KR20110038854A - Apparatus and method of manufacturing the patterned retarder, patterned retarder made by such a method - Google Patents

Abstract

PURPOSE: An apparatus for manufacturing a patterned retarder, and a method for the same are provided to improve the productivity by simplifying the manufacturing process and preventing an orientation defect. CONSTITUTION: An apparatus for manufacturing a patterned retarder comprises: a transport unit(11) for reeling and transferring a roll film; an alignment layer forming unit(3) for forming an alignment layer on the film; a first alignment part(13) for aligning by projecting light to a predetermined period; and a second alignment part(15) for aligning to the different direction with the first alignment part.

Description

Apparatus and method of manufacturing the patterned retarder, patterned retarder made by such a method}

The present invention relates to an apparatus and method for manufacturing a patterned retarder, and a retarder manufactured by the method. More particularly, the patterned retarder can be applied to a stereoscopic image display device or a semi-transmissive LCD using a polarizing glasses method. It further relates to a manufacturing apparatus, a manufacturing method and a retarder manufactured by the method.

In general, a patterned retarder (also called a birefringent medium or a retardation film) may be applied to a stereoscopic image display device of polarized glasses to be used to implement a stereoscopic image. In addition, the patterned retarder is provided on one surface of a transflective LCD, and functions as a compensation film for optimizing the optical characteristics of the reflecting and transmitting portions, respectively, so as to obtain good identification of the LCD image regardless of whether the external light is bright or dark. It can also be used to.

10 and 11 illustrate stereoscopic trademarks including a patterned retarder 101 including a film (polarizing plate) 105, an alignment layer 107, and a liquid crystal coating layer 109 on one surface of the image display panel 103. The device is shown. Here, the left circularly polarized light part (L) and the right circularly polarized light part (R) have a structure in which they are alternately repeatedly arranged in a stripe shape. The light passing through the left circular polarizer L passes through the polarizing film of the left eye in the polarizing glasses of the user, and the light passing through the right circular polarizing unit R passes through the polarizing film of the right eye in the polarizing glasses of the user. It is possible to realize a three-dimensional image by forming different images in (iii).

As described in Japanese Patent Application Laid-Open No. 10-227998, Japanese Patent Application Laid-Open No. 10-177156, Japanese Patent Application Laid-Open No. 2003-337226, and Korean Publication No. 10-2002-0059028, there are three methods for manufacturing a conventional patterned retarder. Can be divided.

First, an alignment film or an alignment film is formed on a sheet of substrate, and the first patterned region is formed by etching, laser irradiation, or sand blasting, and then the same pattern as the first patterned region generating method is used. The patterned retarder is formed in the form of a single layer with the two patterned regions in the form of a single layer, or the patterned retarder is formed in a stacked form on the first patterned region.

Second, after the alignment film is formed on the sheet substrate, the alignment film is patterned using a photosensitive photoresist forming rubbing roll, the liquid crystal coating layer is applied on the alignment film, and then patterned retarder is formed by ultraviolet irradiation. .

Third, after the alignment film is formed on the sheet substrate, the alignment film is patterned by using a mask and light irradiation, the liquid crystal coating layer is applied on the alignment film, and then patterned retarder is formed by ultraviolet irradiation. .

The first method was complicated by the apparatus and method, and the manufacture of the patterned retarder was not easy.

Since the second method uses a rubbing roll to orientate, the precision of the orientation is inferior and there is a fear of an orientation defect.

In the first, second, and third methods, the patterned retarder is manufactured by using a single substrate, and the pattern precision of the patterned retarder is decreased at the edge of the substrate, which is applied to an image display apparatus such as a liquid crystal display device. In order to apply, it is necessary to manufacture larger than the image area of an image display apparatus, and to cut | disconnect again according to the image area size. In particular, in order to apply this to a liquid crystal display, a process of laminating a patterned retarder using an adhesive on a polarizing plate positioned on the liquid crystal panel or stacking a patterned retarder using a frame fixing or the like was necessary. . In this case, the process was complicated and the application process margin was narrow because each patterned retarder was prepared according to the size of the liquid crystal panel. In addition, there is a problem that takes a long time to produce a patterned retarder.

Accordingly, the present invention has been proposed to solve the above problems, and the object of the present invention is to provide a manufacturing apparatus for a continuous patterned retarder which is simple, prevents orientation defects, improves quality, and has a wide application process margin. It provides a manufacturing method and a patterned retarder manufactured by the method.

In addition, the present invention is to provide a patterning retarder manufacturing apparatus, a manufacturing method and a retarder manufactured by the method to simplify the manufacturing process, improve the productivity by employing a process suitable for short time mass production.

In order to achieve the above object, the present invention provides a transfer unit for unwinding and / or winding a roll film, an alignment film forming unit for forming an alignment film on the transferred film, and a first light source on the alignment film formed on the film. A first alignment portion for irradiating light from the first alignment portion, the second alignment portion having a lattice or stripe pattern that is repeated between the second light source and the alignment layer on the alignment layer passing through the first alignment portion; Forming a patterned retarder by irradiating light from a third light source after forming a liquid crystal coating layer on an upper portion of the second alignment portion which is irradiated with light from a light source and oriented in a direction different from that of the first alignment portion; An apparatus for manufacturing a patterned retarder including a patterned retarder forming unit is provided.

In addition, the present invention is the step of unwinding and / or winding and transporting the roll film, forming an alignment film on the conveyed film, by irradiating light from the first light source to the alignment film formed on the film, the primary orientation in a constant direction And irradiating light from the second light source in a lattice or stripe shape repeated through the first mask disposed between the second light source and the alignment film to the alignment film after the primary alignment. Patterning retarder comprising the step of secondary orientation in the other direction, and after forming the liquid crystal coating layer on the alignment layer after the secondary alignment, irradiating light from a third light source to form a patterned retarder It provides a method of manufacturing.

In addition, there is provided a patterned retarder manufactured by the manufacturing method.

The present invention has the effect of improving the quality by preventing the occurrence of alignment defects in the adjacent portions of the alignment region made in a different direction because the alignment is made in a non-contact manner.

Further, when the patterned retarder of the present invention is applied to a stereoscopic image display device, the manufacturing process is simplified, and the patterned retarder of the present invention can be cut and provided according to the size of the image display device, thereby increasing the process margin. Can be improved. In addition, the patterned retarder of the present invention can be manufactured continuously and has the effect of improving mass production and productivity.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a configuration diagram for explaining a first embodiment of the present invention and shows a manufacturing apparatus of a patterned retarder.

The apparatus for manufacturing a patterned retarder may include an optical alignment unit 1 and a patterned retarder forming unit 3. The photo-alignment part 1 is a conveying part 11 provided with the 1st roll 7 which unwinds the film 5, and the 2nd roll 9 by which the film 5 is wound, and the 1st oriented in a specific direction The alignment unit 13 and the second alignment unit 15 are aligned in a direction different from the first alignment unit 13.

In addition, an alignment film forming unit (not shown) for forming an alignment film on the film 5 before the first alignment unit 13 is included. The alignment film forming unit may be a flow casting method and a conventional apparatus such as an air knife, gravure, reverse roll, kiss roll, spray or blade, etc. may be used. have. The alignment film may be formed in the process immediately before the alignment by the alignment film forming unit, and in some cases, the alignment film may be formed on the film 5 through a separate alignment film forming process. In addition, a conventional drying apparatus can be used for an oriented film formation part, as needed, in order to harden the formed oriented film.

The first roll 7 and the second roll 9 of the transfer unit 11 are independently connected to a driving source (not shown) such as a motor and a power transmission member (not shown) such as a belt or a chain to receive and rotate a driving force. It is desirable to be arranged so that it can.

In addition, a plurality of guide rolls (not shown) and accumulators (not shown) for controlling the feeding amount of the film according to the process may be provided for maintaining the tension and transferring the stable film.

The first alignment unit 13 is provided with a first light source 19 capable of aligning the entire region of the alignment film provided on the film 5 in one direction. It is preferable that the 1st light source 19 can irradiate an electron beam or polarized electromagnetic waves. Among polarized electromagnetic waves, ultraviolet rays are more preferable in terms of ease of handling.

In particular, in the embodiment of the present invention, the first light source 19 may be arbitrarily selected according to the type of alignment film provided on the film 5 surface, and may be any type as long as it can be oriented in a non-contact manner.

It is preferable that the 2nd orientation part 15 is provided in the moving direction side to which the film 5 moves based on the 1st orientation part 13. The second alignment unit 15 may include a second light source 21 and a first mask 23. The second light source 21 provided in the second alignment unit 15 orients the alignment film in a direction different from that of the first light source 19 of the first alignment unit 13 described above. It is preferable to be able to investigate). Among polarized electromagnetic waves, ultraviolet rays are more preferable in view of ease of handling. In the different directions, the second orientation is preferably performed in a direction perpendicular to the first orientation.

The first mask 23 is preferably disposed between the second light source 21 and the film 5. As shown in FIG. 2, the first mask 23 is alternately provided with the light blocking portion A and the light passing portion B in a stripe shape at regular intervals. In addition, the mask of the present invention may have a lattice shape in which the light blocking portion A and the light passing portion B are alternately repeated up, down, left, and right.

Light blocking portion (A) is made of a structure that is blocked to block light, the light passing portion (B) is a structure that allows light to pass through a certain size. The first mask 23 has a predetermined length D along the moving direction of the film 5.

In the second alignment unit 15, optical alignment may be performed while the movement of the film 5 is fixed by using an accumulator or the like according to the characteristics of the optical alignment pattern, or optical alignment may be performed while the film 5 is moved. .

In addition, when the optical alignment is performed while the film 5 is moved, the length D of the first mask 23 is maintained because the first mask 23 is maintained in a fixed state and the alignment is performed while the film 5 is moved. Continuous orientation is possible while minimizing

Therefore, the continuous speed is possible, thereby greatly improving the process speed.

The patterned retarder forming portion 3 is provided on one side of the second alignment portion 15 to form a liquid crystal coating layer on the alignment film provided on the film 5. The patterned retarder forming unit 3 is illustrated in the embodiment of the present invention by showing an example disposed on one side of the second alignment unit 15 for a continuous process, but is not limited thereto. It may also be made of a separate device to proceed to a separate process.

The patterned retarder forming unit 3 includes a mixed solution applying unit 31, a mixed solution drying unit 33, and a hardening unit 35.

The mixed solution application part 31 is a uniform coating of a coating liquid containing a liquid crystal compound, a monomer, and a solvent on the alignment film. The mixed solution application part 31 may be a flow casting method and an air knife, gravure, reverse roll, kiss roll, spray, blade, or the like. Conventional devices can be used.

The mixed solution drying unit 33 is for drying the mixed solution applied by the mixed solution applying unit 31 to form a coating layer, which may also be a common drying apparatus.

The hardening part 35 irradiates and hardens the formed coating layer using a third light source (not shown), and a conventional device such as a light source for irradiating electromagnetic waves may be used.

In addition, after the patterned retarder forming unit 3, the present invention may include a defect inspection unit (not shown) to perform defect inspection of the patterned retarder. The defect inspection unit specifies the specified defect by scanning the polarization filter, etc., and displays the specified defect using a marking device such as ink marking or barcode marking on the specified defect, or the defect information (shape, size, position) in a separate storage unit. ) Can be stored and applied to a stereoscopic image display device.

The manufacturing method of the patterned retarder of the 1st Example of this invention made in this way is demonstrated in detail with reference to FIG.

First, the film 5 is conveyed by the conveying part 11 (S1). At this time, the film 5 is preferably moved in a conventional roll to roll (roll to roll) method. In addition, it is preferable to use a guide roll (not shown) for maintaining the tension and stable film transfer, and an accumulator (not shown) for controlling the feeding amount of the film according to the process.

An alignment film is formed on the film 5 (S3). Formation of the alignment film is carried out by an alignment film applying apparatus, and drying is performed by a drying apparatus as necessary. In addition, this process may be abbreviate | omitted when an orientation film is formed on the film 5 through a separate orientation film formation process.

In the first alignment unit 13, the alignment layer formed on one surface of the film 5 is aligned in the predetermined direction by the first light source 19 (S5). At this time, since the alignment film is made while the film 5 moves, the alignment is performed in the entire region.

In addition, according to the pattern shape or process of the patterned retarder, the first orientation may be performed while the film 5 is fixed.

And while the film 5 is moved, the second alignment portion 15 in the second alignment is made (S6). At this time, in the second alignment unit 15, the light irradiated by the second light source 21 passes through only the light passing portion B of the first mask 23, and the second alignment unit 15 performs alignment in a secondary manner. In this case, the direction of the alignment formed in the second alignment unit 15 is different from the direction of the alignment formed in the first alignment unit 13.

Preferably, the second orientation is performed in a direction perpendicular to the first orientation. In addition, according to the pattern shape or process of the patterned retarder, the second orientation may be performed while the film 5 is fixed.

That is, when the film 5 passes through the first alignment portion 13 and the second alignment portion 15, the alignment film provided on one surface of the film 5 is oriented in different directions as shown in FIG. 4. The regions 5a and 5b are alternately arranged to form a stripe shape.

After the secondary alignment, the liquid crystal coating layer is formed after curing of the alignment layer (S7). In the forming of the liquid crystal coating layer (S7), a mixed solution including a liquid crystal compound, a monomer, and a solvent is applied to the aligned portion of the film 5 (S9). And the mixed solution is dried to form a coating layer (S11). The coating layer is photocured (S13). Through this process, the liquid crystal coating layer is aligned according to the alignment direction of the alignment layer, thereby manufacturing a patterned retarder.

5 illustrates the structure of the patterned retarder of the present invention. Patterned retarders are provided on top of the film 5 and the film 5 and are oriented in different directions and have stripe shapes and alternately arranged alignment regions 5a and 5b, which are arranged in this orientation region 5a, And a liquid crystal coating layer 41 disposed on the top of 5b).

The film 5 of the present invention is preferably an optical film, and more preferably a polarizing plate. The said optical film and a polarizing plate can use a well-known thing. On the other hand, in order to make left circle polarization and right circle polarization in a stereoscopic image display apparatus using a patterned retarder, a process of laminating a patterned retarder on a polarizing plate with an adhesive or the like is required. However, in the case of using the polarizing plate as the film 5, such a lamination step is omitted, so that not only process shortening but also manufacturing cost can be reduced.

The polarizing plate includes a polarizer protective film laminated on at least one surface of the polarizer and the polarizer. As the polarizer, those in which the dichroic dye is adsorbed and oriented on a film made of polyvinyl alcohol-based resin can be used. As a polyvinyl alcohol-type resin which comprises the said polarizer, the copolymer etc. of polyvinyl acetate which is a homopolymer of vinyl acetate, a vinyl acetate, and the other monomer copolymerizable with this can be used. As the other monomer copolymerizable with vinyl acetate, unsaturated carboxylic acids, unsaturated sulfonic acids, olefins, vinyl ethers and acrylamides having an ammonium group may be used. The thickness of the polarizer is not particularly limited and may be prepared in the conventional thickness used in the art.

The polarizer protective film is preferably excellent in transparency, mechanical strength, thermal stability, moisture shielding, isotropy, etc., for example, polyester-based films such as polyethylene terephthalate, polyethylene isophthalate, polybutylene terephthalate; Cellulose films such as diacetyl cellulose and triacetyl cellulose; Polycarbonate film; Acrylic films such as polymethyl (meth) acrylate and polyethyl (meth) acrylate; Styrene-based films such as polystyrene acrylonitrile-styrene copolymer; Polyolefin-based films such as polyethylene, polypropylene, cyclo- or polyolefin-based films having a norbornene structure, and ethylene propylene copolymers; Polyimide film; Polyether sulfone-based film; A sulfone film etc. can be used, The thickness of these is also not specifically limited.

In addition, the slow axis direction of the 1st orientation and the 2nd orientation of the liquid crystal coating layer of this invention maintains 45 degree and 135 degree, respectively, independently of the absorption axis (stretch-axis) direction of a polarizing plate, and forms a right polarizing part and a left circular polarizing part, respectively. .

Such a patterned retarder can be continuously produced in long lengths, which facilitates mass production, thereby increasing productivity. In addition, the patterned retarder of the embodiment of the present invention can be attached to an image panel having a variety of conditions to form a flexible (base) consisting of a film (flexible).

FIG. 6 is a configuration diagram for explaining a second embodiment of the present invention and shows a manufacturing apparatus of a patterned retarder. The description of the second embodiment of the present invention will be described only in comparison with the above-described embodiment, and the same parts will be replaced by the description of the above-described example.

In the first embodiment described above, the first mask 23 is disposed only on the second alignment portion 15. However, the apparatus for manufacturing the patterned retarder of the second embodiment of the present invention includes the first alignment portion 13 and There is a difference in that the masks 51 and 53 are disposed in the two alignment portions 15, respectively.

In the masks 51 and 53, the light blocking portion A and the light passing portion B are alternately disposed. Further, these masks 51 and 53 are preferably provided at positions where the respective light blocking portions A and the light passing portions B cross each other.

The masks 51 and 53 have a structure that can be employed according to the type or characteristics of the alignment layer, and the masks 51 and 53 are alternately repeated up, down, left, and right at positions where the light blocking portion and the light passing portion cross each other. It may have a grid shape.

As shown in FIG. 9, the second embodiment of the present invention performs a primary alignment by using the second mask 51 of the first alignment unit 13 in a non-contact manner to the moving film surface (S21). .

Then, the alignment is performed in a specific direction only in the light passing portion B according to the shape of the second mask 51 in the first alignment portion 13. At this time, the alignment film portion of the film 5 projected onto the light blocking portion A of the second mask 51 is not aligned.

Subsequently, secondary alignment is performed by using the first mask 53 of the second alignment unit 15 in a non-contact manner to the moving film surface (S23). Then, the light passing portion B of the first mask 53 in the second alignment portion 15 is oriented in a different direction to the portion of the alignment layer that has not been previously aligned. In the previously oriented part, light is blocked from being projected by the light blocking part A of the first mask 53 of the first alignment part 15.

Accordingly, the two alignment regions oriented in the alignment layer while the film 5 passes the first alignment unit 13 and the second alignment unit 15 are each formed in a stripe shape and are oriented in different directions and alternately arranged. Has a form. The result of this orientation is the same as in the first embodiment described above.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a diagram showing the configuration of an apparatus for manufacturing a patterned retarder for explaining the first embodiment of the present invention.

2 is a plan view of a mask applied to the first embodiment of the present invention.

3 is a flowchart illustrating a method of manufacturing a patterned retarder to explain the first embodiment of the present invention.

FIG. 4 is a view showing a state in which alignment is performed on the alignment layer in order to explain the first embodiment of the present invention.

FIG. 5 is a diagram illustrating a portion of a patterned retarder cut out to explain the first embodiment of the present invention. FIG.

FIG. 6 is a diagram showing the configuration of an apparatus for manufacturing a patterned retarder for explaining the second embodiment of the present invention.

7 and 8 are plan views illustrating masks applicable to the second embodiment of the present invention.

9 is a flowchart for explaining a second embodiment of the present invention.

10 and 11 are schematic views of a stereoscopic image display apparatus to which a patterned retarder is applied.

Claims (13)

A transfer unit for unwinding and / or winding and transporting the roll film, An alignment film forming unit for forming an alignment film on the film to be transferred; A first alignment part which irradiates light from a first light source to the alignment film formed on the film and orients it in a predetermined direction; Irradiating light from a second light source in a lattice or stripe pattern repeated through the first mask disposed between the second light source and the alignment film to the alignment film passing through the first alignment part in a direction different from the alignment direction of the first alignment part. A second alignment portion to orient, After the liquid crystal coating layer is formed on the alignment layer, a patterned retarder forming unit which forms a patterned retarder by irradiating light from a third light source. Apparatus for manufacturing a patterned retarder comprising a. The method according to claim 1, The transfer unit A first roller on which the roll film is unwound; a second roller spaced from the first roller; a second roller to be wound up after forming a patterned retarder on the film unloaded from the first roller; A driving source for rotating the first roller or the second roller, Apparatus for producing a patterned retarder comprising a. The method according to claim 1, The first alignment portion A second mask disposed between the first light source and the alignment layer to orient the alignment layer in a repeating lattice or stripe shape, Apparatus for producing a patterned retarder comprising a. The method of claim 3, And a patterned retarder for orientating in the second alignment portion in addition to the region oriented in the first alignment portion. The method according to claim 1, The said 1st light source and the said 2nd light source are manufacturing apparatus of the patterned retarder which irradiates an electron beam or a polarized electromagnetic wave. The method according to claim 1, The film is a polarizing plate manufacturing apparatus of the patterned retarder. Unwinding and / or winding and transporting the roll film, Forming an alignment layer on the transferred film Irradiating the alignment film formed on the film with light from a first light source to primary alignment in a predetermined direction, The alignment film after the primary alignment is irradiated with light from the second light source in a lattice or stripe pattern repeated through a first mask disposed between the second light source and the alignment layer, so that the alignment layer is irradiated with light in the direction different from the primary alignment direction. Differential orientation, Forming a patterned retarder by irradiating light from a third light source after forming a liquid crystal coating layer on top of the alignment layer having secondary alignment; Method of manufacturing a patterned retarder comprising a. The method of claim 7, In the primary alignment step, a second mask is further disposed between the first light source and the alignment layer to orient the alignment layer in a repeating lattice or stripe shape. The method according to claim 8, Wherein the step of the second alignment, the method of manufacturing a patterned retarder to orientate other than the area oriented in the step of the first alignment. The method of claim 7, Forming the patterned retarder is Applying a coating solution containing a liquid crystal compound, a monomer and a solvent onto the alignment layer; Drying the applied coating solution to form a coating layer, Curing the coating layer by irradiating with light; Method of manufacturing a patterned retarder comprising a. The method of claim 7, And the first light source or the second light source irradiates an electron beam or polarized electromagnetic waves. The method of claim 7, And said film is a polarizing plate. The patterned retarder manufactured by the manufacturing method of any one of Claims 7-12.

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