressing a molding mold having a pattern shape implemented on the layer and the coating liquid injected into the molding mold The pattern guide roll for conveying the molding mold may be further configured. .

An object of the present invention is to use a roll stamper to form a radio wave blocking pattern directly on the substrate by indenting the polymer layer-coated substrate with an intaglio groove and filling the groove with a light absorbing material including a conductive material, thereby eliminating the need for an expensive mask. It is an object of the present invention to provide a multifunctional optical filter for a plasma display panel capable of forming a micro waveguide.

Multifunctional optical filter for plasma display panel comprising an anti-reflection layer, a transparent substrate, an external light blocking layer, an electromagnetic wave blocking layer, and a near infrared ray blocking and color correction layer according to the present invention for achieving the above object, (a) on the substrate Forming an anti-glare-hard-coating layer or an anti-reflection coating layer; (b) processing the groove by transferring the fine pattern of the roll stamper by pressurizing using a roll stamper while supplying a photocurable molding resin onto the substrate on the opposite side of the anti-glare hard coating layer or the anti-reflective coating layer; (c) exposing the processed surface of the groove to scattered light to completely cure the groove; (d) filling a conductive light absorbing material by using a blade in the grooves completely cured; (e) obtaining an electromagnetic wave blocking pattern by irradiating ultraviolet rays completely on the filled grooves to obtain an electromagnetic wave blocking pattern (f) coating a UV curable resin on the electromagnetic wave blocking pattern; (g) exposing ultraviolet rays under the electromagnetic wave blocking pattern to expose the same; (h) immersing and developing the UV curable resin laminated on the substrate after the exposure is finished; (i) irradiating ultraviolet rays from above the waveguide formed by the development to completely cure the developed waveguide; (j) forming an external light absorbing part by laminating an adhesive layer containing a near infrared ray blocking and color correction pigment on the completely cured waveguide and simultaneously supplying a transparent resin containing absorbing particles; (k) irradiating ultraviolet rays on the formed external light absorbing unit to completely cure the external light absorbing unit; (l) forming an anti-glare hard coating layer or an anti-reflection layer on the pressure-sensitive adhesive layer; characterized in that formed by.

Multifunctional optical filter for plasma display panel according to the present invention as described above is formed by directly transferring the electromagnetic shielding pattern of the micro-size to a transparent substrate using a roll stamper to form an electromagnetic shielding pattern by using a separate expensive mask (photomask) There is no need to do so, the structure of the filter is simplified by omitting the polyester film and the adhesive layer, and the loss of the raw material layer is reduced, thereby reducing the production cost.

In addition, by filling the light absorbing material containing a conductive material in the groove formed by pressing the roll stamper without using a mask, and coating a UV curable resin and irradiating UV light from the bottom to form a micro waveguide and filling the light absorbing material Since the light blocking structure can be obtained, the exposure process can be simplified, the production time can be reduced, and the light transparency can be increased to improve the display image quality.

In addition, by forming an electromagnetic wave shielding pattern directly on the transparent substrate without using a mask, it is possible to expect a stable yield by simplifying the electromagnetic wave shielding layer forming process.

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

According to the present invention, a groove is formed on a transparent substrate, which is a transparent film or glass, and then a conductive electromagnetic wave blocking pattern is formed by filling a light absorbing material including a conductive material with a roll stamper, thereby eliminating the process of curing, developing, and etching. It is possible to apply the photoreactive transparent resin on the substrate on which the electromagnetic wave shielding pattern is formed and irradiate UV light, and then fill the light absorbing material with the upper and lower rolls in a lamination method to form a near-infrared shielding layer, thereby significantly increasing the productivity. And maximize production yield.

Functional layers included in the optical filter for display of the present invention may be a conventional functional layer known in the art, may have a conventional function, for example, anti-reflective function, selective light absorption function, electromagnetic wave blocking function, near infrared ray It includes a blocking function.

Fig. 2 is a sectional view showing the structure of the optical filter of the present invention attached to a PDP panel.

As shown in FIG. 2, the optical filter 100 for display attached to the PDP panel 200 includes an anti-glare layer 80, a substrate 10, an external light absorbing portion 60 and a waveguide 50, and a near infrared ray blocking and And a color correction layer 70 and an antireflection layer 90.

The outermost layer of the optical filter 100 includes an anti-reflection layer 90 for suppressing reflection of external light, and an external infrared ray blocking and color correction layer 70 including a near infrared ray blocking material and a light selective absorbing material. The contrast enhancement layer including the light absorbing portion 60 and the waveguide 50 is laminated on the front or rear side of the transparent substrate 10 on which the electromagnetic wave shielding layer is directly formed using a transparent adhesive layer to obtain an optical filter for display. Can be.

As the near-infrared ray blocking material, a dye mixture of nickel-based and diammonium-diammonium-based dyes or a dye or an organic dye containing a compound containing copper or zinc ions may be used, and octaphenyltetraaza Derivative pigments in which a metal element is present as a central group in the porphyrin or tetraaza porphyrin ring and in which a substance in the group consisting of ammonia, water and halogen form a coordination bond with the metal element may be used. The solution may be prepared by mixing with a solvent and coated on a transparent substrate with a thickness of 1 to 20 μm to prepare a near-infrared blocking and color correction layer 70.

The anti-reflection layer 90 may be formed by performing a hard coating made of an acrylic resin on the substrate 10 by using scratch resistance to form a low refractive index single layer or alternately stacking a high refractive index transparent film and a low refractive index transparent film. As the formation method, the method of vacuum-forming said material and the method of roll-coating or die-coating the solution containing this material by the wet method are mentioned.

The anti-reflection layer 90, the near infrared ray blocking and color correction layer 70, and the contrast enhancing layer may be formed on separate substrates, or may be formed by incorporating the near infrared ray blocking and selective light absorbing dyes into the adhesive.

3 is a diagram illustrating a pattern constituted according to the present invention by way of example.

4 to 11 show the shape of the optical filter according to the step of constructing the optical filter for display according to the present invention.

Multifunctional optical filter for plasma display panel according to the present invention,

Including an antireflection layer, a transparent substrate, an external light blocking layer, an electromagnetic wave blocking layer, and a near infrared ray blocking and color correction layer,

(a) forming an anti-glare-hard-coating layer 80 or an anti-reflection coating layer 90 on the substrate 10;

(b) by using a roll stamper while transferring the photocurable molding resin 20 onto the substrate on the opposite side of the anti-glare hard coating layer 80 or the anti-reflective coating layer 90 to transfer the fine pattern of the roll stamper. Machining the grooves 30a;

(c) exposing the processed pattern surface of the groove (30a) to scattered light to completely cure the groove (30a);

(d) filling a conductive light absorbing material by using a blade into the fully cured groove (30a);

(e) obtaining an electromagnetic wave blocking pattern 30 by irradiating ultraviolet rays on the filled grooves 30a to completely cure them;

(f) coating a UV curable resin 40 on the electromagnetic wave shielding pattern 30;

(g) exposing ultraviolet rays under the electromagnetic wave blocking pattern 30 to expose the same;

(h) immersing and developing the UV curable resin 40 laminated on the substrate after the exposure is finished;

(i) completely curing the developed waveguide (50) by irradiating ultraviolet rays from above the waveguide (50) formed by the development;

(j) forming an external light absorbing part 60 by laminating an adhesive layer containing near-infrared blocking and color correction pigments on the completely cured waveguide 50 and simultaneously supplying a transparent resin mixed with absorbing particles;

(k) irradiating ultraviolet rays on the formed external light absorbing unit 60 to completely cure the external light absorbing unit 60;

(l) forming an anti-glare hard coating layer 80 or an anti-reflection layer 90 on the pressure-sensitive adhesive layer.

Referring to the method of manufacturing a multifunctional optical filter for a plasma display panel as described above in detail, it has the following features.

In order to manufacture the optical filter according to the present invention, it is composed of a transparent film, a sheet, a glass, and the like, and on one side of the substrate 10 shown in Fig. 4, an antireflection layer 90 or an antiglare hard coating layer 80 is It is formed (see Fig. 5).

On the opposite side of the anti-reflection layer 90 or the anti-glare hard coating layer 80, the groove 30a is pressurized while supplying the photocurable molding resin 20 using a roll stamper to form the electromagnetic wave shielding pattern 30. ) (See Fig. 6). The roll stamper used at this time is manufactured by the soft mold method or the hard mold method, and the hard mold is PDMS, epoxy, PU (urethane), ALKYD (alkyd), PHENOL (phenol), MELAMINE (melamine), UREA (urea) Resin can be used as a material, and a silicone resin can be used as a material for a soft mold.

Next, the grooves transferred by the roll stamper are filled with a light absorbing material including a conductive material by using a blade (see Fig. 7).

The electromagnetic wave shielding pattern according to the present invention is designed to not only laminate an adhesive layer containing infrared blocking and color correction pigments, but also to block electromagnetic waves so as to improve contrast when filling the light absorbing material between waveguides. The material constituting the light absorbing material to be filled in the grooves is a conductive paste composition of UV and EB curing type, includes nano-sized metal powder, contains additives and solvents to obtain dispersion safety, curing speed and curing A binder and a hardening | curing agent which adjust a grade are included. In addition, the structure is designed to eliminate the moire phenomenon with the panel pattern, Preferably, the horizontal size of each cell of the electromagnetic wave shielding pattern is 100 ~ 2000㎛, the line width is 5 ~ 40㎛, the vertical size is 50-300 micrometers, and the line width is 5-40 micrometers. In addition, the electromagnetic shielding pattern is manufactured to be inclined to 3 to 50 degrees to the horizontal pattern of the panel, is produced to be shifted from each other in 2 to 5 steps in the vertical pattern, it is configured to maximize the electromagnetic shielding efficiency using HFSS.

On the formed electromagnetic wave shielding pattern 30, a UV curable monomer or oligomer (hereinafter referred to as UV curable resin 40), which becomes a material of the waveguide, is coated (see Fig. 8). At this time, the photoinitiator is added to the UV curable resin 40. At this time, the UV curable resin 40 (UV curable resin) used as a coating agent has a high transparency and a difference between the refractive index of PET and 0.01 or less. This material has a hardness of 2H or higher after curing, is less deformed by heat or moisture, contains two or more kinds of initiators having different reaction wavelengths without yellowing by heat or light, and includes a material that improves leveling during coating. do. As the photoinitiator added to the coating agent, benzyl dimethyl ketal, diethyl oxy acetophenone, hydroxy methpropiophenone or the like or a mixture thereof may be used.

When the ultraviolet ray is irradiated below the electromagnetic wave blocking pattern 30, the coated UV curable resin is divided into a cured part and an uncured part.

After exposure, when the UV curable resin 40 laminated on the transparent substrate is immersed in a developing solution, the cured portion becomes the waveguide 50, and the remaining uncured portion is removed (see FIG. 9). In this case, isoprophenol alcohol (IPA), methanol, water, toluene, acetone, propylene glycol mono methyl ether acetate (PGMEA), and the like may be used as the developer.

After the development is completed, it is taken out of the developer and exposed to scattered light from the top of the waveguide to completely cure the developed waveguide. The external light blocking effect of the manufactured waveguide may vary depending on the waveguide height and sidewall inclination, and the waveguide height and sidewall. The slope may vary depending on the coating thickness of the UV curable resin, the UV exposure time, and the electromagnetic wave shielding pattern.

When the waveguide is fully cured, it fills the transparent resin with the light absorbing particles mixed between the waveguides (see FIG. 10). The transparent resin is mixed with the light absorbing particles and colored pigments or dyes to give a specific color or to block a specific wavelength. It may be. According to the present invention, the transparent resin is filled between the waveguides using a black fill process. Specifically, the adhesive film is attached while filling the light absorbing portion between the waveguides by the upper and lower rolls while supplying the light absorbing material. The adhesive film is formed in one piece by attaching a transparent film to the pressure-sensitive adhesive in which the infrared ray blocking and color correction pigments are mixed, and does not use a squeeze method to fill the light absorbing material between the waveguides. The use has the advantage of simplifying the process and increasing the production rate.

After the transparent resin is completely filled in the light absorbing portion between the waveguides 50, the transparent resin is cured by being exposed to scattered light such as ultraviolet rays above the transparent resin between the waveguides, and thus the external light absorbing portion 60 is formed between the waveguides. ) Is formed.

An anti-glare hard coating layer 80 or an anti-reflection layer 90 is formed on the waveguide 50 and the external light absorbing portion 60 to suppress an image immersion phenomenon (see FIG. 11).

The above description is merely illustrative of the technical details of the present invention, and those skilled in the art to which the present invention pertains may various modifications and changes without departing from the essential characteristics of the present invention. Therefore, the embodiments disclosed in the present invention are not intended to limit the technical idea of the present invention but to describe the present invention, and the scope of the technical idea of the present invention is not limited by these embodiments. The scope of protection of the present invention should be interpreted by the following claims, and all technical ideas within the scope equivalent thereto should be construed as being included in the scope of the present invention.

1 is a view showing an optical member manufacturing apparatus having a fine pattern.

Fig. 2 is a sectional view showing the structure of the optical filter of the present invention attached to a PDP panel.

3 shows an exemplary form of an electromagnetic wave shielding pattern constructed in accordance with the present invention.

4 to 11 show the shape of the optical filter according to the step of constructing the multifunctional optical filter according to the present invention.

** Explanation of symbols on the main parts of the drawing **

10 base material 20 photocurable molding resin

30: electromagnetic wave shielding pattern 30a: groove

40: UV curable resin 50: Waveguide

60: external light absorbing unit 70: near infrared ray blocking and color correction layer

80: anti-glare hard coating layer (anti-glare layer)

90: antireflection layer

100: optical filter 200: PDP panel

Claims (8)

In the optical filter for display comprising an antireflection layer, a transparent substrate, an external light blocking layer, an electromagnetic wave blocking layer and a near infrared ray blocking and color correction layer, (a) forming an anti-glare-hard-coating layer or an anti-reflection coating layer on the substrate; (b) processing the groove by transferring the fine pattern of the roll stamper by pressurizing using a roll stamper while supplying a photocurable molding resin onto the substrate on the opposite side of the anti-glare hard coating layer or the anti-reflective coating layer; (c) exposing the processed surface of the groove to scattered light to completely cure the groove; (d) filling a conductive light absorbing material by using a blade in the grooves completely cured; (e) irradiating UV light on the filled grooves to completely cure the electromagnetic wave blocking pattern; (f) coating a UV curable resin on the electromagnetic wave blocking pattern; (g) exposing ultraviolet rays under the electromagnetic wave blocking pattern to expose the same; (h) immersing and developing the UV curable resin laminated on the substrate after the exposure is finished; (i) irradiating ultraviolet rays from above the waveguide formed by the development to completely cure the developed waveguide; (j) forming an external light absorbing part by laminating an adhesive layer containing a near infrared ray blocking and color correction pigment on the completely cured waveguide and simultaneously supplying a transparent resin containing absorbing particles; (k) irradiating ultraviolet rays on the formed external light absorbing unit to completely cure the external light absorbing unit; (l) forming an anti-glare hard coating layer or an anti-reflection layer on the pressure-sensitive adhesive layer; Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The roll stamper may be configured by a hard mold or a soft mold Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The processed groove is characterized in that the ■ shape Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The electromagnetic shielding pattern is manufactured by inclining the panel horizontal pattern by 3 to 50 degrees, and the vertical pattern is produced by shifting each other in 2 to 5 steps. Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The electromagnetic shielding pattern is a structure that maximizes the electromagnetic shielding efficiency using HFSS Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The horizontal size of each cell of the electromagnetic wave blocking pattern is 100 ~ 2000㎛, line width 5 ~ 40㎛, vertical size is 50 ~ 300㎛, characterized in that the line width 5 ~ 40㎛ Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, Step (j) is characterized in that made by a roll-to-roll process Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper. The method of claim 1, The pressure-sensitive adhesive layer is characterized in that the transparent film is integrally attached to Method for manufacturing a multifunctional optical filter for plasma display panel using a roll stamper.

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