KR20100080387A - Method of manuracturing optical element - Google Patents

Abstract

PURPOSE: A manufacturing method of an optical element destroying an optical shield layer by a projection unit is provided to easily manufacture the product without complicated manufacturing process. CONSTITUTION: An optical sheet(410) includes a base unit(412) and plural protrusion units(415). The flat base unit passes through the light. A plurality of projections is installed in one surface(416) of the base unit. A light blocking layer secluding the light is pressurized by the optical sheet. The protrusion units destroy the projection layer. An opening unit is formed.

Description

Manufacturing Method of Optical Device {METHOD OF MANURACTURING OPTICAL ELEMENT}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical element used for an illumination device (backlight) for illuminating a transmissive display device such as a liquid crystal display device from the back, or an optical element disposed on the front surface of a transmissive display device to control a viewing angle. It relates to a manufacturing method of.

Background Art In recent years, liquid crystal displays have become the mainstream of image display devices, and have been used in a wide range of devices such as mobile phones, digital cameras, or liquid crystal televisions. Although the size of a liquid crystal display differs by these instruments, a main structure is substantially the same regardless of a magnitude | size, A liquid crystal display is equipped with the liquid crystal panel containing a liquid crystal, and the backlight as a light source. In a liquid crystal display, various optical elements are used or designed in order to adjust the viewing angle, brightness, etc. of light by diffusing and condensing light from a backlight.

Further, in liquid crystals, especially nematic liquid crystals, since the rotational action of the polarization plane varies depending on the angle of incidence of light, the modulation action on light incident in the diagonal direction and exiting in the diagonal direction is insufficient, and as a result, observation from the diagonal direction is observed. In contrast, a decrease in contrast and an inversion phenomenon occur.

As a method of avoiding this, Patent Literature 1 and Patent Literature 2 describe methods for diffusing light after condensing and converting light from a backlight into a liquid crystal panel and exiting the liquid crystal panel.

As an optical element for condensing light from a backlight, Patent Literature 2 discloses a light shielding portion in which an array of lenticular lenses or microlenses and an opening through which light passes near its focal plane reflect light to other portions thereof. What is formed is disclosed. As a method for forming such an opening and a light shielding portion, Citation Document 2 discloses a light-shielding material at a portion other than a portion in which the adhesive photosensitive resin layer is lost by self alignment using the light-collecting action of the lens itself. A method of forming is disclosed.

On the other hand, the optical element of Patent Literature 1 is disposed between the liquid crystal panel and the backlight, and is larger than the light input surface in order to parallelize the light incident through the opening and the light incident through the opening by total reflection. It is an optical element provided with the protruding micro collimator which has the light output surface of area, and the lens which further makes the light which passed the said micro collimator parallelize. Light from the backlight reaches the optical element through the openings, and the openings are spaced at intervals corresponding to the microcollimator and the lens, and a light shielding layer for blocking the light fills between the openings and the openings.

Like the micro collimator, a light shielding layer is formed on an optical sheet which has a light input surface and a light output surface having different areas, and which condenses / diffuses light using total reflection. Patent Document 3 describes a method of filling pigment particles and removing excess particles with a brush or the like.

[Patent Document 1] International Publication WO 95/14255 Pamphlet

[Patent Document 2] Japanese Unexamined Patent Publication No. 2000-171617

[Patent Document 3] Japanese Unexamined Patent Publication No. 62-245239.

However, the method of losing the adhesiveness of the adhesive photosensitive resin layer by the self-alignment of the lens, and forming the light shielding layer only on the portion which does not lose the adhesiveness, the thickness of the light shielding layer is limited to one to several parts of the light-shielding fine particles. It is difficult to form thickly, and therefore, there existed a problem that sufficient light shielding performance was not obtained. Alternatively, by application of this method, a transferable ink containing a light-shielding pigment is prepared in advance, a tacky adhesive layer is formed by using self alignment, and the ink containing the light-shielding pigment in the pattern of the pressure-sensitive adhesive layer is transferred. Although there is also a method of forming the openings and the light shielding layer, however, also in this method, if the pigment concentration in the ink is increased or the thickness of the ink layer is thick, there is a problem that it is not resolved.

Moreover, the method of filling ink (light-shielding microparticles | fine-particles) in the groove | channel between the processus part which becomes an opening part, and removing excess ink needs to scrape off and remove excess ink after filling of an ink, and a manufacturing process This tends to be troublesome. In addition, there is a fear that product quality may be deteriorated due to factors such as ink remaining on the protrusions corresponding to the openings or damage of the protrusions when the ink is removed. This invention is made | formed in view of such a subject, and an object of this invention is to provide the manufacturing method of the optical element which is easy to manufacture.

An optical sheet manufacturing method of an optical element of the present invention for achieving the above object, the optical sheet having a flat base for passing light and a plurality of projections for passing the light provided on one surface of the base portion Is pressed onto a substrate through which light passes, and the optical sheet presses the shielding layer that blocks the light provided on the substrate, and breaks the shielding layer by the projection to form an opening through which the light passes. Contains

In the manufacturing method of the optical element of the present invention, since the projections are arranged in accordance with the positions of the openings while forming the openings through which the light passes through the breakage of the light shielding layer, the complexity of the manufacturing process can be suppressed and the manufacturing Is easy.

EMBODIMENT OF THE INVENTION Hereinafter, the Example of this invention is described with reference to drawings. In addition, in the Example described below, about the member which has a function common in each Example, the same code | symbol is attached | subjected and the overlapping description is abbreviate | omitted.

< First embodiment >

1 is a view for explaining the outline of a manufacturing method of an optical device, Figure 2 is a view for explaining a manufacturing process of the optical device in detail, Figure 3 is an application example of the optical device manufactured by the first embodiment It is a figure explaining.

Referring to FIG. 1, a method of manufacturing an optical device according to an embodiment includes a flat base portion 412 through which light passes and a plurality of protrusions through which light provided on one surface 417 of the base portion 412 passes. The optical sheet forming process of forming the optical sheet 410 having a 415 is included.

The manufacturing method of the optical element is a softer and transparent buffer layer 422 than the protrusion 415 on the diffusion plate 421 (corresponding to the substrate) through which light passes, and a material softer than the buffer layer 422 on the buffer layer 422. The method further includes forming a light shielding layer 423.

The diffuser plate 421 uniformly supplies surface-emitted light to the optical sheet 410. The buffer layer 422 is tacky and is, for example, a pressure sensitive adhesive (PSA). The light shielding layer 423 is made by dispersing fine particles such as titanium oxide and silicon oxide in a binder such as a transparent resin. The thickness t of the light shielding layer 423 is several micrometers to several tens of micrometers, and is smaller than the height H of the projection part 415 (H> t). The light blocking layer 423 has a diffusion reflectivity of 50 to 90%. Here, the light shielding layer 423 blocks most of the light, but does not completely block and transmit the light at all.

In the method for manufacturing an optical element, after the optical sheet forming step and the light shielding layer forming step, the optical sheet 410 is stacked on the diffusion plate 421, and the light blocking layer provided on the diffusion plate 421 by the optical sheet 410. And a pressing step of pressing the 423 to break the light shielding layer 423 by the protrusion 415 to form an opening through which the light passes.

As shown in FIG. 2 (A), in the optical sheet forming step, the plurality of protrusions 415 on the surface 417 of the base portion 412 are known ultraviolet curable resins (hereinafter, simply referred to as "UV resin"). Is filled in a model (not shown) and irradiated with ultraviolet rays to cure and form a UV resin. The optical element 410 may be integrally formed with the base portion 412 and the plurality of protrusions 415 by melt extrusion molding.

2B and 2C illustrate a method of forming the buffer layer 422 and the light shielding layer 423 on the diffusion plate 421. As shown in FIG. 2 (B), a film sheet in which a buffer layer 422 and a light shielding layer 423 having adhesiveness are formed between a pair of release films 424 and 425 in advance is prepared. Next, as shown in FIG. 2 (C), the film sheet is bonded to the diffusion plate 421 using the adhesiveness of the buffer layer 422 while peeling off the release film 424 on the buffer layer 422 side. .

As shown in FIG. 2D, the pressing step causes the light shielding layer 423 to be destroyed by the protrusion 415 after the release film 425 is peeled off, and the protrusion 415 is eaten by the buffer layer 422. Let go By the pressing step, the optical sheet 410 and the diffusion plate 421 are integrated to form the optical element 400.

The protrusion 415 penetrates through the light blocking layer 423. The broken light shielding layer 423 enters between the protrusion 415 and the protrusion 415 together with the buffer layer 422. Between the protrusion 415 and the protrusion 415, a layer of air 405 (hereinafter referred to as an “air layer 405”) is formed between the light shielding layer 423 and the optical sheet 410.

If the light shielding layer 423 is flexible like the buffer layer 422, when the protrusion 415 presses the light shielding layer 423, the light shielding layer 423 is deformed along the outer shape of the protrusion 415 to form an opening. Since the 415 may be covered, it is desirable that the light shielding layer 423 is soft and easily broken by the pressurization by the protrusion 415.

In the first embodiment, the buffer layer 422 and the light shielding layer 423 were prepared in advance between the release films 424 and 425, and were bonded to the diffusion plate 423 to be used. Instead, the buffer layer 422 and the light shielding layer 423 may be sequentially formed on the diffusion plate 421. In addition, for the purpose of preventing the scattering of powder of the crushed light shielding layer 423 upon breakage of the light shielding layer 423, or preventing damage to the edges of the upper end of the protrusion 415, the buffer layer may be formed on both sides of the light shielding layer 423. 422) may be formed. At this time, in order not to inhibit the total reflection of the light at the side of the projection part 415, it is preferable to make the refractive index of the transparent buffer layer on the optical sheet 410 side smaller than the refractive index of the projection part 415.

The effects of the first embodiment will be described below.

In the method of manufacturing the optical element, the breakage of the manufacturing process is performed in order to arrange the protrusions 415 in accordance with the positions of the openings while forming the openings through which the light passes through the breakage of the light shielding layer 423 by the protrusions 415. It can suppress and manufacture is easy.

In addition, the manufacturing method of the optical element allows the projection 415 to be eaten into the flexible buffer layer 422 as compared with the projection 415, thereby preventing damage to the projection 415, and furthermore, to provide an optical element of good quality ( 400).

3 shows a use form of the optical element of the first embodiment.

As shown in Fig. 3A, the optical element 400 manufactured by the method of manufacturing the optical element according to the first embodiment is disposed between the liquid crystal panel 50 and the backlight 52, and the diffusion plate ( By injecting the light 53 of the backlight uniformed by the 421, the light can be focused in the front direction, and the light 54 having improved brightness can be supplied to the liquid crystal panel 50.

The optical element 400 shown in FIG. 3B is disposed downstream of the light 51 in the emission direction with respect to the liquid crystal panel 50, and the light 51 is incident by injecting light 51 from the optical sheet 410. The viewing angle of can be enlarged.

In addition, in the Example shown to FIG. 3B, in order to improve contrast in a bright room, the light shielding layer 423 is the light shielding layer 423 which absorbs light, such as black. This light-absorbing light shielding layer 423 is formed by dispersing fine particles such as carbon, black resin beads, and black pigment in a binder such as a transparent resin. The substrate 421 may be a transparent plate or a transparent film instead of the diffusion plate. As this transparent plate or transparent film, plastic plates, films, glass plates, etc., such as an acrylic resin, a styrene resin, a polycarbonate resin, and a polyester resin, can be used. This transparent plate or transparent film may form a well-known anti-glare layer AG, anti-reflective layer AR, low reflection layer LR, etc. on the emission side surface.

< Second embodiment >

4 is a view for explaining the outline of the manufacturing method of the optical device, Figure 5 is a view for explaining the optical sheet forming process, Figure 6 is a view for explaining the degree of pressing, Figure 7 is a portion of the optical device It is an enlarged view.

Referring to FIG. 4, a method of manufacturing an optical device according to an embodiment includes a plurality of flat base portions 112 that allow light to pass therethrough, and a plurality of passages of light provided on one surface 117 of the base portion 112. The optical sheet forming process of forming the optical sheet 110 provided with the protrusion 115 of this is included. The optical sheet 110 has the plurality of convex lenses 111 (corresponding to the lenses) at positions corresponding to the protrusions 115 of the other surface 116 which is different from the surface 117 of the base portion 112. Equipped.

The manufacturing method of the optical element is a flexible and transparent buffer layer 122 on the diffusion plate 121 (corresponding to the substrate) through which light passes, and a material softer than the buffer layer 122 on the buffer layer 122. The method further includes forming a light shielding layer 123. As the diffusion plate 121, the buffer layer 122, and the light shielding layer 123, those similar to those described in the first embodiment can be used.

In the manufacturing method of the optical element, after the optical sheet forming step and the light shielding layer forming step, the optical sheet 110 is stacked on the diffuser plate 121, and the light shielding layer provided on the diffuser plate 121 by the optical sheet 110 ( And a pressing step of pressing the 123 to break the light shielding layer 123 by the protrusion 115 to form an opening through which the light passes.

As shown in FIG. 5, the optical sheet forming step includes a lens forming step of forming a plurality of convex lenses 111 on the surface 116 of the base portion 112, and a UV resin layer 113 cured by light. The hardening layer forming process of forming a in the surface 117 of the base part 112 is included. The optical sheet forming step includes a curing step of irradiating light to the UV resin layer 113 through the convex lens 111 to form a curing unit 114 on which the UV resin layer 113 is cured, and a curing unit ( The UV resin layer 113 different from 114 is removed, and the process of forming the protrusion part further including the hardened part 114 as the protrusion part 115 is further included.

As shown in Fig. 5A, in the lens forming step, the base portion 112 and the plurality of convex portions are irradiated with ultraviolet rays to an ultraviolet curable resin (hereinafter only referred to as "UV resin") or by melt extrusion molding. The lens 111 is integrally formed.

The plurality of convex lenses 111 are, for example, one-dimensional lenticular lenses or two-dimensional microlens arrays. The array of microlens arrays may be a random array in addition to the tetragonal array arranged vertically and horizontally and the hexagonal most dense array arranged without a gap in a hexagon. In the cured layer forming step, the UV resin is applied to the surface 117 after the lens forming step.

As shown in FIG.5 (B), in the hardening process, the UV resin apply | coated to the surface 117 by hard alignment is hardened. That is, the ultraviolet-ray 10 is irradiated to the UV resin layer 113 through the convex lens 111, and the part corresponding to the convex lens 111 in the UV resin layer 113 is hardened. The irradiation direction of the ultraviolet ray 10 is substantially perpendicular to the planes 116 and 117 of the base portion 112, and the focus 15 of the convex lens 111 is positioned on the UV resin layer 113.

As shown in FIG. 5 (C), in the process of forming the protrusions, the hardened portion 114 and the other UV resin layer 113, that is, the uncured UV resin are washed away with, for example, a solvent to form the protrusions 115. do.

The protrusions 115 formed as described above become one-dimensional protrusions in the same manner as the convex lens 111 when the plurality of convex lenses 111 are one-dimensional lenticular lenses, and in the case of the two-dimensional microlens array Is also arranged in two dimensions.

As shown in FIG. 6, the pressing step causes the light shielding layer 123 to be destroyed by the protrusion 115, and the protrusion 115 is fed into the buffer layer 122. By the pressing process, the optical sheet 110 and the diffusion plate 121 are integrated to form the optical element 100.

The second embodiment exhibits approximately the same effects as the first embodiment.

Unlike the embodiment, a tacky adhesive layer is formed at the position corresponding to the protrusion 115 and the protrusion 115 on the surface 117 by using self-alignment of the lens 111, It is also possible to transfer the ink containing the light-shielding pigment into the pattern to form an opening and a light shielding layer (transfer method). In this method, however, raising the pigment concentration in the ink may cause a decrease in resolution.

Meanwhile, in the present embodiment, the light blocking layer 123 is formed between the protrusion 115 and the protrusion 115 while forming an opening through which light passes through the light blocking layer 123 by the protrusion 115. Since it forms, even if the density | concentration of the light-shielding microparticles | fine-particles contained in the light shielding layer 123 is raised, resolution is favorable.

Unlike the embodiment, although the projection 115 and the opening can be aligned by a mechanical method, it is difficult to achieve both high resolution and large area in this method. On the other hand, in the present embodiment, the projections 115 are arranged in accordance with the positions of the openings while forming the openings through which light passes through the breakage of the light shielding layer 123 by the projections 115. Easily compatible.

As shown in FIG. 7, in the optical element 100, the light scattered by the diffusion plate 121 passes through the protrusion 115 and the convex lens 111 and is aimed in the front direction by the lens action. Accordingly, the optical element 100 is disposed between the liquid crystal panel including the liquid crystal and the backlight as a light source, and the light of the brightness of the front direction is increased to the liquid crystal panel by injecting light of the backlight from the diffusion plate 121. Can supply

The air layer 105 may be omitted, but if the air layer 105 is present as in the embodiment, light is totally reflected due to the difference in the refractive index between the light shielding layer 123 and the air layer 105, so that there is no air layer 105 Compared with this, since the light shielding property of the light shielding layer 123 can be improved, it is preferable. In addition, since the light totally reflected on the side surface 118 of the protrusion 115 is caused by the difference in the refractive index between the protrusion 115 and the air layer 105, the light incident on the adjacent convex lens 111 (FIG. 7). Can be reduced.

In the method of manufacturing an optical device according to the embodiment, when the protrusions 115 are fed into the buffer layer 122, the broken light shielding layer 123 is pushed against the buffer layer 122 so that the protrusions 115 and the protrusions ( Since it enters between 115, the light shielding layer 123 protrudes toward the optical sheet 110 in the optical element 100. When light is reflected from the light shielding layer 123, only complete scattering reflection occurs rarely, and the scattering reflection and specular reflection (mirror reflection) which are not directional are often mixed with each other. In the optical element 100, since the light shielding layer 123 protrudes toward the optical sheet 110, the specular reflection component during scattering reflection is perpendicular to the interface between the buffer layer 122 and the diffusion plate 121. The ratio of the aromatic component increases compared with the case where the light shielding layer 123 and the base part 112 are substantially parallel. As a result, since the number of reflections can be suppressed and the light can be emitted from the protrusion 115, the light utilization efficiency is improved.

< Third embodiment >

8 is a view for explaining another optical device manufacturing method according to the third embodiment.

As shown in Fig. 8, the third embodiment is substantially the same as the second embodiment, but in the curing step of the second embodiment, the focus 25 of the convex lens 211 is located farther from the UV resin layer 213. In terms of positioning, it differs from the second embodiment. For this reason, the projection part 215 which has a trapezoid shape in cross section can be formed, and a pressurizing process destroys the light shielding layer 223 by the projection part 215 which has a taper shape toward the front end part. Therefore, in addition to the effect of the second embodiment, in the pressing step, the force for pressing the protrusion 215 can be reduced.

9 shows usage forms of the optical elements of the second and third embodiments.

As shown in Fig. 9A, the optical element 100 or 200 manufactured by the method for manufacturing the optical element according to the second and third embodiments is the optical element according to the first embodiment described above. Similar to the optical device 400 manufactured by the manufacturing method, the light 53 of the backlight disposed between the liquid crystal panel 50 and the backlight 52 and uniformized by the diffusion plate 121 or 221 is used. By making it incident, light can be condensed in the front direction, and the light 54 whose brightness is improved can be supplied to the liquid crystal panel 50.

As shown in Fig. 9B, the optical element 100 or 200 manufactured by the method for manufacturing the optical element according to the second and third embodiments is applied to the liquid crystal panel 50 with respect to the light ( It is arrange | positioned downstream of the emission direction of 51, and the light angle of the light 51 can be extended by injecting the light 51 from the lens 111 or 211. The light shielding layer 123 or 223 is a light absorbing light shielding layer similar to the light shielding layer 423 in the optical element 400 manufactured by the manufacturing method according to the first embodiment. 221 may also be a transparent plate or a transparent film, similarly to the base material 421 in the optical element 400 manufactured by the manufacturing method according to the first embodiment.

< Fourth embodiment >

10 is a view for explaining a manufacturing method of the optical element according to the fourth embodiment, Figure 11 is a plan view of the optical sheet according to the fourth embodiment seen from the projection side.

The manufacturing method of the optical element according to the fourth embodiment is substantially the same as in the second embodiment, but in the second embodiment, the plurality of convex lens elements 111 are formed of a one-dimensional lenticular lens and a two-dimensional microlens array. Although any of these was included, it is limited only to a two-dimensional microlens array in the fourth embodiment. Moreover, the hardening process is different from 2nd Example.

10A is a perspective view of a microlens array sheet used in the fourth embodiment. In the microlens array sheet of this example, the convex lenses 311 are arranged most densely in a hexagon. The direction in which the convex lenses 311 are sequentially arranged is referred to as (31), and the direction in which the convex lenses 311 are alternately arranged is referred to as (32). Hereinafter, the microlens array sheet used in the fourth embodiment will be described as an example in which the convex lenses 311 are arranged most densely in a hexagon, but the fourth embodiment is not limited to this, but the square array or random It is also adaptable to arrangement.

As shown in FIG. 10 (B), the curing step of the fourth embodiment diffuses or irradiates the ultraviolet rays 30 in one direction 31 along the surface of the UV resin layer 313, or irradiates the ultraviolet rays 30. By varying the angle of irradiation, ultraviolet rays are irradiated stepwise in one direction 31 along the surface of the UV resin layer 313.

By this irradiation, for example, as shown in Fig. 11A, a projection 315A having an elliptical cross section in a plane parallel to the surface 317 of the base portion 312 is formed. The elliptical long axis is along the direction 31. Alternatively, as shown in Fig. 11B, the projections 315B connected along the direction 31 are formed. Since each of the projections 315A and 315B has such a shape, the viewing angle is different in the direction 31 and in the direction 32 perpendicular to this. That is, the method of manufacturing the optical element according to the fourth embodiment exhibits the effect that an optical element having a different viewing angle in two directions can be manufactured in addition to the effect of the second embodiment.

The present invention is not limited to the above-described embodiments, but can be variously modified within the scope of the claims. For example, in the first embodiment, if the buffer layer 422 has a sufficient thickness, the cross-sectional shape of the protrusion 415 may be a triangular pointed tip. In addition, in FIG.3 (B) regarding a use form, when the liquid crystal panel 50 and the optical element 400 are bonded by the base part 412, since the self-reliability is unnecessary to the optical element 400 itself, pressurization is carried out. After the step, the substrate 421 may be peeled off.

1 is a view for explaining the outline of a manufacturing method of an optical element.

2 is a view for explaining a method of manufacturing a detailed optical device.

3 is a view for explaining a form of use of an optical element.

4 is a view for explaining an outline of a manufacturing method of an optical device according to a second embodiment.

5 is a view for explaining an optical sheet forming process according to the second embodiment.

It is a figure for demonstrating a pressurization process.

7 is a partially enlarged view of an optical element. 8 is a view for explaining the manufacturing method of the optical device according to the third embodiment.

9 is a diagram illustrating an example when an optical element is applied to a liquid crystal display.

10 is a view for explaining a method of manufacturing an optical device according to the fourth embodiment.

11 is a plan view of an optical sheet according to a fourth embodiment as seen from the projection side.

<Description of the code>

10, 20, 30: UV 15, 25: focus

31: one-way 50: liquid crystal panel

52: backlight 100, 400: optical element

105, 405: Air layer 110, 210, 410: Optical sheet

111, 211, 311: Convex lens (equivalent to lens)

112, 212, 312, 412: base portion 113, 213, 313: hardened layer

114: hardened part

115, 215, 315A, 315B, 415: protrusions

116, 216, 316, 416: face of base part (equivalent to one face)

117, 217, 317, 417: surface of the base portion (equivalent to the other side)

121, 221, 421: diffuser plate (equivalent to substrate)

122, 222, 422: buffer layer 123, 223, 423: light shielding layer

Claims (4)

An optical sheet having a flat base portion through which light passes and a plurality of projections through which light is provided on one surface of the base portion is superimposed on a substrate through which light passes, and the optical sheet is provided with light provided on the substrate. And a pressing step of pressing the blocking light shielding layer to form an opening through which light passes through the light shielding layer by the projection. 2. The method of claim 1, further comprising forming a buffer layer on the substrate that is more flexible and transparent than the protrusions, and the light blocking layer made of a material softer than the buffer layer on the buffer layer, wherein the pressing step is performed by the protrusions. And destroying the light shielding layer and allowing the protrusion to penetrate the buffer layer. The method of claim 1, wherein the protrusion has a tapering shape toward an end portion. The optical element according to any one of claims 1 to 3, wherein the optical sheet is provided with a plurality of lenses at positions corresponding to the protrusions on other surfaces different from one surface of the base portion. Manufacturing method.

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