KR20100106678A - Process for optical sheet - Google Patents

Process for optical sheet Download PDF

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Publication number
KR20100106678A
KR20100106678A KR1020090024756A KR20090024756A KR20100106678A KR 20100106678 A KR20100106678 A KR 20100106678A KR 1020090024756 A KR1020090024756 A KR 1020090024756A KR 20090024756 A KR20090024756 A KR 20090024756A KR 20100106678 A KR20100106678 A KR 20100106678A
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KR
South Korea
Prior art keywords
molding mold
pattern
curable resin
optical sheet
coating
Prior art date
Application number
KR1020090024756A
Other languages
Korean (ko)
Inventor
김경화
Original Assignee
주식회사 코오롱
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 주식회사 코오롱 filed Critical 주식회사 코오롱
Priority to KR1020090024756A priority Critical patent/KR20100106678A/en
Publication of KR20100106678A publication Critical patent/KR20100106678A/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
    • B29D11/00788—Producing optical films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets

Abstract

PURPOSE: A method for manufacturing optical sheets is provided to manufacture optical sheets having a desired optical property by lowering the failure rate of transferred patterns. CONSTITUTION: A method for manufacturing optical sheets comprises the following steps. A film-type mold(50) is transferred. The pattern(21) of the transferred mold is coated with curable resin fluid(1) in several steps and is partially filled with the curable resin fluid. A base film(10) is transferred. The pattern of the mold is adjacent to the binding position of the base film and the mold, is coated with the curable resin fluid, and is filled with the curable resin fluid to target thickness. The base film and the mold are coupled.

Description

Process for manufacturing optical sheet

The present invention relates to a method for manufacturing an optical sheet, and more particularly, to a method for manufacturing an optical sheet having a microlens pattern.

At present, the demand for the production of microstructures having a three-dimensional shape is rapidly increasing, and the construction of complex shapes having vertical cross sections including curved surfaces, such as a circle or an ellipse, as well as a basic structure having a rectangular vertical cross section. There is a lot of research being done. As a method for manufacturing a microstructure having a three-dimensional shape, a method of forming a structure using a polymer pattern having a three-dimensional shape or using a micromachining technique is mainly used.

As a representative method for forming a polymer pattern having a three-dimensional shape, the stereo lithography process is actively researched around the world, and a number of patents for the stereo lithography itself and its application are registered (Korean Patent No. 0183038, No. 0257033, No.0257034, No.0513646, U.S. Patent No.6777170, No.6833234). However, the stereolithography process has been used in limited research fields because of the costly and time-consuming fatal disadvantages of using expensive equipment.

In order to solve the fatal drawback of the stereo lithography process, the expensive equipment usage and the long time-consuming problem, the incline lithography (US Pat. ) Has been proposed and research has been conducted.

Meanwhile, as a micromachining technique for manufacturing a microstructure having a three-dimensional shape, a method of controlling an internal stress of a material for manufacturing a curved electrode used for an optical micro shutter or the like (US Patent No. 5233459, No.6829399, No. 6888142, No. 6972889) are representative. It has the advantage of effectively controlling the opening and closing of the light by using the curved electrode having a large deformation, but it is difficult to uniformly control the internal stress of the material, and it is bent in all directions due to the physical property that is bent by the internal stress of the material. There is a problem in implementing reproducibility.

In addition, a method of reflowing a photoresist is used for fabricating microlenses. The microlenses that control the direction of light travel have a continuous curved surface and form a rectangular photoresist at the position where the lens is to be formed to satisfy the requirement that the surface should be smooth, and then reshape by applying heat. Although a method of manufacturing microlenses has been proposed, there is a problem in that deformation of the photoresist lens is easily caused by heat and chemicals.

In order to mass produce microlens arrays, injection molding is typically used to harden plastic materials under high temperature and high pressure conditions using a metal microlens array stamper. . Forming a microlens array stamper

(F. Czerwinski, et. Al., "Texture instability in Ni electrodeposits applied in optical disk technology", Journal of Materials Science, Vol. 35, pp. 331-335). , 2000) or a method of transferring a positively formed positive photoresist mold twice (N. Lee, et. Al.,

"Fabrication of metallic nano-stamper and replication of nano-patterned substrate for patterned media", Nanotechnologies, Vol. 15, pp. 901-906, 2004) is typically used, but the method of etching the metal does not have a uniform shape, and the method of transferring the positively formed positive photoresist mold twice has several problems.

In the case of such a stamper method, it is difficult to process the stamper mold with metal as described above, which makes the manufacturing process of the stamper itself difficult, and the longer the area, the longer the manufacturing time, the more difficult it is to manufacture a stamper mold having a uniform thickness, and the handling process. There is a problem that can not be restored when folded or modified in the.

Thus, there is a method in which the molding mold is in the form of a film, that is, a method of manufacturing a film having a micropattern in a soft mold method, which is a molding mold in the form of a film having a pattern that is inverse to the desired micropattern, and the fine to be manufactured. The base film of the film having the pattern is coalesced, and the curable resin crude liquid is injected into the molding mold prior to the coalescence, and then the base film is transferred to the base film to transfer the pattern and harden to form a film having a fine pattern.

When using a molding mold in the form of a film, the molding mold can be easily handled, yield can be improved, manufacturing cost can be reduced, and the manufacturing pattern can be advantageously less constrained.

However, since the reversed phase of the desired pattern is transferred to the base film by collectively injecting the curable resin crude liquid into the mold in which the pattern is engraved, there is a problem in that bubbles are formed at the apex part of the pattern in a specific pattern. This problem leads to the defect of the film to be finally obtained and impairs the optical properties.

One embodiment of the present invention has been made in view of the above problems, and provides a method of manufacturing an optical sheet that can reduce the defect in the shape of the transferred pattern in manufacturing an optical sheet having a microlens pattern using a molding mold in the form of a film. I would like to.

This ultimately provides a method of manufacturing an optical sheet that can ensure excellent optical properties.

In this regard, in one embodiment of the present invention, a method of manufacturing an optical sheet having a plurality of microlens pattern with or without an anchor layer, wherein the reverse pattern of the microlens pattern is formed on a film. Transferring the molding mold; A pre-coating step of filling the curable resin crude liquid with at least a part of the pattern depth by coating the curable resin crude liquid in a plurality of steps to the pattern of the molding mold to be transferred; Apart from this, the step of transferring the base film to be the base of the optical sheet; A main coating step of filling the curable resin crude liquid to a desired pattern thickness with or without an anchor layer by further coating the curable resin crude liquid on the pattern of the molded mold at an adjacent position where the base film and the molding mold are coalesced; Incorporating the base film and the molding mold; Curing the curable resin crude liquid between the base film and the molding mold to transfer the pattern from the molding mold to the base film; And it provides a method for producing an optical sheet comprising a step of separating the molding mold.

In the manufacturing method according to an embodiment of the present invention, the pre-coating step is to pass the molding mold through a plurality of coating stages continuously arranged in the conveying direction of the molding mold step by step to coat the curable resin crude liquid in the pattern of the molding mold At the same time, it may be carried out by a method of degassing so that no air remains between the curable resin and the molding mold.

In the manufacturing method according to a preferred embodiment, the degassing is present with the coating roller and the molding mold provided in the coating end, and the resin filled in the molding mold by the rotation of the pressure roller running in engagement with the coating roller and It can be carried out by a method of forcibly discharging the air present between the molding mold.

In the manufacturing method of the optical sheet according to the embodiment of the present invention, the pre-coating process may be performed by a method for filling the curable resin crude liquid to 70 to 150% of the depth of the molding mold pattern.

Preferably in terms of easy bubble removal and increase the production rate, as the curable resin crude liquid may be used having a viscosity of 30 to 2000cps.

In the method of manufacturing the optical sheet according to the embodiment of the present invention, the curable resin crude liquid may include a thermosetting resin or an ultraviolet curable resin.

In the method for manufacturing an optical sheet according to an embodiment of the present invention, which is preferable in terms of ease of transfer of a pattern from a molding mold, the molding mold in the form of a film may be a release surface of a patterned surface.

According to the manufacturing method of the optical sheet according to the embodiment of the present invention, as well as the improvement of the glass properties of the continuous mass production of the optical sheet, the handleability of the molding mold and the production yield, etc. by using the molding mold in the form of a film, By lowering the defective rate of the pattern to be transferred, an optical sheet capable of preserving the intended optical characteristics can be more easily manufactured.

Hereinafter, the present invention will be described in detail.

The present invention relates to a method for producing an optical sheet, and in particular, having a structured surface on one side and a flat surface on the other side and a pattern layer made of a transparent polymer composition; The present invention relates to a method for manufacturing an optical sheet including a base layer adjacent to a flat surface of a pattern layer.

An example of the structure of such an optical sheet is the same as that of FIG. 1, but the manufacturing method of the present invention is not limited to manufacturing an optical sheet having such a pattern.

According to FIG. 1, the optical sheet has a base film 10 and a plurality of lens type patterns 21 having a hemispherical cross section. According to FIG. 1, the lens type pattern 21 does not have an anchor layer, but the lens type in which the anchor layer exists may also be included in the scope of the present invention.

According to one example of the manufacturing process of the present invention, as a molding mold for forming a lens type pattern having a hemispherical cross section, a film type one is used, and the cross section is as shown in FIG. 3. The molding mold 50 in the form of a film can be prepared by a method known in the art, for example, by using a metal master roll (Master Roll) by applying a curable resin to cure or bead on the base film It can be prepared by applying a curable resin to the cured resin and curing it using a master film in the form of an array.

At this time, the material of the film-forming molding mold is not particularly limited, but may be preferably a transparent film such as PET, in consideration of adhesion to the curable resin crude liquid and releasability after curing.

The pattern 51 of the molding mold in the form of a film is a reverse phase of the pattern 21 formed on the desired optical sheet.

Referring to FIG. 4, a process of manufacturing an optical sheet having a microlens pattern according to one embodiment of the present invention using the molding mold 50 in the form of a film is as follows. 5 is an example of an optical sheet manufacturing process corresponding to the comparative example, but the serial number is the same, but this is only for convenience of description and should not be understood as being exactly the same.

One example of the apparatus shown in FIG. 4 shows an example using a device in which the molding mold 50 in the form of a film is driven in the form of an endless belt, but the manufacturing process of the present invention is not limited to such an apparatus. Of course.

First, the molding mold 50 in the form of a film having the reverse phase pattern 51 of the microlenses is transferred.

The molding mold in the form of a transferred film is finally integrated with the base film 10 of the optical sheet to be manufactured. Usually, as shown in FIG. A curable resin crude liquid 1 capable of forming a microlens pattern is injected between the base film 10 and the pattern 51 of the molding mold, and after the coalescence, the pattern is transferred to the base film 10 and the hardening means 60 is formed. By curing through) to form a microlens pattern 21 on the optical sheet.

However, when the microlens pattern is formed in this manner, the curable resin crude liquid 1 is filled in the pattern 51 of the molding mold as a whole, and thus the curable resin crude liquid 1 cannot be filled in the entire pattern. A less filled portion, ie, bubble 100, may be created.

The resulting microlens pattern is recessed in the groove 100 ', which causes product defects and ultimately impairs the optical properties of the optical sheet having the microlens pattern.

Accordingly, in the optical sheet manufacturing process according to the embodiment of the present invention, the curable resin crude liquid is preliminarily filled in at least a part of the pattern depth of the molding mold in multiple steps while transferring the molding mold in the form of a film, and then the substrate of the optical sheet is prepared. The pattern is transferred by finally filling the curable resin crude liquid to the depth of the pattern of the remaining molding mold at an adjacent position where it is incorporated with the film and then integrating with the base film of the optical sheet. Preferably, the curable resin crude liquid is preliminarily filled in multiple stages and degassing can be performed simultaneously.

As an example for implementing such a process, FIG. 4 shows a schematic diagram of a device having a pre-coating zone 30 including three stages of pre-coating stages (31, 32, 33 in the molding mold running direction). The pre-coating zone 30 is not limited to three of the number of pre-coating stages, and the number may be changed in consideration of the fact that bubbles can be sufficiently removed from the crude liquid applied to the molding mold pattern.

The preliminary coating stages 31, 32, and 33 are not particularly limited in the method of coating, and may be transformed into various forms such as spray, dipping, and direct coating in consideration of easily removing bubbles. will be. In terms of removing bubbles of the curable resin applied to the molding mold pattern and securing the uniformity of the coating, the preliminary coating means includes a crude liquid coating roller 70, and each coating roller is engaged with the driving pressure. The main roller may be of a type that rotates together with the pressing roller 80.

As the coating roller and the pressure roller rotate in contact with each other in the preliminary coating stage as described above, when the molding mold is present and the curable resin is filled, the air remaining between the molding mold and the curable resin is removed as the two rollers rotate. By forcibly discharging, a state in which no air remains between the molding mold and the curable resin can be obtained, so that an optical sheet having no pattern of incomplete shape (defect) can be obtained.

After the pre-coating zone 30 including a plurality of coating means, the molding mold pattern is preferably filled in the curable resin crude liquid to 70 to 150% of the depth in terms of removing bubbles, and in particular, the pre-coating zone 30 Filling the curable resin crude liquid 1 to about 30 to 90% of the depth of the molding mold pattern while passing through the first coating end 31 constituting the s) may be optimal in terms of preventing bubble generation.

The curable resin crude liquid capable of enabling such a process is not particularly limited to thermosetting resin or ultraviolet curable resin, but the curable resin crude liquid has a viscosity of 30 to 2000 cps in view of easy bubble removal and high production speed. More preferably, it may be preferable to use a viscosity of 100 to 500cps.

Considering the use as an optical sheet, the curable resin crude liquid is not limited as long as it is a resin of a material capable of forming a transparent lens, and conventionally known resins used for a prism sheet or a prism film can be used. For example, the composition may include a mixture of a monomer or oligomer for ultraviolet polymerization and a photoinitiator.

The molding mold conveyed through the pre-coating zone 30 is incorporated with the base film 10 of the optical sheet which is transferred separately from each other. At the adjacent point to be coalesced, the final desired pattern thickness (where thickness is the thickness of the anchor layer) May or may not be taken into consideration), and the main coating stage 40 for filling the curable crude liquid 1 is provided. In other words, the coating stage 40 can finally adjust the thickness of the pattern of the desired optical sheet, that is, the total thickness of the pattern with or without the anchor layer.

The molding mold 50 filled with the curable resin crude liquid 1 in the pattern to the desired thickness via the main coating stage 40 is incorporated with the base film 10 of the transferred optical sheet, and the combined portion is a curing means ( 60), and finally the microlens pattern 21 is transferred to the base film 10 and entangled, and the molding mold returns to its original concave pattern.

The optical sheet obtained through such a series of processes has a microlens pattern 21 as shown in FIG. 1 and has a smooth and intact hemispherical lens shape.

However, the optical sheet obtained through the process as shown in FIG. 5 may have a plurality of microlenses having an incomplete hemispherical shape with grooves at or near the apex of the microlens.

On the other hand, the molding mold 50 in the form of a film may be a release treatment on the pattern surface 51 to be easily demolded after curing of the curable resin crude liquid.

In addition, in the optical sheet of the present invention, the base film 10 may have a thickness of about 10 to 400 μm, and any substrate may be used as long as it is a sheet made of a transparent resin used in an optical sheet such as a prism sheet or a prism film. Examples thereof include polyethylene terephthalate film, polycarbonate film, polypropylene film, polyethylene film, polystyrene film or polyepoxy film.

1 shows an example of an optical sheet having a general microlens pattern.

2 is a cross-sectional view of FIG.

3 is a cross-sectional view of a molding mold in the form of a film for molding a microlens pattern.

Figure 4 is a schematic diagram of a process for producing an optical sheet according to the process of the present invention using a molding mold in the form of a film.

Figure 5 is a schematic diagram of a process for producing an optical sheet according to a process different from the present invention using a molding mold in the form of a film.

Claims (7)

In the method of manufacturing an optical sheet having a plurality of microlens pattern with or without anchor layer, Transferring a molding mold in the form of a film formed on one surface of a pattern in which an inverse image of the microlens pattern is formed; A pre-coating step of filling the curable resin crude liquid with at least a part of the pattern depth by coating the curable resin crude liquid in a plurality of steps to the pattern of the molding mold to be transferred; Apart from this, the step of transferring the base film to be the base of the optical sheet; A main coating step of filling the curable resin crude liquid to a desired pattern thickness with or without an anchor layer by further coating the curable resin crude liquid on the pattern of the molded mold at an adjacent position where the base film and the molding mold are coalesced; Incorporating the base film and the molding mold; Curing the curable resin crude liquid between the base film and the molding mold to transfer the pattern from the molding mold to the base film; And Method for producing an optical sheet comprising the step of separating the molding mold. The method of claim 1, wherein the pre-coating step passes the molding mold through a plurality of coating stages continuously arranged in the conveying direction of the molding mold, thereby gradually coating the curable resin crude liquid in the pattern of the molding mold and simultaneously between the curable resin and the molding mold. Method of producing an optical sheet which is carried out by a method of degassing so that no air remains in the. 3. The degassing process according to claim 2, wherein the degassing exists between the coating roller and the molding mold provided at the coating end and between the resin filled in the molding mold and the molding mold by the rotation of the pressure roller running in engagement with the coating roller. Method of manufacturing an optical sheet to be carried out by forcibly discharging the air present in the.  The optical sheet manufacturing method according to claim 1 or 2, wherein the pre-coating step is to fill the curable resin crude liquid so that 70 to 150% of the depth of the molding mold pattern. The method for producing an optical sheet according to claim 1, wherein a viscosity of 30 to 2000 cps is used as the curable resin crude liquid. The optical sheet manufacturing method according to claim 1, wherein the curable resin crude liquid contains a thermosetting resin or an ultraviolet curable resin. The method of claim 1, wherein the molding mold in the form of a film is a pattern surface is released.
KR1020090024756A 2009-03-24 2009-03-24 Process for optical sheet KR20100106678A (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101115033B1 (en) * 2011-06-29 2012-02-28 (주)코원티엔에스 Apparatus for making film with uv layer
WO2013100703A1 (en) * 2011-12-30 2013-07-04 미래나노텍 주식회사 Forming mold filling assembly and fine pattern forming apparatus including same
KR101501989B1 (en) * 2013-12-31 2015-03-12 주식회사 효성 Optical film using release film and method of producing the same
KR101717883B1 (en) * 2016-07-22 2017-03-22 주식회사 이그린 Mat for preventing weeds with retroreflecting function and retroreflecting strap using the same
CN110919950A (en) * 2019-11-29 2020-03-27 上海绘兰材料科技有限公司 Soft mold forming process of brightness enhancement film and product prepared by soft mold forming process
WO2024012075A1 (en) * 2022-07-13 2024-01-18 凯鑫森(上海)功能性薄膜产业股份有限公司 Scratch-resistant wire drawing film, apparatus therefor, preparation method therefor, and use thereof

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101115033B1 (en) * 2011-06-29 2012-02-28 (주)코원티엔에스 Apparatus for making film with uv layer
WO2013100703A1 (en) * 2011-12-30 2013-07-04 미래나노텍 주식회사 Forming mold filling assembly and fine pattern forming apparatus including same
KR20130079275A (en) * 2011-12-30 2013-07-10 미래나노텍(주) Assembly for filling mold and patterning appartus for transparent base material having the same
KR101501989B1 (en) * 2013-12-31 2015-03-12 주식회사 효성 Optical film using release film and method of producing the same
KR101717883B1 (en) * 2016-07-22 2017-03-22 주식회사 이그린 Mat for preventing weeds with retroreflecting function and retroreflecting strap using the same
CN110919950A (en) * 2019-11-29 2020-03-27 上海绘兰材料科技有限公司 Soft mold forming process of brightness enhancement film and product prepared by soft mold forming process
WO2024012075A1 (en) * 2022-07-13 2024-01-18 凯鑫森(上海)功能性薄膜产业股份有限公司 Scratch-resistant wire drawing film, apparatus therefor, preparation method therefor, and use thereof

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